Jeep Wrangler 2004 Repair Manual[1]

Published on March 2017 | Categories: Documents | Downloads: 88 | Comments: 0 | Views: 294
of 2436
Download PDF   Embed   Report

Comments

Content


Welcome
2004 TJ J eep
®
Wrangler
Technical Publications
Click on the icon for the desired manual
Service Manual
Transmission Chassis Body Powertrain
DaimlerChrysler Corporation
UNITED STATES and CANADA
The special service tools referred to herein are required for certain service oper-
ations. These special service tools or their equivalent, if not obtainable through a
local source, are available through the following outlet.
28635 Mound Road, Warren, Michigan 48092, U.S.A.
MILLER SPECIAL TOOLS
SPX Corporation
Telephone 1-800-801-5420 FAX 1-800-578-7375
INTERNATIONAL
The special service tools referred to herein are required for certain service oper-
ations. These special service tools or their equivalent, if not obtainable through a
local source, are available through the following outlet.
28635 Mound Road, Warren, Michigan 48092, U.S.A.
MILLER SPECIAL TOOLS
SPX Corporation
Telephone 1-507-455-7320 FAX 1-800-578-7375
NEXT PAGE ᮣ
FOREWORD
The i nformati on contai ned i n thi s servi ce manual has been prepared for the professi onal automoti ve tech-
ni ci an i nvol ved i n dai l y repai r operati ons. I nformati on descri bi ng the operati on and use of standard and
opti onal equi pment i s i ncl uded i n the Owner’s Manual provi ded wi th the vehi cl e.
I nformati on i n thi s manual i s di vi ded i nto groups. These groups contai n descri pti on, operati on, di agnosi s,
testi ng, adjustments, removal , i nstal l ati on, di sassembl y, and assembl y procedures for the systems and compo-
nents. To assi st i n l ocati ng a group ti tl e page, use the Group Tab Locator on the fol l owi ng page. The sol i d bar
after the group ti tl e i s al i gned to a sol i d tab on the fi rst page of each group. The fi rst page of the group has
a contents secti on that l i sts major topi cs wi thi n the group. I f you are not sure whi ch Group contai ns the i nfor-
mati on you need, l ook up the Component/System i n the al phabeti cal i ndex l ocated i n the rear of thi s manual .
A Servi ce Manual Comment form i s i ncl uded at the rear of thi s manual . Use the form to provi de
Dai ml erChrysl er Corporati on wi th your comments and suggesti ons.
Ti ghteni ng torques are provi ded as a speci fi c val ue throughout thi s manual . Thi s val ue represents the
mi dpoi nt of the acceptabl e engi neeri ng torque range for a gi ven fastener appl i cati on. These torque val ues are
i ntended for use i n servi ce assembl y and i nstal l ati on procedures usi ng the correct OEM fasteners. When
repl aci ng fasteners, al ways use the same type (part number) fastener as removed.
Dai ml erChrysl er Corporati on reserves the ri ght to change testi ng procedures, speci fi cati ons, di agnosi s,
repai r methods, or vehi cl e wi ri ng at any ti me wi thout pri or noti ce or i ncurri ng obl i gati on.
NEXT PAGE ᮣ
GROUP TAB LOCATOR
Introduction
0
Lubrication & Maintenance
2
Suspension
3
Differential & Driveline
5
Brakes
6
Clutch
7
Cooling
8A
Audio/Video
8B
Chime/Buzzer
8E
Electronic Control Modules
8F
Engine Systems
8G
Heated Systems
8H
Horn
8I
Ignition Control
8J
Instrument Cluster
8L
Lamps
8N
Power System
8O
Restraints
8P
Speed Control
8Q
Vehicle Theft Security
8R
Wipers/Washers
8W
Wiring
9
Engine
11
Exhaust System
13
Frame & Bumpers
14
Fuel System
19
Steering
21
Transmission and Transfer Case
22
Tires/Wheels
23
Body
24
Heating & Air Conditioning
25
Emissions Control
Component and System Index
Service Manual Comment Forms (Rear of Manual)
INTRODUCTION
TABLE OF CONTENTS
page page
VEHICLE IDENTIFICATION NUMBER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
VEHICLE EMISSION CONTROL INFORMATION
(VECI) LABEL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 2
VEHICLE CERTIFICATION LABEL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 2
BODY CODE PLATE
DESCRIPTION
BODY CODE PLATE . . . . . . . . . . . . . . . . . . . . 3
INTERNATIONAL SYMBOLS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FASTENER IDENTIFICATION
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FASTENER USAGE
DESCRIPTION
DESCRIPTION - FASTENER USAGE . . . . . . . . 9
DESCRIPTION - THREADED HOLE REPAIR . . 9
METRIC SYSTEM
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 10
TORQUE REFERENCES
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 12
VEHICLE IDENTIFICATION
NUMBER
DESCRIPTION
The Vehi cl e I denti fi cati on Number (VI N) pl ate i s
l ocated on the l ower wi ndshi el d fence near the l eft
A-pi l l ar. The VI N contai ns 17 characters that provi de
data concerni ng the vehi cl e. Refer to the VI N decod-
i ng chart to determi ne the i denti fi cati on of a vehi cl e.
The Vehi cl e I denti fi cati on Number i s al so
i mpri nted on the:
• Vehi cl e Safety Certi fi cati on Label .
• Frame rai l .
To protect the consumer from theft and possi bl e
fraud the manufacturer i s requi red to i ncl ude a
Check Di gi t at the ni nth posi ti on of the Vehi cl e I den-
ti fi cati on Number. The check di gi t i s used by the
manufacturer and government agenci es to veri fy the
authenti ci ty of the vehi cl e and offi ci al documenta-
ti on. The formul a to use the check di gi t i s not
rel eased to the general publ i c.
VEHICLE IDENTIFICATION NUMBER DECODING CHART
POSITION INTERPRETATION CODE = DESCRIPTION
1 Country of Origin 1 = Manufactured By DaimlerChrysler
Corporation
2 Make J = Jeep
3 Vehicle Type 4 = MPV
4 Gross Vehicle Weight Rating E = 3001-4000 lbs.
F = 4001-5000 lbs.
5 Vehicle Line A = Wrangler 4X4 (LHD)
4 = Wrangler 4X4 (RHD)
6 Series 2 = SE
3 = X
4 = Sport
5 = Sahara
6 = Rubicon
7 Body Style 9 = Open Body
8 Engine 1 = 2.4L 4 cyl DOHC Gasoline
S = 4.0L 6 cyl Gasoline
TJ INTRODUCTION 1
POSITION INTERPRETATION CODE = DESCRIPTION
9 Check Digit 0 through 9 or X
10 Model Year 4=2004
11 Assembly Plant P = Toledo #2
12 thru 17 Vehicle Build Sequence
VEHICLE EMISSION CONTROL
INFORMATION (VECI) LABEL
DESCRIPTION
Al l model s have a Vehi cl e Emi ssi on Control I nfor-
mati on (VECI ) Label . Dai ml erChrysl er permanentl y
attaches the l abel i n the engi ne compartment (Fi g.
1). I t cannot be removed wi thout defaci ng i nforma-
ti on and destroyi ng the l abel .
The l abel contai ns the vehi cl e’s emi ssi on speci fi ca-
ti ons and vacuum hose routi ngs. Al l hoses must be
connected and routed accordi ng to the l abel .
The VECI l abel contai ns the fol l owi ng:
• Engi ne fami l y and di spl acement
• Evaporati ve fami l y
• Emi ssi on control system schemati c
• Certi fi cati on appl i cati on
• Engi ne ti mi ng speci fi cati ons (i f adjustabl e)
• I dl e speeds (i f adjustabl e)
• Spark pl ug and gap
The l abel al so contai ns an engi ne vacuum sche-
mati c. These l abel s are permanentl y attached and
cannot be removed wi thout defaci ng i nformati on and
destroyi ng l abel .
VEHICLE CERTIFICATION
LABEL
DESCRIPTION
A vehi cl e certi fi cati on l abel (Fi g. 2) i s attached to
every Dai ml erChrysl er Corporati on vehi cl e. The l abel
certi fi es that the vehi cl e conforms to al l appl i cabl e
Federal Motor Vehi cl e Standards. The l abel al so l i sts:
• Month and year of vehi cl e manufacture.
• Gross Vehi cl e Wei ght Rati ng (GVWR). The gross
front and rear axl e wei ght rati ngs (GAWR’s) are
based on a mi ni mum ri m si ze and maxi mum col d ti re
i nfl ati on pressure.
• Vehi cl e I denti fi cati on Number (VI N).
• Type of vehi cl e.
• Type of rear wheel s.
• Bar code.
• Month, Day and Hour (MDH) of fi nal assembl y.
• Pai nt and Tri m codes.
• Country of ori gi n.
The l abel i s l ocated on the dri ver-si de door shut-
face.
Fig. 1 VECI Label Location
1 - VECI LABEL
Fig. 2 VEHICLE CERTIFICATION LABEL - TYPICAL
2 INTRODUCTION TJ
VEHICLE IDENTIFICATION NUMBER (Continued)
BODY CODE PLATE
DESCRIPTION
BODY CODE PLATE
A metal body code pl ate i s attached to the fl oor pan
under the dri vers seat (Fi g. 3). Di sengage the snaps
attachi ng the carpet to the fl oor pan to read the
i nformati on. There are seven l i nes of i nformati on on
the body code pl ate. Li nes 4, 5, 6, and 7 are not used
to defi ne servi ce i nformati on. I nformati on reads from
l eft to ri ght, starti ng wi th l i ne 3 i n the center of the
pl ate to l i ne 1 at the bottom of the pl ate (Fi g. 4).
The l ast code i mpri nted on a vehi cl e code pl ate wi l l
be fol l owed by the i mpri nted word END. When two
vehi cl e code pl ates are requi red, the l ast avai l abl e
spaces on the fi rst pl ate wi l l be i mpri nted wi th the
l etters CTD (for conti nued).
When a second vehi cl e code pl ate i s necessary, the
fi rst four spaces on each row wi l l not be used because
of the pl ate overl ap.
Fig. 3 Body Code Plate Location
1 - SNAP
2 - REAR CARPET
3 - BODY CODE PLATE
4 - SNAP
5 - FLOOR PAN
6 - FRONT CARPET
Fig. 4 Body Code Plate Decoding
1 - PRIMARY PAINT
2 - SECONDARY PAINT
3 - ROOF
4 - CAR LINE SHELL
5 - ENGINE
6 - TRIM
7 - VIN
8 - MARKET
9 - TRANSMISSION
10 - PAINT PROCEDURE
11 - VEHICLE ORDER NUMBER
TJ INTRODUCTION 3
BODY CODE PLATE— LINE 3
DIGITS 1 THROUGH 12
Vehi cl e Order Number
DIGITS 13, 14, AND 15
Roof
• VJN = Soft Top Whi te
• VJU = Soft Top Spi ce
• VJX = Soft Top Bl ack
• VKN = Hard Top Whi te
• VKU = Hard Top Spi ce
• VKX = Hard Top Bl ack
DIGITS 16, 17, AND 18
Car Li ne Shel l
• TJJ = Wrangl er (LHD)
• TJU = Wrangl er (RHD)
DIGIT 19
Pri ce Cl ass
• L = Wrangl er (Al l )
DIGITS 20 AND 21
Body Type
• 77 = Wheel Base (93.4 i n.)
BODY CODE PLATE— LINE 2
DIGITS 1, 2, AND 3
Pai nt Procedure
DIGIT 4
Open Space
DIGITS 5 THROUGH 8
Pri mary Pai nt
(Refer to 23 - BODY/PAI NT - SPECI FI CATI ONS)
for col or codes.
DIGIT 9
Open Space
DIGITS 10 THROUGH 13
Secondary Pai nt
DIGIT 14
Open Space
DIGITS 15 THROUGH 18
I nteri or Tri m Code
DIGIT 19
Open Space
DIGITS 20, 21, AND 22
Engi ne Code
• ED1 = 2.4L 4 cyl . MPI Gasol i ne
• ERH = 4.0L 6 cyl . MPI Gasol i ne
BODY CODE PLATE— LINE 1
DIGITS 1, 2, AND 3
Transmi ssi on Codes
• DDD = NV3550 5 - speed Manual
• DDK = AX15 5 - speed Manual
• DG6 = 42RLE 4 - speed Automati c
DIGIT 4
Open Space
DIGIT 5
Market Code
• B = I nternati onal
DIGIT 6
Open Space
DIGITS 7 THROUGH 23
Vehi cl e I denti fi cati on Number (VI N)
(Refer to VEHI CLE DATA/VEHI CLE I NFORMA-
TI ON/VEHI CLE I DENTI FI CATI ON NUMBER -
DESCRI PTI ON) for breakdown of VI N code.
4 INTRODUCTION TJ
BODY CODE PLATE (Continued)
INTERNATIONAL SYMBOLS
DESCRIPTION
The graphi c symbol s i l l ustrated i n the fol l owi ng
I nternati onal Control and Di spl ay Symbol s Chart
(Fi g. 5) are used to i denti fy vari ous i nstrument con-
trol s. The symbol s correspond to the control s and di s-
pl ays that are l ocated on the i nstrument panel .
Fig. 5 INTERNATIONAL CONTROL AND DISPLAY SYMBOLS
1 High Beam 13 Rear Window Washer
2 Fog Lamps 14 Fuel
3 Headlamp, Parking Lamps, Panel Lamps 15 Engine Coolant Temperature
4 Turn Warning 16 Battery Charging Condition
5 Hazard Warning 17 Engine Oil
6 Windshield Washer 18 Seat Belt
7 Windshield Wiper 19 Brake Failure
8 Windshield Wiper and Washer 20 Parking Brake
9 Windscreen Demisting and Defrosting 21 Front Hood
10 Ventilating Fan 22 Rear hood (Decklid)
11 Rear Window Defogger 23 Horn
12 Rear Window Wiper 24 Lighter
TJ INTRODUCTION 5
FASTENER IDENTIFICATION
DESCRIPTION
The SAE bol t strength grades range from grade 2
to grade 8. The hi gher the grade number, the greater
the bol t strength. I denti fi cati on i s determi ned by the
l i ne marks on the top of each bol t head. The actual
bol t strength grade corresponds to the number of l i ne
marks pl us 2. The most commonl y used metri c bol t
strength cl asses are 9.8 and 10.9. The metri c
strength cl ass i denti fi cati on number i s i mpri nted on
the head of the bol t. The hi gher the cl ass number,
the greater the bol t strength. Some metri c nuts are
i mpri nted wi th a si ngl e-di gi t strength cl ass on the
nut face. Refer to the Fastener I denti fi cati on and
Fastener Strength Charts (Fi g. 6) and (Fi g. 7).
6 INTRODUCTION TJ
Fig. 6 FASTENER IDENTIFICATION
TJ INTRODUCTION 7
FASTENER IDENTIFICATION (Continued)
Fig. 7 FASTENER STRENGTH
8 INTRODUCTION TJ
FASTENER IDENTIFICATION (Continued)
FASTENER USAGE
DESCRIPTION
DESCRIPTION - FASTENER USAGE
WARNING: USE OF AN INCORRECT FASTENER
MAY RESULT IN COMPONENT DAMAGE OR PER-
SONAL INJURY.
Fasteners and torque speci fi cati ons references i n
thi s Servi ce Manual are i denti fi ed i n metri c and SAE
format.
Duri ng any mai ntenance or repai r procedures, i t i s
i mportant to sal vage al l fasteners (nuts, bol ts, etc.)
for reassembl y. I f the fastener i s not sal vageabl e, a
fastener of equi val ent speci fi cati on must be used.
DESCRIPTION - THREADED HOLE REPAIR
Most stri pped threaded hol es can be repai red usi ng
a Hel i coi l ௡. Fol l ow the vehi cl e or Hel i coi l ௡ recommen-
dati ons for appl i cati on and repai r procedures.
TJ INTRODUCTION 9
METRIC SYSTEM
DESCRIPTION
The metri c system i s based on quanti ti es of one,
ten, one hundred, one thousand and one mi l l i on.
The fol l owi ng chart wi l l assi st i n converti ng metri c
uni ts to equi val ent Engl i sh and SAE uni ts, or vi se
versa.
CONVERSION FORMULAS AND EQUIVALENT VALUES
MULTIPLY BY TO GET MULTIPLY BY TO GET
in-lbs x 0.11298 = Newton Meters (N·m) N·m x 8.851 = in-lbs
ft-lbs x 1.3558 = Newton Meters (N·m) N·m x 0.7376 = ft-lbs
Inches Hg (60°F) x 3.377 = Kilopascals (kPa) kPa x 0.2961 = Inches Hg
psi x 6.895 = Kilopascals (kPa) kPa x 0.145 = psi
Inches x 25.4 = Millimeters (mm) mm x 0.03937 = Inches
Feet x 0.3048 = Meters (M) M x 3.281 = Feet
Yards x 0.9144 = Meters M x 1.0936 = Yards
mph x 1.6093 = Kilometers/Hr. (Km/h) Km/h x 0.6214 = mph
Feet/Sec x 0.3048 = Meters/Sec (M/S) M/S x 3.281 = Feet/Sec
mph x 0.4470 = Meters/Sec (M/S) M/S x 2.237 = mph
Kilometers/Hr. (Km/h) x 0.27778 = Meters/Sec (M/S) M/S x 3.600 Kilometers/Hr. (Km/h)
COMMON METRIC EQUIVALENTS
1 inch = 25 Millimeters 1 Cubic Inch = 16 Cubic Centimeters
1 Foot = 0.3 Meter 1 Cubic Foot = 0.03 Cubic Meter
1 Yard = 0.9 Meter 1 Cubic Yard = 0.8 Cubic Meter
1 Mile = 1.6 Kilometers
Refer to the Metri c Conversi on Chart to convert
torque val ues l i sted i n metri c Newton- meters (N·m).
Al so, use the chart to convert between mi l l i meters
(mm) and i nches (i n.) (Fi g. 8).
10 INTRODUCTION TJ
Fig. 8 METRIC CONVERSION CHART
TJ INTRODUCTION 11
METRIC SYSTEM (Continued)
TORQUE REFERENCES
DESCRIPTION
I ndi vi dual Torque Charts appear wi thi n many or
the Groups. Refer to the Standard Torque Speci fi ca-
ti ons Chart for torque references not l i sted i n the
i ndi vi dual torque charts (Fi g. 9).
Fig. 9 TORQUE SPECIFICATIONS
12 INTRODUCTION TJ
LUBRICATION & MAINTENANCE
TABLE OF CONTENTS
page page
INTERNATIONAL SYMBOLS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
PARTS & LUBRICANT RECOMMENDATION
DESCRIPTION - LUBRICANT
RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . 1
FLUID TYPES
DESCRIPTION
DESCRIPTION - FUEL REQUIREMENTS . . . . . 2
DESCRIPTION - ENGINE OIL AND
LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . 3
DESCRIPTION - HOAT COOLANT . . . . . . . . . . 4
DESCRIPTION - TRANSFER CASE - NV231 . . 5
DESCRIPTION - TRANSFER CASE - NV241 . . 5
DESCRIPTION - AXLE LUBRICATION . . . . . . . 5
DESCRIPTION - MANUAL TRANSMISSION . . . 5
DESCRIPTION - AUTOMATIC
TRANSMISSION FLUID . . . . . . . . . . . . . . . . . . 6
DESCRIPTION - POWER STEERING FLUID . . 6
OPERATION - AUTOMATIC TRANSMISSION
FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FLUID CAPACITIES
SPECIFICATIONS - FLUID CAPACITIES . . . . . . . 6
MAINTENANCE SCHEDULES
DESCRIPTION
DESCRIPTION – DOMESTIC SCHEDULES . . . 7
DESCRIPTION – GASOLINE ENGINES –
EXPORT SCHEDULES. . . . . . . . . . . . . . . . . . 13
DESCRIPTION – DIESEL ENGINES –
EXPORT SCHEDULES. . . . . . . . . . . . . . . . . . 18
HOISTING
STANDARD PROCEDURE - HOISTING
RECOMMENDATIONS . . . . . . . . . . . . . . . . . . 21
TOWING
STANDARD PROCEDURE - TOWING
RECOMMENDATIONS . . . . . . . . . . . . . . . . . . 22
JUMP STARTING
STANDARD PROCEDURE - JUMP STARTING
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . 23
EMERGENCY TOW HOOKS
DESCRIPTION — EMERGENCY TOW HOOKS . 24
INTERNATIONAL SYMBOLS
DESCRIPTION
Dai ml erChrysl er Corporati on uses i nternati onal
symbol s to i denti fy engi ne compartment l ubri cant
and fl ui d i nspecti on and fi l l l ocati ons (Fi g. 1).
PARTS & LUBRICANT
RECOMMENDATION
DESCRIPTION - LUBRICANT
RECOMMENDATIONS
Chassis
Component Fluid, Lubricant, or Genuine Part
Steering Gear
& Linkage, Ball
Joints, Prop
Shafts &
Yokes, Wheel
Bearings
Moparா Multi-Purpose Lubricant
NLGI Grade 2 EP, GC-LB
Fig. 1 INTERNATIONAL SYMBOLS
TJ LUBRICATION & MAINTENANCE 0 - 1
Body
Component Fluid, Lubricant, or Genuine Part
Hinges:
Door And
Hood
Moparா Engine Oil
Liftgate Moparா Multi-Purpose Lube NLGI
Grade 2 EP, GC-LB
Latches:
Door,
Hood/Safety
Catch, Liftgate
Moparா Multi-Purpose Lube NLG
Grade 2 EP, GC-LB
Seat
Regulator &
Track
Moparா Multi-Purpose Lube NLGI
Grade 2 EP, GC-LB
Window
System
Components
Moparா Spray White Lube
Lock
Cylinders
Moparா Lock Cylinder Lube
Parking Brake
Mechanism
Moparா Wheel Brg. Grease NLGI
Grade 1, GC-LBB
Soft Top Moparா Soft Top Zipper Cleaner &
Lubricant
FLUID TYPES
DESCRIPTION
DESCRIPTION - FUEL REQUIREMENTS
Your engi ne i s desi gned to meet al l emi ssi ons reg-
ul ati ons and provi de excel l ent fuel economy and per-
formance when usi ng hi gh qual i ty unl eaded “regul ar”
gasol i ne havi ng an octane rati ng of 87. The routi ne
use of premi um gasol i ne i s not recommended. Under
normal condi ti ons the use of premi um fuel wi l l not
provi de a benefi t over hi gh qual i ty regul ar gasol i nes
and i n some ci rcumstances may resul t i n poorer per-
formance.
Li ght spark knock at l ow engi ne speeds i s not
harmful to your engi ne. However, conti nued heavy
spark knock at hi gh speeds can cause damage and
i mmedi ate servi ce i s requi red. Engi ne damage resul t-
i ng from operati on wi th a heavy spark knock may
not be covered by the new vehi cl e warranty.
Poor qual i ty gasol i ne can cause probl ems such as
hard starti ng, stal l i ng and hesi tati ons. I f you experi -
ence these symptoms, try another brand of gasol i ne
before consi deri ng servi ce for the vehi cl e.
Over 40 auto manufacturers worl d-wi de have
i ssued and endorsed consi stent gasol i ne speci fi cati ons
(the Worl dwi de Fuel Charter, WWFC) to defi ne fuel
properti es necessary to del i ver enhanced emi ssi ons,
performance and durabi l i ty for your vehi cl e. We rec-
ommend the use of gasol i nes that meet the WWFC
speci fi cati ons i f they are avai l abl e.
REFORMULATED GASOLINE
Many areas of the country requi re the use of
cl eaner burni ng gasol i ne referred to as “reformu-
l ated” gasol i ne. Reformul ated gasol i ne contai n oxy-
genates, and are speci fi cal l y bl ended to reduce
vehi cl e emi ssi ons and i mprove ai r qual i ty.
We strongl y support the use of reformul ated gaso-
l i ne. Properl y bl ended reformul ated gasol i ne wi l l pro-
vi de excel l ent performance and durabi l i ty for the
engi ne and fuel system components.
GASOLINE/OXYGENATE BLENDS
Some fuel suppl i ers bl end unl eaded gasol i ne wi th
oxygenates such as 10% ethanol , MTBE, and ETBE.
Oxygenates are requi red i n some areas of the country
duri ng the wi nter months to reduce carbon monoxi de
emi ssi ons. Fuel s bl ended wi th these oxygenates may
be used i n your vehi cl e.
CAUTION: DO NOT use gasoline containing METH-
ANOL. Gasoline containing methanol may damage
critical fuel system components.
MMT IN GASOLINE
MMT i s a manganese-contai ni ng metal l i c addi ti ve
that i s bl ended i nto some gasol i ne to i ncrease octane.
Gasol i ne bl ended wi th MMT provi de no performance
advantage beyond gasol i ne of the same octane num-
ber wi thout MMT. Gasol i ne bl ended wi th MMT
reduce spark pl ug l i fe and reduce emi ssi on system
performance i n some vehi cl es. We recommend that
gasol i nes free of MMT be used i n your vehi cl e. The
MMT content of gasol i ne may not be i ndi cated on the
gasol i ne pump; therefore, you shoul d ask your gaso-
l i ne retai l er whether or not hi s/her gasol i ne contai ns
MMT.
I t i s even more i mportant to l ook for gasol i ne wi th-
out MMT i n Canada because MMT can be used at
l evel s hi gher than al l owed i n the Uni ted States.
MMT i s prohi bi ted i n Federal and Cal i forni a refor-
mul ated gasol i ne.
SULFUR IN GASOLINE
I f you l i ve i n the northeast Uni ted States, your
vehi cl e may have been desi gned to meet Cal i forni a
l ow emi ssi on standards wi th Cl eaner-Burni ng Cal i -
forni a reformul ated gasol i ne wi th l ow sul fur. I f such
fuel s are not avai l abl e i n states adopti ng Cal i forni a
emi ssi on standards, your vehi cl es wi l l operate sati s-
factori l y on fuel s meeti ng federal speci fi cati ons, but
0 - 2 LUBRICATION & MAINTENANCE TJ
PARTS & LUBRICANT RECOMMENDATION (Continued)
emi ssi on control system performance may be
adversel y affected. Gasol i ne sol d outsi de of Cal i forni a
i s permi tted to have hi gher sul fur l evel s whi ch may
affect the performance of the vehi cl e’s catal yti c con-
verter. Thi s may cause the Mal functi on I ndi cator
Lamp (MI L), Check Engi ne or Servi ce Engi ne Soon
l i ght to i l l umi nate. We recommend that you try a di f-
ferent brand of unl eaded gasol i ne havi ng l ower sul fur
to determi ne i f the probl em i s fuel rel ated pri or to
returni ng your vehi cl e to an authori zed deal er for
servi ce.
CAUTION: If the Malfunction Indicator Lamp (MIL),
Check Engine or Service Engine Soon light is flash-
ing, immediate service is required; see on-board
diagnostics system section.
MATERIALS ADDED TO FUEL
Al l gasol i ne sol d i n the Uni ted States and Canada
are requi red to contai n effecti ve detergent addi ti ves.
Use of addi ti onal detergents or other addi ti ves i s not
needed under normal condi ti ons.
FUEL SYSTEM CAUTIONS
CAUTION: Follow these guidelines to maintain your
vehicle’s performance:
• The use of l eaded gas i s prohi bi ted by Federal
l aw. Usi ng l eaded gasol i ne can i mpai r engi ne perfor-
mance, damage the emi ssi on control system, and
coul d resul t i n l oss of warranty coverage.
• An out-of-tune engi ne, or certai n fuel or i gni ti on
mal functi ons, can cause the catal yti c converter to
overheat. I f you noti ce a pungent burni ng odor or
some l i ght smoke, your engi ne may be out of tune or
mal functi oni ng and may requi re i mmedi ate servi ce.
Contact your deal er for servi ce assi stance.
• When pul l i ng a heavy l oad or dri vi ng a ful l y
l oaded vehi cl e when the humi di ty i s l ow and the tem-
perature i s hi gh, use a premi um unl eaded fuel to
hel p prevent spark knock. I f spark knock persi sts,
l i ghten the l oad, or engi ne pi ston damage may resul t.
• The use of fuel addi ti ves whi ch are now bei ng
sol d as octane enhancers i s not recommended. Most
of these products contai n hi gh concentrati ons of
methanol . Fuel system damage or vehi cl e perfor-
mance probl ems resul ti ng from the use of such fuel s
or addi ti ves i s not the responsi bi l i ty of
Dai ml erChrysl er Corporati on and may not be covered
under the new vehi cl e warranty.
NOTE: Intentional tampering with emissions control
systems can result in civil penalties being assessed
against you.
DESCRIPTION - ENGINE OIL AND LUBRICANTS
WARNING: NEW OR USED ENGINE OIL CAN BE
IRRITATING TO THE SKIN. AVOID PROLONGED OR
REPEATED SKIN CONTACT WITH ENGINE OIL.
CONTAMINANTS IN USED ENGINE OIL, CAUSED BY
INTERNAL COMBUSTION, CAN BE HAZARDOUS TO
YOUR HEALTH. THOROUGHLY WASH EXPOSED
SKIN WITH SOAP AND WATER. DO NOT WASH
SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR
SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO
NOT POLLUTE, DISPOSE OF USED ENGINE OIL
PROPERLY. CONTACT YOUR DEALER OR GOVERN-
MENT AGENCY FOR LOCATION OF COLLECTION
CENTER IN YOUR AREA.
When servi ce i s requi red, Dai ml erChrysl er Corpo-
rati on recommends that onl y Mopar௡ brand parts,
l ubri cants and chemi cal s be used. Mopar௡ provi des
the best engi neered products for servi ci ng
Dai ml erChrysl er Corporati on vehi cl es.
Onl y l ubri cants beari ng desi gnati ons defi ned by
the fol l owi ng organi zati on shoul d be used.
• Soci ety of Automoti ve Engi neers (SAE)
• Ameri can Petrol eum I nsti tute (API )
• Nati onal Lubri cati ng Grease I nsti tute (NLGI )
API SERVICE GRADE CERTIFIED
Use an engi ne oi l that i s API Certi fi ed. MOPAR௡
provi des engi ne oi l s, that meet or exceed thi s
requi rement.
SAE VISCOSITY
An SAE vi scosi ty grade i s used to speci fy the vi s-
cosi ty of engi ne oi l . Use onl y engi ne oi l s wi th mul ti -
pl e vi scosi ti es such as 5W-30 or 10W-30. These are
speci fi ed wi th a dual SAE vi scosi ty grade whi ch i ndi -
cates the col d-to-hot temperature vi scosi ty range.
Sel ect an engi ne oi l that i s best sui ted to your par-
ti cul ar temperature range and vari ati on (Fi g. 2).
Fig. 2 Temperature/Engine Oil Viscosity
TJ LUBRICATION & MAINTENANCE 0 - 3
FLUID TYPES (Continued)
ENERGY CONSERVING OIL
An Energy Conservi ng type oi l i s recommended for
gasol i ne engi nes. The desi gnati on of ENERGY CON-
SERVI NG i s l ocated on the l abel of an engi ne oi l con-
tai ner.
CONTAINER IDENTIFICATION
Standard engi ne oi l i denti fi cati on notati ons have
been adopted to ai d i n the proper sel ecti on of engi ne
oi l . The i denti fyi ng notati ons are l ocated on the front
l abel of engi ne oi l pl asti c bottl es and the top of
engi ne oi l cans (Fi g. 3).
Thi s symbol means that the oi l has been certi fi ed
by the Ameri can Petrol eum I nsti tute (API ). Di aml er-
Chrysl er onl y recommend API Certi fi ed engi ne oi l s.
Use Mopar௡ engi ne oi l or equi val ent.
GEAR LUBRICANTS
SAE rati ngs al so appl y to mul ti grade gear l ubri -
cants. I n addi ti on, API cl assi fi cati on defi nes the
l ubri cants usage. Such as API GL-5 and SAE 75W-
90.
LUBRICANTS AND GREASES
Lubri cati ng grease i s rated for qual i ty and usage
by the NLGI . Al l approved products have the NLGI
symbol (Fi g. 4) on the l abel . At the bottom of the
NLGI symbol i s the usage and qual i ty i denti fi cati on
l etters. Wheel beari ng l ubri cant i s i denti fi ed by the
l etter “G”. Chassi s l ubri cant i s i denti fi ed by the l etter
“L”. The l etter fol l owi ng the usage l etter i ndi cates
the qual i ty of the l ubri cant. The fol l owi ng symbol s
i ndi cate the hi ghest qual i ty.
SPECIALIZED LUBRICANTS AND OILS
Some mai ntenance or repai r procedures may
requi re the use of speci al i zed l ubri cants or oi l s. Con-
sul t the appropri ate secti ons i n thi s manual for the
correct appl i cati on of these l ubri cants.
DESCRIPTION - HOAT COOLANT
WARNING: ANTIFREEZE IS AN ETHYLENE-GLYCOL
BASE COOLANT AND IS HARMFUL IF SWAL-
LOWED OR INHALED. IF SWALLOWED, DRINK
TWO GLASSES OF WATER AND INDUCE VOMIT-
ING. IF INHALED, MOVE TO FRESH AIR AREA.
SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT
STORE IN OPEN OR UNMARKED CONTAINERS.
WASH SKIN AND CLOTHING THOROUGHLY AFTER
COMING IN CONTACT WITH ETHYLENE-GLYCOL.
KEEP OUT OF REACH OF CHILDREN. DISPOSE OF
GLYCOL BASE COOLANT PROPERLY, CONTACT
YOUR DEALER OR GOVERNMENT AGENCY FOR
LOCATION OF COLLECTION CENTER IN YOUR
AREA. DO NOT OPEN A COOLING SYSTEM WHEN
THE ENGINE IS AT OPERATING TEMPERATURE OR
HOT UNDER PRESSURE, PERSONAL INJURY CAN
RESULT. AVOID RADIATOR COOLING FAN WHEN
ENGINE COMPARTMENT RELATED SERVICE IS
PERFORMED, PERSONAL INJURY CAN RESULT.
CAUTION: Use of Propylene-Glycol based coolants
is not recommended, as they provide less freeze
protection and less corrosion protection.
The cool i ng system i s desi gned around the cool ant.
The cool ant must accept heat from engi ne metal , i n
the cyl i nder head area near the exhaust val ves and
engi ne bl ock. Then cool ant carri es the heat to the
radi ator where the tube/fi n radi ator can transfer the
heat to the ai r.
The use of al umi num cyl i nder bl ocks, cyl i nder
heads, and water pumps requi res speci al corrosi on
protecti on. Mopar௡ Anti freeze/Cool ant, 5
Year/100,000 Mi l e Formul a (MS-9769), or the equi va-
l ent ethyl ene-gl ycol base cool ant wi th organi c corro-
si on i nhi bi tors (cal l ed HOAT, for Hybri d Organi c
Addi ti ve Technol ogy) i s recommended. Thi s cool ant
offers the best engi ne cool i ng wi thout corrosi on when
mi xed wi th 50% ethyl ene-gl ycol and 50% di sti l l ed
water to obtai n a freeze poi nt of -37°C (-35°F). I f i t
l oses col or or becomes contami nated, drai n, fl ush,
and repl ace wi th fresh properl y mi xed cool ant sol u-
ti on.
Fig. 3 API Certification Mark
Fig. 4 NLGI SYMBOL
1 - WHEEL BEARINGS
2 - CHASSIS LUBRICATION
3 - CHASSIS AND WHEEL BEARINGS
0 - 4 LUBRICATION & MAINTENANCE TJ
FLUID TYPES (Continued)
CAUTION: Moparா Antifreeze/Coolant, 5
Year/100,000 Mile Formula (MS-9769) may not be
mixed with any other type of antifreeze. Mixing of
coolants other than specified (non-HOAT or other
HOAT), may result in engine damage that may not
be covered under the new vehicle warranty, and
decreased corrosion protection.
COOLANT PERFORMANCE
The requi red ethyl ene-gl ycol (anti freeze) and water
mi xture depends upon cl i mate and vehi cl e operati ng
condi ti ons. The cool ant performance of vari ous mi x-
tures fol l ows:
Pure Water-Water can absorb more heat than a
mi xture of water and ethyl ene-gl ycol . Thi s i s for pur-
pose of heat transfer onl y. Water al so freezes at a
hi gher temperature and al l ows corrosi on.
100 percent Ethylene-Glycol-The corrosi on
i nhi bi ti ng addi ti ves i n ethyl ene-gl ycol need the pres-
ence of water to di ssol ve. Wi thout water, addi ti ves
form deposi ts i n system. These act as i nsul ati on
causi ng temperature to ri se to as hi gh as 149°C
(300°F). Thi s temperature i s hot enough to mel t pl as-
ti c and soften sol der. The i ncreased temperature can
resul t i n engi ne detonati on. I n addi ti on, 100 percent
ethyl ene-gl ycol freezes at -22°C (-8°F).
50/50 Ethylene-Glycol and Water-I s the recom-
mended mi xture, i t provi des protecti on agai nst freez-
i ng to -37°C (-34°F). The anti freeze concentrati on
must always be a mi ni mum of 44 percent, year-round
i n al l cl i mates. I f percentage i s l ower, engi ne parts
may be eroded by cavi tati on. Maxi mum protecti on
agai nst freezi ng i s provi ded wi th a 68 percent anti -
freeze concentrati on, whi ch prevents freezi ng down to
-67.7°C (-90°F). A hi gher percentage wi l l freeze at a
warmer temperature. Al so, a hi gher percentage of anti -
freeze can cause the engi ne to overheat because spe-
ci fi c heat of anti freeze i s l ower than that of water.
CAUTION: Richer antifreeze mixtures cannot be
measured with normal field equipment and can
cause problems associated with 100 percent ethyl-
ene-glycol.
COOLANT SELECTION AND ADDITIVES
The use of al umi num cyl i nder bl ocks, cyl i nder
heads and water pumps requi res speci al corrosi on
protecti on. Onl y Mopar௡ Anti freeze/Cool ant, 5
Year/100,000 Mi l e Formul a (gl ycol base cool ant wi th
corrosi on i nhi bi tors cal l ed HOAT, for Hybri d Organi c
Addi ti ve Technol ogy) i s recommended. Thi s cool ant
offers the best engi ne cool i ng wi thout corrosi on when
mi xed wi th 50% di sti l l ed water to obtai n to obtai n a
freeze poi nt of -37°C (-35°F). I f i t l oses col or or
becomes contami nated, drai n, fl ush, and repl ace wi th
fresh properl y mi xed cool ant sol uti on.
CAUTION: Do not use coolant additives that are
claimed to improve engine cooling.
DESCRIPTION - TRANSFER CASE - NV231
Recommended l ubri cant for the NV231 transfer
case i s Mopar௡ ATF +4, Automati c Transmi ssi on
Fl ui d.
DESCRIPTION - TRANSFER CASE - NV241
Recommended l ubri cant for the NV241 transfer
case i s Mopar௡ ATF +4, Automati c Transmi ssi on
Fl ui d.
DESCRIPTION - AXLE LUBRICATION
NOTE: DiamlerChrysler recommends using Moparா
lubricants or lubricants of equal quality.
FRONT AXLE
• 181 FBI (Model 30) - Mopar௡ Gear Lubri cant
80W-90 (Trai l er Towi ng Mopar௡ Syntheti c Gear
Lubri cant 75W-140)
• 216 FBI (Model 44) - Mopar௡ Gear Lubri cant
80W-90 (Trai l er Towi ng Mopar௡ Syntheti c Gear
Lubri cant 75W-140)
• RUBI CON 216 FBI (Model 44) - Mopar௡ Syn-
theti c Gear Lubri cant 75W-140
REAR AXLE
• 194 RBI (Model 35) - Mopar௡ Gear Lubri cant
80W-90 (Trai l er Towi ng Mopar௡ Syntheti c Gear
Lubri cant 75W-140)
• 194 RBI (Model 35) 4.56 Rati o - 2.4 L Eni gne
and 42 RLE Automati c Transmi ssi on - Mopar௡ Syn-
theti c Gear Lubri cant 75W-140
• 226 RBI (Model 44) - Mopar௡ Gear Lubri cant
80W-90 (Trai l er Towi ng Mopar௡ Syntheti c Gear
Lubri cant 75W-140)
• RUBI CON 226 RBI (Model 44) - Mopar௡ Syn-
theti c Gear Lubri cant 75W-140
NOTE: Trac-lokா equipped axles require 118 ml (4
ounces) of Limited Slip Additive in the lubricant.
DESCRIPTION - MANUAL TRANSMISSION
NOTE: DaimlerChrysler recommends using Moparா
lubricants or lubricants of equal quality.
• NV1500 - Mopar௡ Manual Transmi ssi on Lubri -
cant
• NV3550 - Mopar௡ Manual Transmi ssi on Lubri -
cant
TJ LUBRICATION & MAINTENANCE 0 - 5
FLUID TYPES (Continued)
DESCRIPTION - AUTOMATIC TRANSMISSION
FLUID
NOTE: Refer to Service Procedures in this group for
fluid level checking procedures.
Mopar௡ ATF +4, Automati c Transmi ssi on Fl ui d i s
the recommended fl ui d for Dai ml erChrysl er auto-
mati c transmi ssi ons.
Dexron II fluid IS NOT recommended. Clutch
chatter can result from the use of improper
fluid.
Mopar௡ ATF +4, Automati c Transmi ssi on Fl ui d
when new i s red i n col or. The ATF i s dyed red so i t
can be i denti fi ed from other fl ui ds used i n the vehi cl e
such as engi ne oi l or anti freeze. The red col or i s not
permanent and i s not an i ndi cator of fl ui d condi ti on.
As the vehi cl e i s dri ven, the ATF wi l l begi n to l ook
darker i n col or and may eventual l y become brown.
This is normal. ATF+4 al so has a uni que odor that
may change wi th age. Consequentl y, odor and col or
cannot be used to i ndi cate the fl ui d condi ti on or the
need for a fl ui d change.
FLUID ADDITIVES
Dai ml erChrysl er strongl y recommends agai nst the
addi ti on of any fl ui ds to the transmi ssi on, other than
those automati c transmi ssi on fl ui ds l i sted above.
Excepti ons to thi s pol i cy are the use of speci al dyes
to ai d i n detecti ng fl ui d l eaks.
Vari ous “speci al ” addi ti ves and suppl ements exi st
that cl ai m to i mprove shi ft feel and/or qual i ty. These
addi ti ves and others al so cl ai m to i mprove converter
cl utch operati on and i nhi bi t overheati ng, oxi dati on,
varni sh, and sl udge. These cl ai ms have not been sup-
ported to the sati sfacti on of Dai ml erChrysl er and
these addi ti ves must not be used. The use of trans-
mi ssi on “seal ers” shoul d al so be avoi ded, si nce they
may adversel y affect the i ntegri ty of transmi ssi on
seal s.
DESCRIPTION - POWER STEERING FLUID
The recommended fl ui d for the power steeri ng sys-
tem i s Mopar௡ ATF +4.
Mopar௡ ATF+4, when new i s red i n col or. The
ATF+4 i s dyed red so i t can be i denti fi ed from other
fl ui ds used i n the vehi cl e such as engi ne oi l or anti -
freeze. The red col or i s not permanent and i s not an
i ndi cator of fl ui d condi ti on, As the vehi cl e i s dri ven,
the ATF+4 wi l l begi n to l ook darker i n col or and may
eventual l y become brown. THIS IS NORMAL.
ATF+4 al so has a uni que odor that may change wi th
age. Consequentl y, odor and col or cannot be used to
i ndi cate the fl ui d condi ti on or the need for a fl ui d
change.
OPERATION - AUTOMATIC TRANSMISSION
FLUID
The automati c transmi ssi on fl ui d i s sel ected based
upon several qual i ti es. The fl ui d must provi de a hi gh
l evel of protecti on for the i nternal components by
provi di ng a l ubri cati ng fi l m between adjacent metal
components. The fl ui d must al so be thermal l y stabl e
so that i t can mai ntai n a consi stent vi scosi ty through
a l arge temperature range. I f the vi scosi ty stays con-
stant through the temperature range of operati on,
transmi ssi on operati on and shi ft feel wi l l remai n con-
si stent. Transmi ssi on fl ui d must al so be a good con-
ductor of heat. The fl ui d must absorb heat from the
i nternal transmi ssi on components and transfer that
heat to the transmi ssi on case.
FLUID CAPACITIES
SPECIFICATIONS - FLUID CAPACITIES
DESCRIPTION SPECIFICATION
FUEL TANK 19 U.S. Gallons (71.9
Liters)****
ENGINE OIL
Engine Oil - with Filter -
2.4L
3.8 L (4.0 qts.)
Engine Oil - with Filter -
4.0L
5.7 L (6.0 qts.)
ENGINE COOLANT
Cooling System - 2.4 L 8.5 L (9.0 qts.)
Cooling System - 4.0 L 9.9 L (10.5 qts.)
POWER STEERING SYSTEM
Power steering fluid capacities are dependent on
engine/chassis options as well as steering gear/cooler
options. Depending on type and size of internal
cooler, length and inside diameter of cooler lines, or
use of an auxiliary cooler, these capacities may vary.
Refer to 19, Steering for proper fill and bleed
procedures.
AUTOMATIC TRANSMISSION
Service Fill - 42RLE 3.8 L (8.0 pts)
O-haul Fill - 42RLE 8.3 L (17.6 pts.)
Dry fill capacity Depending on type and size of
internal cooler, length and inside diameter of cooler
lines, or use of an auxiliary cooler, these figures may
vary. (Refer to 21 - TRANSMISSION/AUTOMATIC -
42RLE/FLUID - STANDARD PROCEDURE)
0 - 6 LUBRICATION & MAINTENANCE TJ
FLUID TYPES (Continued)
DESCRIPTION SPECIFICATION
TRANSFER CASE
NV231 1.0 L (2.2 pts.)
NV241 2.0 L (4.2 pts.)
MANUAL TRANSMISSION
NV1500 Approximate dry
fill or fill to bottom edge of
the fill plug hole.
2.3 L (4.8 pts.)
NV3550 Approximate dry
fill or fill to bottom edge of
fill plug hole.
1.98 L (4.2 pts.)
FRONT AXLE ± .03 L (1 oz.)
181 FBI (Model 30) 1.2 L (2.5 pts.)
216 RBI (Model 44) 1.89 L (4.0 pts.)
REAR AXLE ± .03 L (1 oz.)
194 RBI (Model 35) 1.66 L (3.5 pts.)*
216 RBI (Model 44) 1.89 L (4.0 pts.)*
* With Trac-lok add 118 ml (4.0 oz.) of Limited Slip
Additive.
****Nominal refill capacities are shown. A variation
may be observed from vehicle to vehicle due to
manufacturing tolerance and refill procedure.
MAINTENANCE SCHEDULES
DESCRIPTION
DESCRIPTION – DOMESTIC SCHEDULES
Mai ntenance Schedul e I nformati on not i ncl uded i n
thi s secti on, i s l ocated i n the appropri ate Owner’s
Manual .
There are two mai ntenance schedul es that show
the required servi ce for your vehi cl e.
Fi rst i s Schedul e ؆B؆. I t i s for vehi cl es that are
operated under the condi ti ons that are l i sted bel ow
and at the begi nni ng of the schedul e.
• Day or ni ght temperatures are bel ow 0°C (32°F)
• Stop and go dri vi ng
• Excessi ve engi ne i dl i ng
• Dri vi ng i n dusty condi ti ons
• Short tri ps of l ess than 16.2 km (10 mi l es)
• More than 50% of your dri vi ng i s at sustai ned
hi gh speeds duri ng hot weather, above 32°C (90°F)
• Trai l er towi ng
• Taxi , pol i ce, or del i very servi ce (commerci al ser-
vi ce)
• Off-road or desert dri vi ng
• If equipped for and operated with E-85
(ethanol) fuel.
NOTE: Most vehicles are operated under the condi-
tions listed for Schedule “B.”
Second i s Schedul e “A”. I t i s for vehi cl es that are
not operated under any of the condi ti ons l i sted under
Schedul e “B.”
Use the schedul e that best descri bes your dri vi ng
condi ti ons. Where ti me and mi l eage are l i sted, fol l ow
the i nterval that occurs fi rst.
CAUTION: Failure to perform the required mainte-
nance items may result in damage to the vehicle.
At Each Stop for Fuel
• Check the engi ne oi l l evel about 5 mi nutes after
a ful l y warmed engi ne i s shut off. Checki ng the oi l
l evel whi l e the vehi cl e i s on l evel ground wi l l
i mprove the accuracy of the oi l l evel readi ng. Add oi l
onl y when the l evel i s at or bel ow the ADD or MI N
mark.
• Check the wi ndshi el d washer sol vent, add as
requi red.
Once a Month
• Check the ti re pressure and l ook for unusual
wear or damage.
• I nspect the battery and cl ean and ti ghten the
termi nal s as requi red.
• Check the fl ui d l evel s of the cool ant reservoi r,
brake master cyl i nder, power steeri ng, and transmi s-
si on, and add as needed.
• Check al l l i ghts and al l other el ectri cal i tems for
correct operati on.
At Each Oil Change
• Change the engi ne oi l fi l ter.
• I nspect the exhaust system.
• I nspect brake hoses.
• Check the cool ant l evel , hoses, and cl amps.
• Rotate the ti res.
• I nspect manual transmi ssi on fl ui d l evel — i f
equi pped.
• After compl eti on of off-road operati on, the
undersi de of the vehi cl e shoul d be thoroughl y
i nspected. Exami ne threaded fasteners for l ooseness.
TJ LUBRICATION & MAINTENANCE 0 - 7
FLUID CAPACITIES (Continued)
Schedule “B”
Fol l ow thi s schedul e i f you usual l y operate your
vehi cl e under one or more of the fol l owi ng condi ti ons.
• Day or ni ght temperatures are bel ow 0°C (32°F)
• Stop and go dri vi ng
• Excessi ve engi ne i dl i ng
• Dri vi ng i n dusty condi ti ons
• Short tri ps of l ess than 16.2 km (10 mi l es)
• More than 50% of your dri vi ng i s at sustai ned
hi gh speeds duri ng hot weather, above 32°C (90°F)
• Trai l er towi ng
• Taxi , pol i ce, or del i very servi ce (commerci al ser-
vi ce)
• Off-road or desert dri vi ng
• If equipped for and operated with E-85
(ethanol) fuel.
Miles 3,000 6,000 9,000 12,000 15,000
(Kilometers) (5 000) (10 000) (14 000) (19 000) (24 000)
Change the engine oil and engine oil filter. X X X X X
Inspect the engine air filter element,
replace if necessary.
X
Lubricate the steering linkage tie rod ends. X X X X X
Lubricate the steering and suspension ball
joints.
X X
Inspect the brake linings. X
Drain and refill the front and rear axle fluid‡ X
Miles 18,000 21,000 24,000 27,000 30,000
(Kilometers) (29 000) (34 000) (38 000) (43 000) (48 000)
Change the engine oil and engine oil filter. X X X X X
Inspect the engine air filter element,
replace if necessary.
X
Inspect the PCV Valve, and replace if
necessary.छ
X
Replace the spark plugs. X
Lubricate the steering linkage tie rod ends. X X X X X
Lubricate the steering and suspension ball
joints.
X X X
Inspect the brake linings. X
Drain and refill the front and rear axle fluid‡ X
Inspect the transfer case fluid, add if
necessary.
X
Miles 33,000 36,000 39,000 42,000 45,000
(Kilometers) (53 000) (58 000) (62 000) (67 000) (72 000)
Change the engine oil and engine oil filter. X X X X X
Inspect the engine air filter element,
replace if necessary.
X
Lubricate the steering linkage tie rod ends. X X X X X
Lubricate the steering and suspension ball
joints.
X X
Inspect the brake linings. X
Drain and refill the front and rear axle fluid‡ X
0 - 8 LUBRICATION & MAINTENANCE TJ
MAINTENANCE SCHEDULES (Continued)
Miles 33,000 36,000 39,000 42,000 45,000
(Kilometers) (53 000) (58 000) (62 000) (67 000) (72 000)
Inspect the drive belt and replace as
needed.
X
Miles 48,000 51,000 54,000 57,000 60,000
(Kilometers) (77 000) (82 000) (86 000) (91 000) (96 000)
Change the engine oil and engine oil filter. X X X X X
Inspect the engine air filter element,
replace if necessary.
X
Inspect the PCV Valve, and replace if
necessary.छ
X
Inspect the ignition cables, and replace
if necessary (2.4L Only).
X
Replace the spark plugs. X
Lubricate the steering linkage tie rod ends. X X X X X
Lubricate the steering and suspension ball
joints.
X X X
Inspect the brake linings. X X
Drain and refill the front and rear axle fluid‡ X X
Drain and refill the automatic transmission
fluid, and change filter.
X
Inspect the drive belt and replace as
needed. Not required if belt was previously.
X
Drain and refill the transfer case fluid. X
Miles 63,000 66,000 69,000 72,000 75,000
(Kilometers) (101 000) (106 000) (110 000) (115 000) (120 000)
Change the engine oil and engine oil filter. X X X X X
Inspect the engine air filter element,
replace if necessary.
X
Lubricate the steering linkage tie rod ends. X X X X X
Lubricate the steering and suspension ball
joints.
X X
Inspect the brake linings. X
Drain and refill the front and rear axle fluid‡ X
Inspect the drive belt and replace as
needed. Not required if belt was previously
replaced.
X
Miles 78,000 81,000 84,000 87,000 90,000
(Kilometers) (125 000) (130 000) (134 000) (139 000) (144 000)
Change the engine oil and engine oil filter. X X X X X
Inspect the engine air filter element,
replace if necessary.
X
TJ LUBRICATION & MAINTENANCE 0 - 9
MAINTENANCE SCHEDULES (Continued)
Miles 78,000 81,000 84,000 87,000 90,000
(Kilometers) (125 000) (130 000) (134 000) (139 000) (144 000)
Inspect the PCV Valve, and replace if
necessary.छ
X
Replace the spark plugs. X
Lubricate the steering linkage tie rod ends. X X X X X
Lubricate the steering and suspension ball
joints.
X X X
Replace the timing belt (2.4L Only). X
Inspect the brake linings. X
Drain and refill the front and rear axle fluid‡ X
Inspect the drive belt and replace as
needed. Not required if belt was previously
replaced.
X
Inspect the transfer case fluid, add if
necessary.
X
Miles 93,000 96,000 99,000 102,000 105,000
(Kilometers) (149 000) (154 000) (158 000) (163 000) (168 000)
Change the engine oil and engine oil filter. X X X X X
Inspect the engine air filter element,
replace if necessary.
X
Lubricate the steering linkage tie rod ends. X X X X X
Lubricate the steering and suspension ball
joints.
X X
Inspect the brake linings. X
Drain and refill the front and rear axle fluid‡ X
Inspect the drive belt and replace as
needed. Not required if belt was previously
replaced.
X
Flush and replace the engine coolant. X
Miles 108,000 111,000 114,000 117,000 120,000
(Kilometers) (173 000) (178 000) (182 000) (187 000) (192 000)
Change the engine oil and engine oil filter. X X X X X
Inspect the engine air filter element,
replace if necessary.
X
Inspect the PCV Valve, and replace if
necessary.छ
X
Replace the spark plugs. X
Inspect the ignition cables, and replace
if necessary (2.4L Only).
X
Lubricate the steering linkage tie rod ends. X X X X X
0 - 10 LUBRICATION & MAINTENANCE TJ
MAINTENANCE SCHEDULES (Continued)
Miles 108,000 111,000 114,000 117,000 120,000
(Kilometers) (173 000) (178 000) (182 000) (187 000) (192 000)
Lubricate the steering and suspension ball
joints.
X X X
Inspect the brake linings. X X
Drain and refill the front and rear axle fluid‡ X X
Drain and refill the automatic transmission
fluid, and replace main sump filter.
X
Inspect the drive belt and replace as
needed. Not required if belt was previously
replaced.
X
Drain and refill the transfer case fluid. X
I nspecti on and servi ce shoul d al so be performed
anyti me a mal functi on i s observed or suspected.
छ Thi s mai ntenance i s recommended by the man-
ufacturer to the owner, but i s not requi red to mai n-
tai n emi ssi ons warranty.
‡Off-hi ghway operati on, trai l er towi ng, taxi , l i mou-
si ne, bus, snow pl owi ng, or other types of commerci al
servi ce or prol onged operati on wi th heavy l oadi ng,
especi al l y i n hot weather, requi re front and rear axl e
servi ce i ndi cated wi th a ‡ i n Schedul e “B”. Perform
these servi ces i f the vehi cl e i s usual l y operated under
these condi ti ons.
Schedule “A”
Miles 6,000 12,000 18,000 24,000 30,000
(Kilometers) (10 000) (19 000) (29 000) (38 000) (48 000)
[Months] [6] [12] [18] [24] [30]
Change the engine oil and engine oil filter. X X X X X
Inspect the engine air filter element, and
replace if necessary.
X
Replace the spark plugs. X
Lubricate the steering linkage joints and
outer tie rod ends.
X X X X X
Lubricate the steering and suspension ball
joints.
X X
Inspect the brake linings. X
Inspect the transfer case fluid. X
Miles 36,000 42,000 48,000 54, 000
(Kilometers) (58 000) (67 000) (77 000) (86 000)
[Months] [36] [42] [48] [54]
Change the engine oil and engine oil filter. X X X X
Lubricate the steering and suspension ball joints. X X
Lubricate the steering linkage joints and outer tie rod
ends.
X X X X
Inspect the brake linings. X X
TJ LUBRICATION & MAINTENANCE 0 - 11
MAINTENANCE SCHEDULES (Continued)
Miles 60,000 66,000 72,000 78,000
(Kilometers) (96 000) (106 000) (115 000) (125 000)
[Months] [60] [66] [72] [78]
Change the engine oil and engine oil filter. X X X X
Inspect the engine air filter element, and replace if
necessary.
X
Inspect the PCV Valve, and replace if necessary.छ X
Replace the ignition cables (2.4L Only). X
Replace the spark plugs. X
Lubricate the steering linkage joints and outer tie rod
ends.
X X X X
Lubricate the steering and suspension ball joints. X X
Inspect the brake linings. X
Inspect the drive belt, and replace as needed. X
Inspect the drive belt, and replace as needed. Not
required if belt was previously replaced.
X
Flush and replace the engine coolant at 60 months,
regardless of mileage.
X
Inspect transfer case fluid. X
Miles 84,000 90,000 96,000 102, 000
(Kilometers) (134 000) (144 000) (154 000) (163 000)
[Months] [84] [90] [96] [102]
Change the engine oil and engine oil filter. X X X X
Inspect the engine air filter element, and replace if
necessary.
X
Inspect the PCV Valve, and replace if necessary.छ X
Replace the spark plugs. X
Lubricate the steering linkage joints and outer tie rod
ends.
X X X X
Lubricate the steering and suspension ball joints. X X
Inspect the brake linings. X
Inspect the drive belt, and replace as needed. Not
required if previously replaced.
X X
Flush and replace the engine coolant if not done at 60
months.
X
Inspect the transfer case fluid. X
Miles 108,000 114,000 120,000
(Kilometers) (173 000) (182 000) (192 000)
[Months] [108] [114] [120]
Change the engine oil and engine oil filter. X X X
Inspect the engine air filter element, and replace if necessary. X
Replace the ignition cables (2.4L Only). X
Inspect the PCV Valve, and replace if necessary.छ X
0 - 12 LUBRICATION & MAINTENANCE TJ
MAINTENANCE SCHEDULES (Continued)
Miles 108,000 114,000 120,000
(Kilometers) (173 000) (182 000) (192 000)
[Months] [108] [114] [120]
Replace the spark plugs. X
Lubricate the steering linkage joints and outer tie rod ends. X X X
Lubricate the steering and suspension ball joints. X X
Inspect the brake linings. X
Replace the timing belt (2.4L Only). X
Inspect the drive belt, and replace as needed. Not required if
previously replaced.
X
Drain and refill the transfer case fluid. X
I nspecti on and servi ce shoul d al so be performed
anyti me a mal functi on i s observed or suspected.
छ Thi s mai ntenance i s recommended by the man-
ufacturer to the owner, but i s not requi red to mai n-
tai n emi ssi ons warranty.
DESCRIPTION – GASOLINE ENGINES –
EXPORT SCHEDULES
Mai ntenance Schedul e I nformati on not i ncl uded i n
thi s secti on, i s l ocated i n the appropri ate Owner’s
Manual .
There are two mai ntenance schedul es that show
the required servi ce for your vehi cl e.
Fi rst i s Schedul e “A”. I t i s for vehi cl es that are not
operated under any of the condi ti ons l i sted under
Schedul e “B.”
Second i s Schedul e ؆B؆. I t i s for vehi cl es that are
operated under the condi ti ons that are l i sted bel ow
and at the begi nni ng of the schedul e.
• Day or ni ght temperatures are bel ow 0°C (32°F).
• Stop and go dri vi ng.
• Extensi ve engi ne i dl i ng.
• Dri vi ng i n dusty condi ti ons.
• Short tri ps of l ess than 16.2 km (10 mi l es).
• More than 50% of your dri vi ng i s at sustai ned
hi gh speeds duri ng hot weather, above 32°C (90°F).
• Trai l er towi ng.
• Taxi , pol i ce, or del i very servi ce (commerci al ser-
vi ce).
• Off-road or desert dri vi ng.
NOTE: Most vehicles are operated under the condi-
tions listed for Schedule “B.”
Use the schedul e that best descri bes your dri vi ng
condi ti ons. Where ti me and mi l eage are l i sted, fol l ow
the i nterval that occurs fi rst.
CAUTION: Failure to perform the required mainte-
nance items may result in damage to the vehicle.
At Each Stop for Fuel
• Check the engi ne oi l l evel about 5 mi nutes after
a ful l y warmed engi ne i s shut off. Checki ng the oi l
l evel whi l e the vehi cl e i s on l evel ground wi l l
i mprove the accuracy of the oi l l evel readi ng. Add oi l
onl y when the l evel i s at or bel ow the ADD or MI N
mark.
• Check the wi ndshi el d washer sol vent, add as
requi red.
Once a Month
• Check the ti re pressure and l ook for unusual
wear or damage.
• I nspect the battery and cl ean and ti ghten the
termi nal s as requi red.
• Check the fl ui d l evel s of the cool ant reservoi r,
brake master cyl i nder, power steeri ng, and transmi s-
si on, and add as needed.
• Check al l l i ghts and al l other el ectri cal i tems for
correct operati on.
At Each Oil Change
• Change the engi ne oi l fi l ter.
• I nspect the exhaust system.
• I nspect brake hoses.
• Check the cool ant l evel , hoses, and cl amps.
• Rotate the ti res.
• I nspect manual transmi ssi on fl ui d l evel — i f
equi pped.
• After compl eti on of off-road operati on, the
undersi de of the vehi cl e shoul d be thoroughl y
i nspected. Exami ne threaded fasteners for l ooseness.
TJ LUBRICATION & MAINTENANCE 0 - 13
MAINTENANCE SCHEDULES (Continued)
Schedule “A”
Kilometers 12 000 24 000 36 000 48 000 60 000
(Miles) (7,500) (15,000) (22,500) (30,000) (37,500)
[Months] [6] [12] [18] [24] [30]
Change the engine oil and engine oil filter. X X X X X
Inspect the engine air filter element,
replace if necessary.
X
Replace the spark plugs. X
Inspect the brake linings. X
Inspect the transfer case fluid. X
Kilometers 72 000 84 000 96 000 108 000
(Miles) (45,000) (52,500) (60,000) (67,500)
[Months] [36] [42] [48] [54]
Change the engine oil and engine oil filter. X X X X
Inspect the engine air filter element, replace if
necessary.
X
Inspect and replace the PCV valve, if necessaryछ. X
Inspect the ignition cables, and replace if necessary
(2.4L Only).
X
Replace the spark plugs. X
Inspect the brake linings. X X
Inspect and replace the Auto Tension Drive Belt, as
needed.
X
Inspect the transfer case fluid. X
Kilometers 120 000 132 000 144 000 156 000
(Miles) (75,000) (82,500) (90,000) (97,500)
[Months] [60] [66] [72] [78]
Change the engine oil and engine oil filter. X X X X
Inspect the brake linings. X
Inspect the engine air filter element, replace if
necessary.
X
Replace the spark plugs. X
Inspect and replace the PCV valve, if necessary.छ X
Inspect the drive belt and replace as needed. Not
required if previously replaced.
X X
Flush and replace the engine coolant at 60 months,
regardless of mileage.
X
Inspect the transfer case fluid. X
0 - 14 LUBRICATION & MAINTENANCE TJ
MAINTENANCE SCHEDULES (Continued)
Kilometers 160 000 168 000 180 000 192 000
(Miles) (100,000) (105,000) (112,500) (120,000)
[Months] [84] [90] [96]
Change the engine oil and engine oil filter. X X X
Inspect the brake linings. X
Inspect the engine air filter element, replace if
necessary.
X
Replace the spark plugs. X
Inspect the ignition cables, replace if necessary (2.4L
Only).
X
Inspect and replace the PCV valve, if necessary.छ X
Inspect the drive belt and replace as needed. Not
required if previously replaced.
X X
Flush and replace the engine coolant if not done at 60
months.
X
Replace the timing belt (2.4L Only). X
Drain the transfer case, and refill. X
I nspecti on and servi ce shoul d al so be performed
anyti me a mal functi on i s observed or suspected.
छ Thi s mai ntenance i s recommended by the man-
ufacturer to the owner, but i s not requi red to mai n-
tai n emi ssi ons warranty.
Schedule “B”
Fol l ow schedul e “B” i f you usual l y operate your
vehi cl e under one or more of the fol l owi ng condi ti ons.
• Day or ni ght temperatures are bel ow 0°C (32°F).
• Stop and go dri vi ng.
• Extensi ve engi ne i dl i ng.
• Dri vi ng i n dusty condi ti ons.
• Short tri ps of l ess than 16.2 km (10 mi l es).
• More than 50% of your dri vi ng i s at sustai ned
hi gh speeds duri ng hot weather, above 32°C (90°F).
• Trai l er towi ng.
• Taxi , pol i ce, or del i very servi ce (commerci al ser-
vi ce).
• Off-road or desert dri vi ng.
Kilometers 5 000 10 000 14 000 19 000 24 000
(Miles) (3,000) (6,000) (9,000) (12,000) (15,000)
Change the engine oil and engine oil filter. X X X X X
Inspect the engine air filter element,
replace if necessary.
X
Inspect the brake linings. X
Drain and refill the front and rear axle fluid‡ X
Kilometers 29 000 34 000 38 000 43 000 48 000
(Miles) (18,000) (21,000) (24,000) (27,000) (30,000)
Change the engine oil and engine oil filter. X X X X X
Inspect the engine air filter element,
replace if necessary.
X
Replace the spark plugs. X
Inspect and replace the PCV valve, if
necessary.छ
X
Inspect the brake linings. X
TJ LUBRICATION & MAINTENANCE 0 - 15
MAINTENANCE SCHEDULES (Continued)
Kilometers 29 000 34 000 38 000 43 000 48 000
(Miles) (18,000) (21,000) (24,000) (27,000) (30,000)
Drain and refill the front and rear axle fluid‡ X
Inspect the transfer case fluid, add if
necessary.
X
Kilometers 53 000 58 000 62 000 67 000 72 000
(Miles) (33,000) (36,000) (39,000) (42,000) (45,000)
Change the engine oil and engine oil filter. X X X X X
Inspect the engine air filter element,
replace if necessary.
X
Inspect the brake linings. X
Drain and refill the front and rear axle fluid‡ X
Inspect the drive belt and replace as
needed.
X
Kilometers 77 000 82 000 86 000 91 000 96 000
(Miles) (48,000) (51,000) (54,000) (57,000) (60,000)
Change the engine oil and engine oil filter. X X X X X
Inspect the engine air filter element,
replace if necessary.
X
Replace the spark plugs. X
Inspect and replace the PCV valve, if
necessary.छ
X
Replace the ignition cables (2.4L Only). X
Inspect the brake linings. X X
Drain and refill the front and rear axle fluid‡ X X
Drain and refill the automatic transmission
fluid, and replace main sump filter.
X
Inspect the drive belt and replace as
needed. Not required if belt was previously
X
Drain and refill the transfer case fluid. X
Kilometers 101 000 106 000 110 000 115 000 120 000
(Miles) (63,000) (66,000) (69,000) (72,000) (75,000)
Change the engine oil and engine oil filter. X X X X X
Inspect the engine air filter element,
replace if necessary.
X
Inspect the brake linings. X
Drain and refill the front and rear axle fluid‡ X
Inspect the drive belt and replace as
needed. Not required if belt was previously
replaced.
X
0 - 16 LUBRICATION & MAINTENANCE TJ
MAINTENANCE SCHEDULES (Continued)
Kilometers 125 000 130 000 134 000 139 000 144 000
(Miles) (78,000) (81,000) (84,000) (87,000) (90,000)
Change the engine oil and engine oil filter. X X X X X
Inspect the engine air filter element,
replace if necessary.
X
Replace the spark plugs. X
Inspect and replace the PCV valve, if
necessary.छ
X
Inspect the brake linings. X
Drain and refill the front and rear axle fluid‡ X
Inspect the drive belt and replace as
needed. Not required if belt was previously
replaced.
X
Replace the timing belt (2.4L Only). X
Inspect the transfer case fluid, add if
necessary.
X
Kilometers 149 000 154 000 158 000 163 000 168 000
(Miles) (93,000) (96,000) (99,000) (102,000) (105,000)
Change the engine oil and engine oil filter. X X X X X
Inspect the engine air filter element,
replace if necessary.
X
Inspect the brake linings. X
Drain and refill the front and rear axle fluid‡ X
Inspect the drive belt and replace as
needed. Not required if belt was previously
replaced.
X
Flush and replace the engine coolant. X
Kilometers 173 000 178 000 182 000 187 000 192 000
(Miles) (108,000) (111,000) (114,000) (117,000) (120,000)
Change the engine oil and engine oil filter. X X X X X
Inspect the engine air filter element,
replace if necessary.
X
Replace the spark plugs. X
Inspect and replace the PCV valve, if
necessary.छ
X
Replace the ignition cables (2.4L Only). X
Inspect the brake linings. X X
Drain and refill the front and rear axle fluid‡ X X
Drain and refill the automatic transmission
fluid, and replace main sump filter.
X
Inspect the drive belt and replace as
needed. Not required if belt was previously
replaced.
X
Drain and refill the transfer case fluid. X
TJ LUBRICATION & MAINTENANCE 0 - 17
MAINTENANCE SCHEDULES (Continued)
I nspecti on and servi ce shoul d al so be performed
anyti me a mal functi on i s observed or suspected.
छ Thi s mai ntenance i s recommended by the man-
ufacturer to the owner, but i s not requi red to mai n-
tai n emi ssi ons warranty.
‡Off-hi ghway operati on, trai l er towi ng, taxi , l i mou-
si ne, bus, snow pl owi ng, or other types of commerci al
servi ce or prol onged operati on wi th heavy l oadi ng,
especi al l y i n hot weather, requi re front and rear axl e
servi ce i ndi cated wi th a ‡ i n Schedul e “B”. Perform
these servi ces i f the vehi cl e i s usual l y operated under
these condi ti ons.
DESCRIPTION – DIESEL ENGINES – EXPORT
SCHEDULES
There are two mai ntenance schedul es that show
the required servi ce for your vehi cl e.
Fi rst i s Schedul e “A”. I t i s for vehi cl es that are not
operated under any of the condi ti ons l i sted under
Schedul e ЉBЉ.
Second i s Schedul e “B”. I t i s for vehi cl es that are
operated under the condi ti ons that are l i sted bel ow
and at the begi nni ng of the schedul e.
• Extensi ve engi ne i dl i ng.
• Dri vi ng i n dusty condi ti ons.
• More than 50% of your dri vi ng i s at sustai ned
hi gh speeds duri ng hot weather, above 32° C (90° F).
• Trai l er towi ng.
• Taxi , pol i ce, or del i very servi ce (commerci al ser-
vi ce).
NOTE: Most vehicles are operated under the condi-
tions listed for Schedule ؆B؆.
Use the schedul e that best descri bes your dri vi ng
condi ti ons. Where ti me and mi l eage are l i sted, fol l ow
the i nterval that occurs fi rst.
CAUTION: Failure to perform the required mainte-
nance items may result in damage to the vehicle.
At Each Stop for Fuel
• Check the engi ne oi l l evel about 5 mi nutes after
a ful l y warmed engi ne i s shut off. Checki ng the oi l
l evel whi l e the vehi cl e i s on l evel ground wi l l
i mprove the accuracy of the oi l l evel readi ng. Add oi l
onl y when the l evel i s at or bel ow the ADD or MI N
mark.
• Check the wi ndshi el d washer sol vent and add i f
requi red.
Once a Month
• Check the ti re pressure and l ook for unusual
wear or damage.
• I nspect the battery and cl ean and ti ghten the
termi nal s as requi red.
• Check the fl ui d l evel s of cool ant deaerati on bot-
tl e, brake master cyl i nder, and transmi ssi on, and add
as needed.
• Check al l l i ghts and al l other el ectri cal i tems for
correct operati on.
At Each Oil Change
• Change the engi ne oi l fi l ter.
• I nspect the exhaust system.
• I nspect the brake hoses.
• Check the manual transmi ssi on fl ui d l evel — i f
equi pped.
• Check the cool ant l evel , hoses, and cl amps.
• I nspect engi ne accessory dri ve bel ts. Repl ace as
necessary.
• I nspect for the presence of water i n the fuel fi l -
ter/water separator uni t.
• Rotate the ti res.
Schedule “A”
Kilometers 20 000 km 40 000 km 60 000 km 80 000 km 100 000
km
Change the engine oil and engine oil filter. X X X X X
Inspect the engine air filter element.
Replace as necessary.
X X X
Replace the engine air filter element. X X
Replace the fuel filter/water separator unit. X X X X X
Replace the engine timing belt, and idler
pulleys.
X
Inspect timing belt tensioner, and replace if
necessary.‡
X
Inspect the engine accessory drive belt. X X X X
Replace the engine accessory drive belt. X
0 - 18 LUBRICATION & MAINTENANCE TJ
MAINTENANCE SCHEDULES (Continued)
Kilometers 20 000 km 40 000 km 60 000 km 80 000 km 100 000
km
Inspect the ball joints. X X X X X
Inspect the brake linings. X X
Inspect the transfer case fluid. X
Kilometers 120 000
km
140 000
km
160 000
km
180 000
km
Change the engine oil and engine oil filter. X X X X
Inspect the engine accessory drive belts, and replace if
necessary.
X X X X
Inspect the engine air filter element. Replace as
necessary.
X X
Replace the engine air filter element. X X
Replace the fuel filter/water separator unit. X X X X
Flush and replace the engine coolant. X
Inspect the ball joints. X X X X
Inspect the brake linings. X X
Drain and refill the automatic transmission fluid, change
sump filter, and cooler return filter (if equipped).
X
Inspect the transfer case fluid. X
Drain and refill the transfer case fluid. X
I nspecti on and servi ce shoul d al so be performed
anyti me a mal functi on i s observed or suspected.
‡ Repl ace i f there i s superfi ci al wear, beari ng cl ear-
ance, or evi dent grease l eak.
WARNING: You can be badly injured working on or
around a motor vehicle. Do only that service work
for which you have the knowledge and the right
equipment. If you have any doubt about your ability
to perform a service job, take your vehicle to a
competent mechanic.
Schedule “B”
Fol l ow schedul e “B” i f you usual l y operate your
vehi cl e under one or more of the fol l owi ng condi ti ons.
• Extensi ve engi ne i dl i ng.
• Dri vi ng i n dusty condi ti ons.
• More than 50% of your dri vi ng i s at sustai ned
hi gh speeds duri ng hot weather, above 32° C (90° F).
• Trai l er towi ng.
• Taxi , pol i ce, or del i very servi ce (commerci al ser-
vi ce).
Kilometers 10 000 km 20 000 km 30 000 km 40 000 km 50 000 km
Change the engine oil and engine oil filter. X X X X X
Inspect the engine air filter element.
Replace as necessary.
X X X
Replace the engine air filter element. X X
Replace the fuel filter/water separator unit. X X
Inspect the engine accessory drive belt. X X X X
Replace the engine accessory drive belt. X
Replace the engine timing belt and idler
pulleys.
X
Inspect the timing belt tensioner.‡ X
Inspect the ball joints. X X X X X
TJ LUBRICATION & MAINTENANCE 0 - 19
MAINTENANCE SCHEDULES (Continued)
Kilometers 10 000 km 20 000 km 30 000 km 40 000 km 50 000 km
Inspect the brake linings. X X
Drain and refill the front and rear axle fluid. X X
Drain and refill the automatic transmission
fluid, and replace sump filter.
X
Kilometers 60 000 km 70 000 km 80 000 km 90 000 km 100 000
km
Change the engine oil and engine oil filter. X X X X X
Inspect the engine air filter element.
Replace as necessary.
X X
Replace the engine air filter element. X X X
Replace the fuel filter/water separator unit. X X X
Inspect the engine accessory drive belt. X X X X
Replace the engine accessory drive belt. X
Replace the engine timing belt, idler
pulleys, and tensioner.
X
Inspect the ball joints. X X X X X
Inspect the brake linings. X X X
Drain and refill the front and rear axle fluid. X X X
Drain and refill the transfer case fluid. X
Drain and refill the automatic transmission
fluid, and replace sump filter.
X
Kilometers 110 000
km
120 000
km
130 000
km
140 000
km
150 000
km
160 000
km
Change the engine oil and
engine oil filter.
X X X X X X
Inspect the engine air filter
element. Replace as
necessary.
X X X
Replace the engine air filter
element.
X X X
Inspect the engine accessory
drive belts, and replace if
necessary.
X X X X X
Replace the engine accessory
drive belt.
X
Inspect the timing belt
tensioner.‡
X
Replace the engine timing
belt and idler pulleys.
X
Replace the fuel filter/water
separator unit.
X X X
Flush and replace the engine
coolant.
X
Inspect the ball joints. X X X X X X
0 - 20 LUBRICATION & MAINTENANCE TJ
MAINTENANCE SCHEDULES (Continued)
Kilometers 110 000
km
120 000
km
130 000
km
140 000
km
150 000
km
160 000
km
Inspect the brake linings. X X X
Drain and refill the front and
rear axle fluid.
X X X
Drain and refill the automatic
transmission fluid, and
replace sump filter.
X
Replace the transmission
cooler return filter (if
equipped).
X
I nspecti on and servi ce shoul d al so be performed
anyti me a mal functi on i s observed or suspected.
‡ Repl ace i f there i s superfi ci al wear, beari ng cl ear-
ance, or evi dent grease l eak.
HOISTING
STANDARD PROCEDURE - HOISTING
RECOMMENDATIONS
Refer to the Owner’s Manual for emergency vehi cl e
l i fti ng procedures.
When properl y posi ti oned, a fl oor jack can be used
to l i ft a Jeep vehi cl e (Fi g. 5). Support the vehi cl e i n
the rai sed posi ti on wi th jack stands at the front and
rear ends of the frame rai l s.
CAUTION: Do not attempt to lift a Jeep vehicle with
a floor jack positioned under:
• An axl e tube.
• A body si de si l l .
• A steeri ng l i nkage component.
• A dri ve shaft.
• The engi ne or transmi ssi on oi l pan.
• The fuel tank.
• A front suspensi on arm.
• Transfer case.
NOTE: Use the correct sub-frame rail or frame rail
lifting locations only.
HOIST
Refer to the Owner’s Manual for emergency vehi cl e
l i fti ng procedures.
A vehi cl e can be l i fted wi th:
• A si ngl e-post, frame-contact hoi st.
• A twi n-post, chassi s hoi st.
• A ramp-type, dri ve-on hoi st.
NOTE: When a frame-contact type hoist is used,
verify that the lifting pads are positioned properly.
WARNING: THE HOISTING AND JACK LIFTING
POINTS PROVIDED ARE FOR A COMPLETE VEHI-
CLE. WHEN A CHASSIS OR DRIVETRAIN COMPO-
NENT IS REMOVED FROM A VEHICLE, THE
CENTER OF GRAVITY IS ALTERED MAKING SOME
HOISTING CONDITIONS UNSTABLE. PROPERLY
SUPPORT OR SECURE VEHICLE TO HOISTING
DEVICE WHEN THESE CONDITIONS EXIST.
Fig. 5 Vehicle Lifting Locations
TJ LUBRICATION & MAINTENANCE 0 - 21
MAINTENANCE SCHEDULES (Continued)
TOWING
STANDARD PROCEDURE - TOWING
RECOMMENDATIONS
Dai ml erChrysl er Corporati on recommends that a
4WD vehi cl e be transported on a fl at-bed devi ce. A
Wheel -l i ft or front end attached Sl i ng-type devi ce can
be used provi ded al l the wheel s are l i fted off the
ground usi ng tow dol l i es (Fi g. 6) and (Fi g. 7).
SAFETY PRECAUTIONS
• Secure l oose and protrudi ng parts.
• Al ways use a safety chai n system that i s i nde-
pendent of the l i fti ng and towi ng equi pment.
• Do not al l ow towi ng equi pment to contact the
di sabl ed vehi cl e’s fuel tank.
• Do not al l ow anyone under the di sabl ed vehi cl e
whi l e i t i s l i fted by the towi ng devi ce.
• Do not al l ow passengers to ri de i n a vehi cl e
bei ng towed.
• Al ways observe state and l ocal l aws regardi ng
towi ng regul ati ons.
• Do not tow a vehi cl e i n a manner that coul d
jeopardi ze the safety of the operator, pedestri ans or
other motori sts.
• Do not attach tow chai ns, T-hooks, J-hooks, or a
tow sl i ng to a bumper, steeri ng l i nkage, dri ve shafts
or a non-rei nforced frame hol e.
GROUND CLEARANCE
CAUTION: If vehicle is towed with wheels removed,
install lug nuts to retain brake drums.
A towed vehi cl e shoul d be rai sed unti l l i fted wheel s
are a mi ni mum 100 mm (4 i n) from the ground. Be
sure there i s adequate ground cl earance at the oppo-
si te end of the vehi cl e, especi al l y when towi ng over
rough terrai n or steep ri ses i n the road. I f necessary,
remove the wheel s from the l i fted end of the vehi cl e
and l ower the vehi cl e cl oser to the ground, to
i ncrease the ground cl earance at the opposi te end of
the vehi cl e. I nstal l l ug nuts on wheel attachi ng studs
to retai n brake drums.
FLAT-BED TOWING RAMP ANGLE
I f a vehi cl e wi th fl at-bed towi ng equi pment i s used,
the approach ramp angl e shoul d not exceed 15
degrees.
VEHICLE TOWING
WARNING: WHEN TOWING A DISABLED VEHICLE
AND THE DRIVE WHEELS ARE SECURED IN A
WHEEL LIFT OR TOW DOLLIES, ENSURE THE
TRANSMISSION IS IN THE PARK POSITION (AUTO-
MATIC TRANSMISSION) OR A FORWARD DRIVE
GEAR (MANUAL TRANSMISSION).DO NOT ATTACH
SLING-TYPE TOWING EQUIPMENT TO THE REAR
OF A TJ.
TOWING-FRONT END LIFTED (WHEEL LIFT)
(1) Rai se the rear of the vehi cl e off the ground and
i nstal l tow dol l i es under rear wheel s.
(2) Attach the wheel l i ft to the front wheel s.
TOWING-REAR END LIFTED (WHEEL LIFT ONLY)
(1) Rai se the front of the vehi cl e off the ground
and i nstal l tow dol l i es under front wheel s.
(2) Attach the wheel l i ft to the rear wheel s.
TOWING-FRONT END LIFTED (SLING-TYPE)
(1) Rai se the rear of the vehi cl e off the ground and
i nstal l tow dol l i es under rear wheel s.
Fig. 6 Tow Vehicles With Approved Equipment
1 - SLING TYPE
2 - WHEEL LIFT
3 - FLAT BED
Fig. 7 Towing With Tow Dollies
1 - TOW DOLLY
0 - 22 LUBRICATION & MAINTENANCE TJ
(2) Attach T-hooks to the access hol es on the out-
board si de of the frame rai l s (Fi g. 8).
(3) Before ti ghteni ng the chai n, posi ti on a protec-
ti ve pad between the chai n and the bumper.
(4) Attach the safety chai ns to the vehi cl e (Fi g. 9).
(5) Turn the i gni ti on swi tch to the OFF posi ti on to
unl ock the steeri ng wheel .
RECREATIONAL TOWING
Refer to the Owners Manual for towi ng procedures.
EMERGENCY TOW HOOKS
WARNING: REMAIN AT A SAFE DISTANCE FROM A
VEHICLE THAT IS BEING TOWED VIA ITS TOW
HOOKS. THE TOW STRAPS/CHAINS COULD BREAK
AND CAUSE SERIOUS INJURY.
Some Jeep vehi cl es are equi pped wi th front emer-
gency tow hooks. The tow hooks shoul d be used for
EMERGENCY purposes onl y.
CAUTION: DO NOT use emergency tow hooks for
tow truck hook-up or highway towing.
J UMP STARTING
STANDARD PROCEDURE - JUMP STARTING
PROCEDURE
WARNING: REVIEW ALL SAFETY PRECAUTIONS
AND WARNINGS IN THE BATTERY SYSTEM SEC-
TION OF THE SERVICE MANUAL. (Refer to 8 -
ELECTRICAL/BATTERY SYSTEM/BATTERY - STAN-
DARD PROCEDURE)
• DO NOT JUMP START A FROZEN BATTERY,
PERSONAL INJURY CAN RESULT.
• IF EQUIPPED, DO NOT JUMP START WHEN
MAINTENANCE FREE BATTERY INDICATOR DOT IS
YELLOW OR BRIGHT COLOR.
• DO NOT JUMP START A VEHICLE WHEN THE
BATTERY FLUID IS BELOW THE TOP OF LEAD
PLATES.
• DO NOT ALLOW JUMPER CABLE CLAMPS TO
TOUCH EACH OTHER WHEN CONNECTED TO A
BOOSTER SOURCE.
• DO NOT USE OPEN FLAME NEAR BATTERY.
• REMOVE METALLIC JEWELRY WORN ON
HANDS OR WRISTS TO AVOID INJURY BY ACCI-
DENTAL ARCING OF BATTERY CURRENT.
• WHEN USING A HIGH OUTPUT BOOSTING
DEVICE, DO NOT ALLOW BATTERY VOLTAGE TO
EXCEED 16 VOLTS. REFER TO INSTRUCTIONS
PROVIDED WITH DEVICE BEING USED.
FAILURE TO FOLLOW THESE INSTRUCTIONS MAY
RESULT IN PERSONAL INJURY.
CAUTION: When using another vehicle as a
booster, do not allow vehicles to touch. Electrical
systems can be damaged on either vehicle.
Fig. 8 T-Hook Attachment
1 - PROTECTIVE PAD
2 - BUMPER
3 - CHAIN
4 - T-HOOK
5 - ACCESS HOLE
6 - FRAME
Fig. 9 Safety Chain Attachment
1 - SAFETY CHAIN
TJ LUBRICATION & MAINTENANCE 0 - 23
TOWING (Continued)
TO JUMP START A DISABLED VEHICLE:
(1) Rai se hood on di sabl ed vehi cl e and vi sual l y
i nspect engi ne compartment for:
• Generator dri ve bel t condi ti on and tensi on.
• Fuel fumes or l eakage, correct i f necessary.
• Frozen battery.
• Yel l ow or bri ght col or test i ndi cator, i f equi pped.
• Low battery fl ui d l evel .
CAUTION: If the cause of starting problem on dis-
abled vehicle is severe, damage to booster vehicle
charging system can result.
(2) When usi ng another vehi cl e as a booster
source, turn off al l accessori es, pl ace gear sel ector i n
park or neutral , set park brake or equi val ent and
operate engi ne at 1200 rpm.
(3) On di sabl ed vehi cl e, pl ace gear sel ector i n park
or neutral and set park brake or equi val ent. Turn
OFF al l accessori es.
(4) Connect jumper cabl es to booster battery. RED
cl amp to posi ti ve termi nal (+). BLACK cl amp to neg-
ati ve termi nal (-). DO NOT al l ow cl amps at opposi te
end of cabl es to touch, el ectri cal arc wi l l resul t (Fi g.
10). Revi ew al l warni ngs i n thi s procedure.
(5) On di sabl ed vehi cl e, connect RED jumper cabl e
cl amp to battery posi ti ve (+) termi nal . Connect
BLACK jumper cabl e cl amp to the engi ne as cl ose to
the ground cabl e connecti on as possi bl e (Fi g. 10).
CAUTION: Do not crank starter motor on disabled
vehicle for more than 15 seconds, starter will over-
heat and could fail.
(6) Al l ow battery i n di sabl ed vehi cl e to charge to
at l east 12.4 vol ts (75% charge) before attempti ng to
start engi ne. I f engi ne does not start wi thi n 15 sec-
onds, stop cranki ng engi ne and al l ow starter to cool
(15 mi n.), before cranki ng agai n.
DISCONNECT CABLE CLAMPS AS FOLLOWS:
• Di sconnect BLACK cabl e cl amp from engi ne
ground on di sabl ed vehi cl e.
• When usi ng a Booster vehi cl e, di sconnect
BLACK cabl e cl amp from battery negati ve termi nal .
Di sconnect RED cabl e cl amp from battery posi ti ve
termi nal .
• Di sconnect RED cabl e cl amp from battery posi -
ti ve termi nal on di sabl ed vehi cl e.
EMERGENCY TOW HOOKS
DESCRIPTION — EMERGENCY TOW HOOKS
WARNING: REMAIN AT A SAFE DISTANCE FROM A
VEHICLE THAT IS BEING TOWED VIA ITS TOW
HOOKS. THE TOW STRAPS/CHAINS COULD BREAK
AND CAUSE SERIOUS INJURY.
Some Jeep vehi cl es are equi pped wi th front emer-
gency tow hooks. The tow hooks shoul d be used for
EMERGENCY purposes onl y.
CAUTION: DO NOT use emergency tow hooks for
tow truck hook-up or highway towing.
Fig. 10 Jumper Cable Clamp Connections
1 - ENGINE GROUND
2 - NEGATIVE JUMPER CABLE
3 - BATTERY NEGATIVE CABLE
4 - POSITIVE JUMPER CABLE
5 - BATTERY POSITIVE CABLE
6 - BATTERY
7 - TEST INDICATOR (IF EQUIPPED)
0 - 24 LUBRICATION & MAINTENANCE TJ
J UMP STARTING (Continued)
SUSPENSION
TABLE OF CONTENTS
page page
WHEEL ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . 1
FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
WHEEL ALIGNMENT
TABLE OF CONTENTS
page page
WHEEL ALIGNMENT
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DIAGNOSIS AND TESTING - SUSPENSION
AND STEERING SYSTEM . . . . . . . . . . . . . . . . 2
STANDARD PROCEDURE
STANDARD PROCEDURE - CAMBER . . . . . . . 4
STANDARD PROCEDURE - CASTER . . . . . . . 4
STANDARD PROCEDURE - TOE POSITION . . 4
SPECIFICATIONS
ALIGNMENT SPECIFICATIONS . . . . . . . . . . . . 5
WHEEL ALIGNMENT
DESCRIPTION
Wheel al i gnment i nvol ves the correct posi ti oni ng of
the wheel s i n rel ati on to the vehi cl e. The posi ti oni ng
i s accompl i shed through suspensi on and steeri ng
l i nkage adjustments. An al i gnment i s consi dered
essenti al for effi ci ent steeri ng, good di recti onal stabi l -
i ty and to mi ni mi ze ti re wear. The most i mportant
measurements of an al i gnment are caster, camber
and toe posi ti on (Fi g. 1).
CAUTION: Never attempt to modify suspension or
steering components by heating or bending.
CAUTION: Components attached with a nut and cot-
ter pin must be torqued to specification. Then if the
slot in the nut does not line up with the cotter pin
hole, tighten nut until it is aligned. Never loosen the
nut to align the cotter pin hole.
NOTE: Periodic lubrication of the front suspension/
steering system components may be required. Rub-
ber bushings must never be lubricated. Refer to
Lubrication And Maintenance for the recommended
maintenance schedule.
OPERATION
• CASTER i s the forward or rearward ti l t of the
steeri ng knuckl e from verti cal . Ti l ti ng the top of the
knuckl e rearward provi des posi ti ve caster. Ti l ti ng the
top of the knuckl e forward provi des negati ve caster.
Caster i s a di recti onal stabi l i ty angl e. Thi s angl e
enabl es the front wheel s to return to a strai ght
ahead posi ti on after turns (Fi g. 1)
• CAMBER i s the i nward or outward ti l t of the
wheel rel ati ve to the center of the vehi cl e. Ti l ti ng the
top of the wheel i nward provi des negati ve camber.
Ti l ti ng the top of the wheel outward provi des posi ti ve
camber. I ncorrect camber wi l l cause wear on the
i nsi de or outsi de edge of the ti re. The angl e i s not
adjustabl e, damaged component(s) must be repl aced
to correct the camber angl e (Fi g. 1)
• WHEEL TOE POSITION i s the di fference
between the l eadi ng i nsi de edges and trai l i ng i nsi de
edges of the front ti res. I ncorrect wheel toe posi ti on
i s the most common cause of unstabl e steeri ng and
uneven ti re wear. The wheel toe posi ti on i s the final
front wheel al i gnment adjustment (Fi g. 1)
• STEERING AXIS INCLINATION ANGLE i s
measured i n degrees and i s the angl e that the steer-
i ng knuckl es are ti l ted. The i ncl i nati on angl e has a
fi xed rel ati onshi p wi th the camber angl e. I t wi l l not
change except when a spi ndl e or bal l stud i s dam-
aged or bent. The angl e i s not adjustabl e, damaged
TJ SUSPENSION 2 - 1
component(s) must be repl aced to correct the steeri ng
axi s i ncl i nati on angl e (Fi g. 1)
• THRUST ANGLE i s the angl e of the rear axl e
rel ati ve to the centerl i ne of the vehi cl e. I ncorrect
thrust angl e can cause off-center steeri ng and exces-
si ve ti re wear. Thi s angl e i s not adjustabl e, damaged
component(s) must be repl aced to correct the thrust
angl e (Fi g. 1)
DIAGNOSIS AND TESTING - SUSPENSION AND STEERING SYSTEM
CONDITION POSSIBLE CAUSES CORRECTION
FRONT END NOISE 1. Loose or worn wheel bearings. 1. Adjust or replace wheel bearings.
2. Loose or worn steering or
suspension components.
2. Tighten or replace components as
necessary.
EXCESSIVE PLAY IN
STEERING
1. Loose or worn wheel bearings. 1. Adjust or replace wheel bearings.
2. Loose or worn steering or
suspension components.
2. Tighten or replace components as
necessary.
3. Loose or worn steering gear. 3. Adjust or replace steering gear.
Fig. 1 Wheel Alignment Measurements
1 - WHEEL CENTERLINE
2 - NEGATIVE CAMBER ANGLE
3 - PIVOT CENTERLINE
4 - SCRUB RADIUS
5 - TRUE VERTICAL
6 - KING PIN
7 - VERTICAL
8 - POSITIVE CASTER
2 - 2 WHEEL ALIGNMENT TJ
WHEEL ALIGNMENT (Continued)
CONDITION POSSIBLE CAUSES CORRECTION
FRONT WHEELS SHIMMY 1. Loose or worn wheel bearings. 1. Adjust or replace wheel bearings.
2. Loose or worn steering or
suspension components.
2. Tighten or replace components as
necessary.
3. Tires worn or out of balance. 3. Replace or balance tires.
4. Alignment. 4. Align vehicle to specifications.
5. Leaking steering dampener. 5. Replace steering dampener.
VEHICLE INSTABILITY 1. Loose or worn wheel bearings. 1. Adjust or replace wheel bearings.
2. Loose or worn steering or
suspension components.
2. Tighten or replace components as
necessary.
3. Tire pressure. 3. Adjust tire pressure.
4. Alignment. 4. Align vehicle to specifications.
EXCESSIVE STEERING
EFFORT
1. Loose or worn steering gear. 1. Adjust or replace steering gear.
2. Power steering fluid low. 2. Add fluid and repair leak.
3. Column coupler binding. 3. Replace coupler.
4. Tire pressure. 4. Adjust tire pressure.
5. Alignment. 5. Align vehicle to specifications.
VEHICLE PULLS TO ONE
SIDE DURING BRAKING
1. Uneven tire pressure. 1. Adjust tire pressure.
2. Worn brake components. 2. Repair brakes as necessary.
3. Air in brake line. 3. Repair as necessary.
VEHICLE LEADS OR
DRIFTS FROM STRAIGHT
AHEAD DIRECTION ON
UNCROWNED ROAD
1. Radial tire lead. 1. Cross front tires.
2. Brakes dragging. 2. Repair brake as necessary.
3. Weak or broken spring. 3. Replace spring.
4. Uneven tire pressure. 4. Adjust tire pressure.
5. Wheel Alignment. 5. Align vehicle.
6. Loose or worn steering or
suspension components.
6. Repair as necessary.
7. Cross caster out of spec. 7. Align vehicle.
KNOCKING, RATTLING
OR SQUEAKING
1. Worn shock bushings. 1. Replace shock.
2. Loose, worn or bent steering/
suspension components.
2. Inspect, tighten or replace components
as necessary.
3. Shock valve. 3. Replace shock.
IMPROPER TRACKING 1. Loose, worn or bent track bar. 1. Inspect, tighten or replace component as
necessary.
2. Loose, worn or bent steering/
suspension components.
2. Inspect, tighten or replace components
as necessary.
TJ WHEEL ALIGNMENT 2 - 3
WHEEL ALIGNMENT (Continued)
STANDARD PROCEDURE
STANDARD PROCEDURE - CAMBER
Before each al i gnment readi ng the vehi cl e shoul d
be jounced (rear fi rst, then front). Grasp each
bumper at the center and jounce the vehi cl e up and
down three ti mes. Al ways rel ease the bumper i n the
down posi ti on.
The wheel camber angl e i s preset. Thi s angl e i s not
adjustabl e and cannot be al tered.
STANDARD PROCEDURE - CASTER
Before each al i gnment readi ng the vehi cl e shoul d
be jounced (rear fi rst, then front). Grasp each
bumper at the center and jounce the vehi cl e up and
down three ti mes. Al ways rel ease the bumper i n the
down posi ti on.
Check the caster of the front axl e for correct angl e.
Be sure the axl e i s not bent or twi sted. Road test the
vehi cl e and observe the steeri ng wheel return-to-cen-
ter posi ti on. Low caster wi l l cause poor steeri ng
wheel returnabi l i ty.
Duri ng the road test, turn the vehi cl e to both the
l eft and ri ght. I f the steeri ng wheel returns to the
center posi ti on unassi sted, the caster angl e i s correct.
However, i f steeri ng wheel does not return toward
the center posi ti on unassi sted, a l ow caster angl e i s
probabl e.
Caster can be adjusted by i nstal l i ng cam bol ts and
rotati ng the cams on the l ower suspensi on arm (Fi g.
2).
NOTE: Changing caster angle will also change the
front propeller shaft angle. The propeller shaft
angle has priority over caster. Refer to Group 3, Dif-
ferential and Driveline for additional information.
STANDARD PROCEDURE - TOE POSITION
Before each al i gnment readi ng the vehi cl e shoul d
be jounced (rear fi rst, then front). Grasp each
bumper at the center and jounce the vehi cl e up and
down three ti mes. Al ways rel ease the bumper i n the
down posi ti on.
NOTE: The wheel toe position adjustment is the
final adjustment. This adjustment must be per-
formed with the engine running, if the vehicle is
equipped with power steering.
(1) Start the engi ne and turn wheel s both ways
before strai ghteni ng the steeri ng wheel . Center and
secure the steeri ng wheel .
(2) Loosen the adjustment sl eeve cl amp bol ts (Fi g.
3).
(3) Adjust the ri ght wheel toe posi ti on wi th the
drag l i nk (Fi g. 4). Turn the sl eeve unti l the ri ght
wheel i s at the correct posi ti ve TOE-I N posi ti on.
Posi ti on the cl amp bol ts as shown (Fi g. 3) and
ti ghten to 49 N·m (36 ft. l bs.). Make sure the toe
setting does not change during clamp tighten-
ing.
(4) Adjust the l eft wheel toe posi ti on wi th the ti e
rod. Turn the sl eeve unti l the l eft wheel i s at the
same TOE-I N posi ti on as the ri ght wheel . Posi ti on
the cl amp bol ts as shown (Fi g. 3) and ti ghten to 27
Fig. 2 Cam Adjuster
1 - ADJUSTMENT CAM
2 - AXLE BRACKET
3 - BRACKET REINFORCEMENT
4 - LOWER SUSPENSION ARM
Fig. 3 Drag Link and Tie Rod Clamp
1 - TIE ROD CLAMP
2 - DRAG LINK CLAMPS
2 - 4 WHEEL ALIGNMENT TJ
WHEEL ALIGNMENT (Continued)
N·m (20 ft. l bs.). Make sure the toe setting does
not change during clamp tightening.
(5) Veri fy the ri ght toe speci fi cati ons and turn off
the engi ne.
SPECIFICATIONS
ALIGNMENT SPECIFICATIONS
NOTE: Alignment specifications are in degrees.
SPECIFICATIONS
DESCRIPTION SPECIFICATION
PREFERRED CASTER
+ 7.0°
CAMBER
(fixed
angle)
Ϫ 0.25°
TOTAL
TOE-IN
+ 0.15°
(each
front
wheel)
RANGE ±1.0° ± 0.63° ±0.06°
MAX RT/LT
DIFFERENCE
0.65° ±1.0° .06°
REAR SPECIFICATION
PREFERRED N/A REAR
CAMBER
–0.25°
TOTAL
TOE-IN
+0.25°
RANGE N/A 0°to
–.50°
0°to .5°
THRUST ANGLE 0°± 0.25°
Fig. 4 Steering Linkage
1 - COTTER PIN
2 - DAMPENER
3 - PITMAN ARM
4 - WASHER
5 - TIE ROD
6 - DRAG LINK
7 - NUT
TJ WHEEL ALIGNMENT 2 - 5
WHEEL ALIGNMENT (Continued)
FRONT
TABLE OF CONTENTS
page page
FRONT
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 6
STANDARD PROCEDURE - LUBRICATION . . . . 6
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . 7
SPECIAL TOOLS
FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . 7
BUSHINGS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
HUB / BEARING
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 9
JOUNCE BUMPER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 10
KNUCKLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10
LOWER BALL JOINT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
LOWER CONTROL ARM
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 11
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11
SHOCK
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 12
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
DIAGNOSIS AND TESTING - SHOCK
ABSORBER . . . . . . . . . . . . . . . . . . . . . . . . . . 12
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12
SPRING
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 13
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 13
STABILIZER BAR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 14
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14
TRACK BAR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 14
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14
UPPER BALL JOINT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
UPPER CONTROL ARM
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 15
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 15
FRONT
DESCRIPTION
FRONT SUSPENSION
The front suspensi on i s a l i nk/coi l desi gn com-
pri sed of:
• Shock absorbers
• Jounce Bumper
• Coi l spri ngs
• Upper and l ower suspensi on arms
• Stabi l i zer bar
• Track bar
CAUTION: Components attached with a nut and cot-
ter pin must be torqued to specification. Then if the
slot in the nut does not line up with the cotter pin
hole, tighten nut until it is aligned. Never loosen the
nut to align the cotter pin hole.
CAUTION: Suspension components with rubber/ure-
thane bushings (except stabilizer bar) should be
tightened with the vehicle at normal ride height. It is
important to have the springs supporting the weight
of the vehicle when the fasteners are torqued. If
springs are not at their normal ride position, vehicle
ride comfort could be affected and premature bush-
ing wear may occur.
STANDARD PROCEDURE - LUBRICATION
Peri odi c l ubri cati on of the suspensi on system i s
requi red. Refer to Lubri cati on And Mai ntenance for
the recommended mai ntenance schedul e.
The fol l owi ng component must be l ubri cated:
• Track bar
2 - 6 FRONT TJ
SPECIFICATIONS
TORQUE CHART
TORQUE SPECIFICATIONS
DESCRIPTION N·m Ft. Lbs. In. Lbs.
Shock Absorber
Upper Nut
23 17 —
Shock Absorber
Lower Nut
28 — 250
Suspension Arm Lower
Axle Bracket Nut
176 130 —
Suspension Arm Lower
Frame Bracket Nut
176 130 —
Suspension Arm Upper
Axle Bracket Nut
81 60 —
Suspension Arm Upper
Frame Bracket Bolt
81 60 —
Stabilizer Bar
Retainer Bolts
61 45 —
Stabilizer Bar
Link Upper Nut
61 45 —
Stabilizer Bar
Link Lower Bolt
102 75 —
Track Bar
Ball Stud Nut
81 60 —
Track Bar
Axle Bracket Bolt
47 40 —
Hub/Bearing
Bolts
102 75 —
Hub/Bearing
Axle Nut
237 175 —
SPECIAL TOOLS
FRONT SUSPENSION
Remover/Installer Suspension Bushing 7932
Nut, Long 7603
TJ FRONT 2 - 7
FRONT (Continued)
BUSHINGS
REMOVAL
(1) Remove the upper suspensi on arm from axl e.
(2) Posi ti on Spacer 7932-3 over the axl e bushi ng
on a 4x2 vehi cl e and ri ght si de on a 4x4 vehi cl e.
(3) Pl ace Recei ver 7932-1 over fl anged end of the
bushi ng. (Fi g. 1).
(4) Pl ace smal l end of Remover/I nstal l 7932-2
agai nst other si de of the bushi ng.
(5) I nstal l bol t 7604 through remover, bushi ng and
recei ver.
(6) I nstal l Long Nut 7603 and ti ghten nut too pul l
bushi ng out of the axl e bracket.
(7) Remove nut, bol t, recei ver, remover and bush-
i ng.
NOTE: On 4x2 vehicle and right side of 4x4 vehicle,
leave Spacer 7932-3 in position for bushing instal-
lation.
INSTALLATION
(1) Pl ace Recei ver 7932-1 on the other si de of the
axl e bracket.
(2) Posi ti on new bushi ng up to the axl e bracket.,
and l arge end of Remover/I nstal l 7932-2 agai nst the
bushi ng (Fi g. 2).
(3) I nstal l bol t 7604 through recei ver, bushi ng and
i nstal l er.
(4) I nstal l Long Nut 7603 and ti ghten nut to draw
the bushi ng i nto the axl e bracket.
(5) Remove tool s and i nstal l the upper suspensi on
arm.
HUB / BEARING
DESCRIPTION
The beari ng used on the front hub of thi s vehi cl e i s
the combi ned hub and beari ng uni t type assembl y.
Thi s uni t assembl y combi nes the front wheel mount-
i ng hub (fl ange) and the front wheel beari ng i nto a
one pi ece uni t. The wheel mounti ng studs are the
onl y repl aceabl e component of the hub/beari ng
assembl y.
Bolt, Special 7604
Remover C-4150A
Fig. 1 Bushing Removal
1 - RECEIVER
2 - AXLE BRACKET
3 - BOLT
4 - REMOVER/INSTALLER
5 - LONG NUT
Fig. 2 Bushing Installation
1 - REMOVER/INSTALLER
2 - AXLE BRACKET
3 - BOLT
4 - RECEIVER
5 - LONG NUT
2 - 8 FRONT TJ
FRONT (Continued)
OPERATION
The hub/beari ng assembl y i s mounted to the steer-
i ng knuckl e and i s retai ned by three mounti ng bol ts
accessi bl e from the back of the steeri ng knuckl e. The
hub/beari ng uni t i s not servi ceabl e and must be
repl aced as an assembl y i f the beari ng or the hub i s
determi ned to be defecti ve.
REMOVAL
(1) Rai se and support the vehi cl e.
(2) Remove the wheel and ti re assembl y.
(3) Remove the brake cal i per, rotor and ABS wheel
speed sensor, (Refer to 5 - BRAKES/HYDRAULI C/
MECHANI CAL/ROTORS - REMOVAL).
(4) Remove the cotter pi n, nut retai ner and axl e
hub nut (Fi g. 3).
(5) Remove the hub beari ng mounti ng bol ts from
the back of the steeri ng knuckl e. Remove hub bear-
i ng from the steeri ng knuckl e and off the axl e shaft.
INSTALLATION
(1) I nstal l the hub beari ng and brake dust shi el d
to the knuckl e.
(2) I nstal l the hub beari ng to knuckl e bol ts and
ti ghten to 102 N·m (75 ft. l bs.).
(3) I nstal l the hub washer and nut. Ti ghten the
hub nut to 237 N·m (175 ft. l bs.). I nstal l the nut
retai ner and a new cotter pi n.
(4) I nstal l the brake rotor, cal i per and ABS wheel
speed sensor, (Refer to 5 - BRAKES/HYDRAULI C/
MECHANI CAL/ROTORS - I NSTALLATI ON).
(5) I nstal l the wheel and ti re assembl y. (Refer to
22 - TI RES/WHEELS/WHEELS - STANDARD PRO-
CEDURE).
(6) Remove support and l ower the vehi cl e.
Fig. 3 Hub Bearing & Knuckle
1 - BRAKE SHIELD
2 - WASHER
3 - RETAINER
4 - COTTER PIN
5 - NUT
6 - HUB AND BEARING ASSEMBLY
7 - STEERING KNUCKLE
8 - BOLT
9 - TONE WHEEL (ABS)
TJ FRONT 2 - 9
HUB / BEARING (Continued)
J OUNCE BUMPER
DESCRIPTION
The jounce bumpers are mounted under the frame
rai l s i nsi de of the coi l spri ngs.
KNUCKLE
REMOVAL
Bal l stud servi ce procedures bel ow requi re removal
of the hub beari ng and axl e shaft. Removal and
i nstal l ati on of upper and l ower bal l studs requi re the
use of Tool Ki t 6289.
(1) Remove hub beari ng and axl e shaft. (Refer to 2
- SUSPENSI ON/FRONT/HUB / BEARI NG -
REMOVAL) (Refer to 3 - DI FFERENTI AL & DRI V-
ELI NE/FRONT AXLE - 181FBI /AXLE SHAFTS -
REMOVAL).
(2) Di sconnect the ti e-rod or drag l i nk from the
steeri ng knuckl e arm,(Refer to 19 - STEERI NG/
LI NKAGE/TI E ROD END - REMOVAL) OR (Refer to
19 - STEERI NG/LI NKAGE/DRAG LI NK -
REMOVAL).
(3) Remove the cotter pi ns from the upper and
l ower bal l studs.
(4) Remove the upper and l ower bal l stud nuts.
(5) Usi ng speci al tool C-4150A seperate the bal l
joi nts from the steeri ng knuckl e. Remove knuckl e
from bal l studs (Fi g. 4).
INSTALLATION
Bal l stud servi ce procedures bel ow requi re removal
of the hub beari ng and axl e shaft. Removal and
i nstal l ati on of upper and l ower bal l studs requi re the
use of Tool Ki t 6289.
(1) Posi ti on the steeri ng knuckl e on the bal l studs.
(2) I nstal l and ti ghten the bottom retai ni ng nut to
109 N·m (80 ft. l bs.) torque. I nstal l new cotter pi n.
(3) I nstal l and ti ghten the top retai ni ng nut to 101
N·m (75 ft. l bs.) torque. I nstal l new cotter pi n.
(4) I nstal l the hub beari ng and axl e shaft. (Refer
to 2 - SUSPENSI ON/FRONT/HUB / BEARI NG -
I NSTALLATI ON) (Refer to 3 - DI FFERENTI AL &
DRI VELI NE/FRONT AXLE - 181FBI /AXLE SHAFTS
- I NSTALLATI ON).
(5) Connect the ti e-rod or drag l i nk end to the
steeri ng knuckl e arm,(Refer to 19 - STEERI NG/
LI NKAGE/TI E ROD END - I NSTALLATI ON) OR
(Refer to 19 - STEERI NG/LI NKAGE/DRAG LI NK -
I NSTALLATI ON).
LOWER BALL J OINT
REMOVAL
Bal l stud servi ce procedures bel ow requi re removal
of the hub beari ng and axl e shaft. (Refer to 2 - SUS-
PENSI ON/FRONT/HUB / BEARI NG - REMOVAL)
(Refer to 3 - DI FFERENTI AL & DRI VELI NE/
FRONT AXLE - 181FBI /AXLE SHAFTS -
REMOVAL). Removal and i nstal l ati on of upper and
l ower bal l studs requi re the use of Tool Ki t 6289.
(1) Posi ti on tool s as shown to remove and i nstal l
bal l stud (Fi g. 5).
Fig. 4 Steering Knuckle Removal/Installation
1 - AXLE YOKE
2 - UPPER BALL STUD
3 - LOWER BALL STUD
4 - STEERING KNUCKLE
2 - 10 FRONT TJ
LOWER CONTROL ARM
DESCRIPTION
The l ower suspensi on arms are steel and use bush-
i ngs at both ends of the arm. The arms mount to the
frame rai l bracket and the axl e brackets.
OPERATION
The l ower suspensi on arm bushi ngs provi de i sol a-
ti on from the axl e. The arm and bushi ngs provi de
l ocati on and react to l oads from the axl e. The l ower
suspensi on arms can be used to adjust caster and
pi ni on angl e by i nstal l i ng a cam bol t servi ce package.
REMOVAL
(1) Rai se and support the vehi cl e.
(2) I f equi pped wi th ABS brakes remove sensor
wi re from the i nboard si de of the arm.
(3) I f the vehi cl e i s equi pped wi th a cam bol t ser-
vi ce package pai nt or scri be al i gnment marks on the
cam adjusters and suspensi on arm for i nstal l ati on
reference (Fi g. 6).
(4) Remove the l ower suspensi on arm nut and bol t
from the axl e (Fi g. 7).
(5) Remove the nut and bol t/cam bol t from the
frame rai l bracket and remove the l ower suspensi on
arm (Fi g. 7).
INSTALLATION
(1) Posi ti on the l ower suspensi on arm i n the axl e
bracket and frame rai l bracket.
NOTE: Small holes in the side of the arm face
inboard.
(2) I nstal l the rear bol t and nut fi nger ti ghten.
(3) I nstal l bol t/cam bol t and new nut fi nger ti ghten
i n the axl e and al i gn the reference marks.
(4) I f equi pped wi th ABS brakes i nstal l sensor
wi re to the i nboard si de of the arm wi th new cl i ps.
(5) Lower the vehi cl e.
(6) Ti ghten axl e bracket nut to 176 N·m (130 ft.
l bs.).
(7) Ti ghten frame bracket nut to 176 N·m (130 ft.
l bs.).
Fig. 5 Lower Ball Stud Remove/Install
1 - SPECIAL TOOL 6289–12
2 - SPECIAL TOOL 6289–4
3 - SPECIAL TOOL 4212F
4 - SPECIAL TOOL 4212F
5 - SPECIAL TOOL 6289–1
6 - SPECIAL TOOL 6289–3
TJ FRONT 2 - 11
LOWER BALL J OINT (Continued)
(8) Al i gn vehi cl e to speci fi cati ons. (Refer to 2 -
SUSPENSI ON/WHEEL ALI GNMENT - STANDARD
PROCEDURE).
SHOCK
DESCRIPTION
The top of the shock absorbers are bol ted to a
frame bracket. The bottom of the shocks are bol ted to
the axl e brackets.
OPERATION
The shock absorbers dampen jounce and rebound
moti on of the vehi cl e over vari ous road condi ti ons
and l i mi t suspensi on rebound travel .
DIAGNOSIS AND TESTING - SHOCK
ABSORBER
A knocki ng or rattl i ng noi se from a shock absorber
may be caused by movement between mounti ng
bushi ngs and metal brackets or attachi ng compo-
nents. These noi ses can usual l y be stopped by ti ght-
eni ng the attachi ng nuts. I f the noi se persi sts,
i nspect for damaged and worn bushi ngs, and attach-
i ng components. Repai r as necessary i f any of these
condi ti ons exi st.
A squeaki ng noi se from the shock absorber may be
caused by the hydraul i c val vi ng and may be i ntermi t-
tent. Thi s condi ti on i s not repai rabl e and the shock
absorber must be repl aced.
The shock absorbers are not refi l l abl e or adjust-
abl e. I f a mal functi on occurs, the shock absorber
must be repl aced. To test a shock absorber, hol d i t i n
an upri ght posi ti on and force the pi ston i n and out of
the cyl i nder four or fi ve ti mes. The acti on throughout
each stroke shoul d be smooth and even.
The shock absorber bushi ngs do not requi re any
type of l ubri cati on. Do not attempt to stop bushi ng
noi se by l ubri cati ng them. Grease and mi neral oi l -
base l ubri cants wi l l deteri orate the bushi ng.
REMOVAL
(1) Remove the nut, retai ner and grommet from
the upper stud through engi ne compartment access
hol e (Fi g. 8).
(2) Remove the l ower nuts and bol ts from the axl e
bracket and remove the shock absorber.
INSTALLATION
(1) Posi ti on the l ower retai ner and grommet on the
upper stud. I nsert the shock absorber through the
shock bracket hol e.
(2) I nstal l the l ower bol ts and nuts. Ti ghten nuts
to 28 N·m (250 i n. l bs.).
Fig. 6 Cam Bolt Service Package
1 - ADJUSTMENT CAM
2 - AXLE BRACKET
3 - BRACKET REINFORCEMENT
4 - LOWER SUSPENSION ARM
Fig. 7 Upper & Lower Suspension Arms
1 - UPPER SUSPENSION ARM
2 - FRONT AXLE
3 - LOWER SUSPENSION ARM
2 - 12 FRONT TJ
LOWER CONTROL ARM (Continued)
(3) I nstal l the upper grommet and retai ner on the
stud and i nstal l the nut and ti ghten to 23 N·m (17 ft.
l bs.).
SPRING
DESCRIPTION
The coi l spri ngs mount up i n the wheel house whi ch
i s part of the uni ti zed body bracket. A rubber dough-
nut i sol ator i s l ocated between the top of the spri ng
and the bracket. The bottom of the spri ng seats on a
axl e pad.
OPERATION
The coi l spri ngs control ri de qual i ty and mai ntai n
proper ri de hei ght. The i sol ators provi de road noi se
i sol ati on.
REMOVAL
(1) Rai se and support the vehi cl e.
(2) Remove the wheel and ti re assembl i es.
(3) Posi ti on a hydraul i c jack under the axl e to sup-
port i t.
(4) Remove the front shocks at the l ower mount-
i ngs, (Refer to 2 - SUSPENSI ON/FRONT/SHOCK -
REMOVAL).
(5) Remove the ABS wi re mounti ng brackets at the
axl e. (i f equi pped)
(6) Remove l ower suspensi on arms mounti ng nuts
and bol ts from the frame, (Refer to 2 - SUSPEN-
SI ON/FRONT/LOWER CONTROL ARM -
REMOVAL).
(7) Remove the track bar from the axl e bracket,
(Refer to 2 - SUSPENSI ON/FRONT/TRACK BAR -
REMOVAL).
(8) Remove the ri ght si de of the drag l i nk from the
ri ght si de knuckl e, (Refer to 19 - STEERI NG/LI NK-
AGE/DRAG LI NK - REMOVAL).
(9) Lower the axl e unti l the spri ng i s free from the
upper mount.
NOTE: Rotation of the spring and prying down
slightly on the axle will aid in removal.
(10) Remove the coi l spri ng retai ner cl i p and
remove the spri ng.
(11) Remove the upper spri ng i sol ator. (i f needed)
(12) Pul l jounce bumper out of mount. (i f needed)
INSTALLATION
(1) I nstal l jounce bumper i nto mount.
(2) I nstal l the spri ng i sol ator.
NOTE: Rotation of the spring and prying down
slightly on the axle will aid in installation.
(3) Posi ti on the coi l spri ng on the axl e pad. I t may
be necessary to rotate the spri ng whi l e i nstal l i ng.
(4) I nstal l the spri ng retai ner cl i p and bol t.
Ti ghten bol t to 21 N·m (16 ft. l bs.).
(5) Rai se the axl e i nto posi ti on unti l the spri ng
seats i n the upper mount.
(6) I nstal l the shock at the axl e, (Refer to 2 - SUS-
PENSI ON/FRONT/SHOCK - I NSTALLATI ON).
(7) I nstal l the ABS wi re mounti ng brackets at the
axl e (i f equi pped).
(8) I nstal l the track bar to the axl e bracket, (Refer
to 2 - SUSPENSI ON/FRONT/TRACK BAR - I NSTAL-
LATI ON).
(9) I nstal l the l ower suspensi on arms to the frame.
I nstal l mounti ng bol ts and nuts fi nger ti ght, (Refer to
2 - SUSPENSI ON/FRONT/LOWER CONTROL ARM
- I NSTALLATI ON).
(10) I nstal l the drag l i nk to the ri ght si de knuckl e,
(Refer to 19 - STEERI NG/LI NKAGE/DRAG LI NK -
I NSTALLATI ON).
(11) Remove the hydraul i c jack from under the
axl e.
(12) I nstal l the wheel and ti re assembl i es, (Refer
to 22 - TI RES/WHEELS/WHEELS - STANDARD
PROCEDURE).
(13) Remove the supports and l ower the vehi cl e.
(14) Ti ghten the l ower suspensi on arms nuts to
115 N·m (85 ft. l bs.) at normal ri de hei ght wi th the
vehi cl e wei ght.
Fig. 8 Coil Spring & Shock Absorber
1 - RETAINER
2 - GROMMET
3 - SHOCK
4 - FRONT AXLE
TJ FRONT 2 - 13
SHOCK (Continued)
STABILIZER BAR
DESCRIPTION
The spri ng steel bar extends across the top of the
chassi s frame rai l s. Li nks are connected from the bar
to the axl e brackets. The stabi l i zer bar and l i nks are
i sol ated by rubber bushi ngs.
OPERATION
The stabi l i zer bar i s used to control vehi cl e body
rol l duri ng turns. The bar hel ps to control the vehi cl e
body i n rel ati onshi p to the suspensi on.
REMOVAL
(1) Remove upper l i nk nuts (Fi g. 9) and separate
the l i nks from the stabi l i zer bar wi th Remover
MB-991113.
(2) Remove front bumper val ence.
(3) Remove stabi l i zer retai ner bol ts (Fi g. 9)and
remove retai ners.
(4) Remove stabi l i zer bar.
(5) Remove l ower l i nk nuts and bol ts and remove
l i nks (Fi g. 9).
INSTALLATION
(1) Center stabi l i zer bar on top of the frame rai l s
and i nstal l retai ners and bol ts. Ti ghten bol ts to 61
N·m (45 ft. l bs.).
(2) Posi ti on l i nks on axl e brackets and i nto the
stabi l i zer bar. I nstal l l ower l i nk bol ts and nuts and
ti ghten to 102 N·m (75 ft. l bs.).
(3) I nstal l upper l i nk nuts and ti ghten to 61 N·m
(45 ft. l bs.).
(4) I nstal l bumper val ence.
TRACK BAR
DESCRIPTION
The bar i s attached to a frame rai l bracket wi th a
bal l stud and an axl e bracket wi th a bushi ng. The
bar i s forged and has non repl aceabl e i sol ator bush-
i ng and bal l stud.
OPERATION
The track bar i s used to control front axl e l ateral
movement and provi des cross car l ocati on of the axl e
assembl y.
REMOVAL
(1) Rai se and support the vehi cl e.
(2) Remove the cotter pi n and nut from the bal l
stud end at the frame rai l bracket (Fi g. 10).
(3) Use a uni versal pul l er tool to separate the
track bar bal l stud from the frame rai l bracket.
(4) Remove the bol t and fl ag nut from the axl e
bracket (Fi g. 10). Remove the track bar.
INSTALLATION
(1) I nstal l the track bar at axl e tube bracket.
Loosel y i nstal l the retai ni ng bol t and fl ag nut.
(2) I t may be necessary to pry the axl e assembl y
over to i nstal l the track bar at the frame rai l . I nstal l
track bar at the frame rai l bracket. I nstal l the
retai ni ng nut on the stud.
(3) Ti ghten the bal l stud nut to 81N·m (60 ft. l bs.)
and i nstal l a new cotter pi n.
(4) Remove the supports and l ower the vehi cl e.
(5) Ti ghten the bol t at the axl e bracket to 47 N·m
(40 ft. l bs.).
Fig. 9 Stabilizer Bar
1 - RETAINER
2 - STABILIZER BAR
3 - LINK
4 - BUSHING
Fig. 10 Track Bar
1 - TRACK BAR
2 - FRAME BRACKET
3 - FRONT AXLE
2 - 14 FRONT TJ
(6) Check al i gnment i f a new track bar was
i nstal l ed. (Refer to 2 - SUSPENSI ON/WHEEL
ALI GNMENT - STANDARD PROCEDURE).
UPPER BALL J OINT
REMOVAL
Bal l stud servi ce procedures bel ow requi re removal
of the hub beari ng and axl e shaft. (Refer to 2 - SUS-
PENSI ON/FRONT/HUB / BEARI NG - REMOVAL)
(Refer to 3 - DI FFERENTI AL & DRI VELI NE/
FRONT AXLE - 181FBI /AXLE SHAFTS -
REMOVAL). Removal and i nstal l ati on of upper and
l ower bal l studs requi re the use of Tool Ki t 6289.
(1) Posi ti on tool s as shown to remove and i nstal l
bal l stud (Fi g. 11).
UPPER CONTROL ARM
DESCRIPTION
The upper suspensi on arms are steel and use rub-
ber bushi ngs at each end of the arm. The arms
mount to the frame rai l bracket and the axl e brack-
ets.
OPERATION
The arm and bushi ngs provi de l ocati on and react
to l oads from the axl e. The bushi ngs provi de i sol ati on
from the axl e.
REMOVAL
(1) Rai se and support the vehi cl e.
(2) Remove the upper suspensi on arm nut and bol t
at the axl e bracket (Fi g. 7).
(3) Remove the nut and bol t at the frame rai l and
remove the upper suspensi on arm.
INSTALLATION
(1) Posi ti on the upper suspensi on arm at the axl e
and frame rai l .
(2) I nstal l the bol ts and fi nger ti ghten the nuts.
(3) Remove the supports and l ower the vehi cl e.
(4) Ti ghten the nut at the axl e and frame brackets
to 81 N·m (60 ft. l bs.).
Fig. 11 Upper
TJ FRONT 2 - 15
TRACK BAR (Continued)
REAR
TABLE OF CONTENTS
page page
REAR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 16
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . 16
JOUNCE BUMPER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 17
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
LOWER CONTROL ARM
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 17
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 17
SHOCK
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 18
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
DIAGNOSIS AND TESTING - SHOCK
ABSORBER . . . . . . . . . . . . . . . . . . . . . . . . . . 18
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 18
SPRING
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 18
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 19
STABILIZER BAR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 19
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 19
TRACK BAR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 20
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 20
UPPER CONTROL ARM
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 20
REAR
DESCRIPTION
REAR SUSPENSION
The rear suspensi on i s l i nk/coi l desi gn compri sed
of:
• Shock absorbers
• Coi l spri ngs
• Upper and l ower suspensi on arms
• Stabi l i zer bar
• Track bar
CAUTION: Suspension components with rubber/ure-
thane bushings (except stabilizer bar) should be
tightened with the vehicle at normal ride height. It is
important to have the springs supporting the weight
of the vehicle when the fasteners are torqued. This
will maintain vehicle ride comfort and prevent pre-
mature bushing wear.
SPECIFICATIONS
TORQUE CHART
TORQUE SPECIFICATIONS
DESCRIPTION N·m Ft. Lbs. In. Lbs.
Shock Absorber
Upper Bolts
35 26 —
Shock Absorber
Lower Nut
100 74 —
Suspension Arm Lower
Axle Bracket Nut
203 150 —
2 - 16 REAR TJ
DESCRIPTION N·m Ft. Lbs. In. Lbs.
Suspension Arm Lower
Frame Bracket Nut
203 150 —
Suspension Arm Upper
Axle Bracket Nut
75 55 —
Suspension Arm Upper
Frame Bracket Bolt
75 55 —
Stabilizer Bar
Retainer Bolts
54 40 —
Stabilizer Bar
Link Nut/Bolt
54 40 —
Track Bar
Frame Bracket Nut
100 74 —
Track Bar
Axle Bracket Bolt
100 74 —
J OUNCE BUMPER
DESCRIPTION
The jounce bumpers are mounted i nsi de the coi l
spri ng to the frame rai l .
OPERATION
The jounce bumpers are used to l i mi t suspensi on
travel i n compressi on.
LOWER CONTROL ARM
DESCRIPTION
The l ower suspensi on arms are steel and use bush-
i ngs at each end of the arm. The arms are mounted
from the frame to the axl e brackets.
OPERATION
The bushi ngs i sol ati on axl e and road noi se. The
arm and bushi ngs provi de l ocati on and react to l oads
from the axl e.
REMOVAL
(1) Rai se and support the vehi cl e.
(2) Remove the l ower suspensi on arm nut and bol t
at the axl e bracket (Fi g. 1).
(3) Remove the nut and bol t at the frame rai l
mount (Fi g. 2) and remove the l ower suspensi on arm.
INSTALLATION
(1) Posi ti on the l ower suspensi on arm i n the axl e
bracket and frame rai l mount.
(2) I nstal l the mounti ng bol ts and fi nger ti ghten
the nuts.
(3) Remove the supports and l ower the vehi cl e.
(4) Ti ghten the l ower suspensi on arm nuts to 203
N·m (150 ft. l bs.).
Fig. 1 Upper & Lower Suspension Arms
1 - UPPER SUSPENSION ARM
2 - REAR AXLE
3 - LOWER SUSPENSION ARM
TJ REAR 2 - 17
REAR (Continued)
SHOCK
DESCRIPTION
The top of the shock absorbers are bol ted to the
frame. The bottom of the shocks are bol ted to the
axl e brackets.
OPERATION
The shock absorbers dampen jounce and rebound
moti on of the vehi cl e over vari ous road condi ti ons
and l i mi t suspensi on rebound travel .
DIAGNOSIS AND TESTING - SHOCK
ABSORBER
A knocki ng or rattl i ng noi se from a shock absorber
may be caused by movement between mounti ng
bushi ngs and metal brackets or attachi ng compo-
nents. These noi ses can usual l y be stopped by ti ght-
eni ng the attachi ng nuts. I f the noi se persi sts,
i nspect for damaged and worn bushi ngs, and attach-
i ng components. Repai r as necessary i f any of these
condi ti ons exi st.
A squeaki ng noi se from the shock absorber may be
caused by the hydraul i c val vi ng and may be i ntermi t-
tent. Thi s condi ti on i s not repai rabl e and the shock
absorber must be repl aced.
The shock absorbers are not refi l l abl e or adjust-
abl e. I f a mal functi on occurs, the shock absorber
must be repl aced. To test a shock absorber, hol d i t i n
an upri ght posi ti on and force the pi ston i n and out of
the cyl i nder four or fi ve ti mes. The acti on throughout
each stroke shoul d be smooth and even.
The shock absorber bushi ngs do not requi re any
type of l ubri cati on. Do not attempt to stop bushi ng
noi se by l ubri cati ng them. Grease and mi neral oi l -
base l ubri cants wi l l deteri orate the bushi ng.
REMOVAL
(1) Rai se and support the vehi cl e and the axl e.
(2) Remove the upper mounti ng bol ts (Fi g. 3).
(3) Remove the l ower nut and bol t from the axl e
bracket. Remove the shock absorber.
INSTALLATION
(1) I nstal l the shock absorber on the upper frame
rai l and i nstal l mounti ng bol ts.
(2) Ti ghten the upper bol ts to 31 N·m (23 ft. l bs.).
(3) I nstal l l ower bol t and nut fi nger ti ght.
(4) Remove the supports and l ower the vehi cl e.
(5) Ti ghten the l ower nut to 100 N·m (74 ft. l bs.).
SPRING
DESCRIPTION
The coi l spri ngs mount between the bottom of the
frame rai l and the top of the axl e. A rubber doughnut
i sol ator i s l ocated between the top of the spri ng and
the frame rai l . A pl asti c i sol ator i s l ocated between
the bottom of the spri ng and the axl e.
OPERATION
The coi l spri ngs control ri de qual i ty and mai ntai n
proper ri de hei ght. The i sol ators are used to i sol ate
road noi se.
REMOVAL
(1) Rai se and support the vehi cl e. Posi ti on a
hydraul i c jack under the axl e to support i t.
(2) Di sconnect the stabi l i zer bar l i nks and shock
absorbers from the axl e brackets. (Refer to 2 - SUS-
Fig. 2 Upper & Lower Suspension Arms
1 - FRAME MOUNT
2 - UPPER SUSPENSION ARM
3 - LOWER SUSPENSION ARM
Fig. 3 Shock Absorber
1 - AXLE BRACKET
2 - SHOCK
2 - 18 REAR TJ
LOWER CONTROL ARM (Continued)
PENSI ON/REAR/STABI LI ZER BAR - REMOVAL)
(Refer to 2 - SUSPENSI ON/REAR/SHOCK -
REMOVAL).
(3) Di sconnect the track bar from the frame rai l
bracket. (Refer to 2 - SUSPENSI ON/REAR/TRACK
BAR - REMOVAL).
(4) Lower the axl e unti l the spri ng i s free from the
upper mount seat and remove the spri ng.
INSTALLATION
NOTE: Springs can be install with either end up.
(1) Posi ti on the coi l spri ng on the axl e pad i sol ator.
(2) Rai se the axl e i nto posi ti on unti l the spri ng
seats on the upper i sol ator.
(3) Connect the stabi l i zer bar l i nks and shock
absorbers to the axl e bracket. Connect the track bar
to the frame rai l bracket.
(4) Remove the supports and l ower the vehi cl e.
(5) Ti ghten the stabi l i zer bar l i nks, shock absorb-
ers and track bar to speci fi ed torque.
STABILIZER BAR
DESCRIPTION
The spri ng steel bar extends across the axl e and
mounts to bracket on the axl e. Li nks are connected
from the bar to the si de of the frame rai l . The stabi -
l i zer bar and l i nks are i sol ated by rubber bushi ngs.
OPERATION
The stabi l i zer bar i s used to control vehi cl e body
rol l duri ng turns. The bar hel ps to control the vehi cl e
body i n rel ati onshi p to the suspensi on.
REMOVAL
(1) Rai se and support the vehi cl e.
(2) Remove the stabi l i zer bar l i nk bol ts from the
frame mounts (Fi g. 4).
(3) Remove the l i nk bol ts from the stabi l i zer bar.
(4) Remove the stabi l i zer bar retai ner bol ts and
retai ners from the axl e mounts (Fi g. 5) and remove
the bar.
INSTALLATION
(1) I nstal l the stabi l i zer bar on the axl e mounts
and i nstal l the retai ners and bol ts.
NOTE: Ensure the bar is centered with equal spac-
ing on both sides and is positioned above the dif-
ferential housing (Fig. 5).
(2) Ti ghten the retai ner bol ts to 54 N·m (40 ft.
l bs.).
(3) I nstal l the l i nks onto the stabi l i zer bar and
frame mounts. I nstal l the bol ts and nuts fi nger ti ght.
(4) Remove support and l ower vehi cl e.
(5) Ti ghten the l i nk nuts/bol ts to 54 N·m (40 ft.
l bs.).
Fig. 4 Stabilizer Bar Link
1 - FRAME MOUNT
2 - LINK
3 - STABILIZER BAR
Fig. 5 Stabilizer Bar
1 - LINK
2 - RETAINER
3 - STABILIZER BAR
4 - AXLE MOUNT
TJ REAR 2 - 19
SPRING (Continued)
TRACK BAR
DESCRIPTION
The bar i s attached to a frame rai l bracket and
axl e bracket. The bar has bushi ngs at both ends.
OPERATION
The track bar i s used to control rear axl e l ateral
movement.
REMOVAL
(1) Rai se and support the vehi cl e.
(2) Remove the bol t and nut from the frame rai l
bracket (Fi g. 6).
(3) Remove the bol t from the axl e bracket (Fi g. 6)
and remove the track bar.
INSTALLATION
(1) I nstal l the track bar i n the axl e bracket and
i nstal l the bol t l oosel y.
(2) I nstal l the track bar i n the frame rai l bracket
and l oosel y i nstal l the bol t and nut.
NOTE: It may be necessary to pry the axle assem-
bly over to install the track bar.
(3) Remove supports and l ower the vehi cl e.
(4) Ti ghten the track bar nut/bol t at both ends to
100 N·m (74 ft. l bs.).
UPPER CONTROL ARM
REMOVAL
(1) Rai se and support the vehi cl e.
(2) Remove the parki ng brake cabl e/bracket and
ABS wi ri ng bracket from the arm i f equi pped
(Fi g. 7).
(3) Remove the upper suspensi on arm nut and bol t
from the axl e bracket (Fi g. 1).
(4) Remove the nut and bol t from the frame rai l
bracket (Fi g. 2)and remove the upper suspensi on
arm.
INSTALLATION
(1) Posi ti on the upper suspensi on arm i n the axl e
bracket and frame rai l bracket.
(2) I nstal l the bol ts and fi nger ti ghten the nuts.
(3) I nstal l the parki ng brake cabl e/bracket and
ABS wi ri ng bracket on the arm i f equi pped.
(4) Remove the supports and l ower the vehi cl e.
(5) Ti ghten the upper suspensi on arm frame rai l
bracket bol t to 75 N·m (55 ft. l bs.).
(6) Ti ghten the upper suspensi on arm axl e bracket
nut to 75 N·m (55 ft. l bs.).
Fig. 6 Rear Track Bar
1 - TRACK BAR
2 - FRAME BRACKET
3 - REAR AXLE
Fig. 7 Parking Brake Cable/Bracket And Wiring
Bracket
1 - UPPER SUSPENSION ARM
2 - WIRING BRACKET
3 - PARKING BRAKE CABLE BRACKET
2 - 20 REAR TJ
DIFFERENTIAL & DRIVELINE
TABLE OF CONTENTS
page page
PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . . . . 1
FRONT AXLE - 181FBI . . . . . . . . . . . . . . . . . . . . 15
FRONT AXLE - 216FBI . . . . . . . . . . . . . . . . . . . . 49
REAR AXLE - 194RBI . . . . . . . . . . . . . . . . . . . . . 84
REAR AXLE - 216RBI . . . . . . . . . . . . . . . . . . . . 118
PROPELLER SHAFT
TABLE OF CONTENTS
page page
PROPELLER SHAFT
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . 1
STANDARD PROCEDURE . . . . . . . . . . . . . . . . . 4
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . 6
SPECIFICATIONS
PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . . 6
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . 7
PROPELLER SHAFT - FRONT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
PROPELLER SHAFT - REAR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
PROPELLER SHAFT - REAR RUBICON
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SINGLE CARDAN UNIVERSAL JOINTS
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 9
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
DOUBLE CARDAN UNIVERSAL JOINTS
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 11
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
PROPELLER SHAFT
DIAGNOSIS AND TESTING
VIBRATION
Ti res that are out-of-round, or wheel s that are
unbal anced, wi l l cause a l ow frequency vi brati on.
Refer to Group 22, Ti res and Wheel s, for addi ti onal
i nformati on.
Brake drums that are unbal anced wi l l cause a
harsh, l ow frequency vi brati on. Refer to Group 5,
Brakes, for addi ti onal i nformati on.
Dri vel i ne vi brati on can al so resul t from l oose or
damaged engi ne mounts. Refer to Group 9 Engi nes
for addi ti onal i nformati on.
Propel l er shaft vi brati on i ncreases as the vehi cl e
speed i s i ncreased. A vi brati on that occurs wi thi n a
speci fi c speed range i s not usual l y caused by a pro-
pel l er shaft bei ng unbal anced. Defecti ve uni versal
joi nts, or an i ncorrect propel l er shaft angl e, are usu-
al l y the cause of such a vi brati on.
TJ DIFFERENTIAL & DRIVELINE 3 - 1
DRIVELINE VIBRATION
Drive Condition Possible Cause Correction
Propeller Shaft Noise 1) Undercoating or other foreign
material on shaft.
1) Clean exterior of shaft and wash
with solvent.
2) Loose U-joint clamp screws. 2) Install new clamps and screws
and tighten to proper torque.
3) Loose or bent U-joint yoke or
excessive runout.
3) Install new yoke.
4) Incorrect driveline angularity. 4) Measure and correct driveline
angles.
5) Rear spring center bolt not in
seat.
5) Loosen spring u-bolts and seat
center bolt.
6) Worn U-joint bearings. 6) Install new U-joint.
7) Propeller shaft damaged or out
of balance.
7) Installl new propeller shaft.
8) Broken rear spring. 8) Install new rear spring.
9) Excessive runout or unbalanced
condition.
9) Re-index propeller shaft, test,
and evaluate.
10) Excessive drive pinion gear
shaft runout.
10) Re-index propeller shaft and
evaluate.
11) Excessive axle yoke deflection. 11) Inspect and replace yoke if
necessary.
12) Excessive transfer case runout. 12) Inspect and repair as necessary.
Universal Joint Noise 1) Loose U-joint clamp screws. 1) Install new clamps and screws
and tighten to proper torque.
2) Lack of lubrication. 2) Replace U-joints as necessary.
3 - 2 PROPELLER SHAFT TJ
PROPELLER SHAFT (Continued)
BALANCE
NOTE: Removing and re-indexing the propeller
shaft 180° relative to the yoke may eliminate some
vibrations.
I f propel l er shaft i s suspected of bei ng unbal anced,
i t can be veri fi ed wi th the fol l owi ng procedure:
(1) Rai se the vehi cl e.
(2) Cl ean al l the forei gn materi al from the propel -
l er shaft and the uni versal joi nts.
(3) I nspect the propel l er shaft for mi ssi ng bal ance
wei ghts, broken wel ds, and bent areas. If the pro-
peller shaft is bent, it must be replaced.
(4) I nspect the uni versal joi nts to ensure that they
are not worn, are properl y i nstal l ed, and are cor-
rectl y al i gned wi th the shaft.
(5) Check the uni versal joi nt cl amp screws torque.
(6) Remove the wheel s and ti res. I nstal l the wheel
l ug nuts to retai n the brake drums or rotors.
(7) Mark and number the shaft si x i nches from the
yoke end at four posi ti ons 90° apart.
(8) Run and accel erate the vehi cl e unti l vi brati on
occurs. Note the i ntensi ty and speed the vi brati on
occurred. Stop the engi ne.
(9) I nstal l a screw cl amp at posi ti on 1 (Fi g. 1).
(10) Start the engi ne and re-check for vi brati on. I f
there i s l i ttl e or no change i n vi brati on, move the
cl amp to one of the other three posi ti ons. Repeat the
vi brati on test.
(11) I f there i s no di fference i n vi brati on at the
other posi ti ons, the source of the vi brati on may not
be propel l er shaft.
(12) I f the vi brati on decreased, i nstal l a second
cl amp (Fi g. 2)and repeat the test.
(13) I f the addi ti onal cl amp causes an addi ti onal
vi brati on, separate the cl amps (1/4 i nch above and
bel ow the mark). Repeat the vi brati on test (Fi g. 3).
(14) I ncrease di stance between the cl amp screws
and repeat the test unti l the amount of vi brati on i s
at the l owest l evel . Bend the sl ack end of the cl amps
so the screws wi l l not l oosen.
(15) I f the vi brati on remai ns unacceptabl e, appl y
the same steps to the front end of the propel l er shaft.
(16) I nstal l the wheel and ti res. Lower the vehi cl e.
RUNOUT
(1) Remove di rt, rust, pai nt, and undercoati ng
from the propel l er shaft surface where the di al i ndi -
cator wi l l contact the shaft.
(2) The di al i ndi cator must be i nstal l ed perpendi c-
ul ar to the shaft surface.
(3) Measure runout at the center and ends of the
shaft suffi ci entl y far away from wel d areas to ensure
Fig. 1 CLAMP SCREW AT POSITION 1
1 - CLAMP
2 - SCREWDRIVER
Fig. 2 TWO CLAMP SCREWS
Fig. 3 CLAMP SCREWS SEPARATED
1 - 1/2 INCH
TJ PROPELLER SHAFT 3 - 3
PROPELLER SHAFT (Continued)
that the effects of the wel d process wi l l not enter i nto
the measurements.
(4) Refer to Runout Speci fi cati ons chart.
(5) I f the propel l er shaft runout i s out of speci fi ca-
ti on, remove the propel l er shaft, i ndex the shaft 180°,
and re-i nstal l the propel l er shaft. Measure shaft
runout agai n.
(6) I f the propel l er shaft runout i s now wi thi n
speci fi cati ons, mark the shaft and yokes for proper
ori entati on.
(7) I f the propel l er shaft runout i s not wi thi n spec-
i fi cati ons, veri fy that the runout of the transmi ssi on/
transfer case and axl e are wi thi n speci fi cati ons.
Correct as necessary and re-measure propel l er shaft
runout.
(8) Repl ace the propel l er shaft i f the runout sti l l
exceeds the l i mi ts.
RUNOUT SPECIFICATIONS
Front of Shaft 0.020 in. (0.50 mm)
Center of Shaft 0.025 in. (0.63 mm)
Rear of Shaft 0.020 in. (0.50 mm)
note:
Measure front/rear runout approximately 3 inches (76
mm) from the weld seam at each end of the shaft
tube for tube lengths over 30 inches. For tube lengths
under 30 inches, the maximum allowed runout is
0.020 in. (0.50 mm) for the full length of the tube.
STANDARD PROCEDURE
PROPELLER SHAFT ANGLE
(1) Pl ace transmi ssi on i n netural .
(2) Rai se and support the vehi cl e at the axl es as
l evel as possi bl e.
(3) Remove any external beari ng snap ri ngs from
uni versal joi nt so protractor base si ts fl at.
(4) Rotate the shaft unti l transmi ssi on/transfer
case output yoke beari ng i s faci ng downward.
NOTE: Always make measurements from front to
rear and from the same side of the vehicle.
(5) Pl ace I ncl i nometer 7663 (J-23498A) on yoke
beari ng (A) paral l el to the shaft (Fi g. 4). Center bub-
bl e i n si ght gl ass and record measurement.
NOTE: This measurement will give you the Output
Yoke Angle (A).
(6) Rotate propel l er shaft 90 degrees and pl ace
I ncl i nometer on yoke beari ng paral l el to the shaft
(Fi g. 5). Center bubbl e i n si ght gl ass and record mea-
surement. Thi s measurement can al so be taken at
the rear end of the shaft.
NOTE: This measurement will give you the Propel-
ler Shaft Angle (C).
(7) Subtract smal l er fi gure from l arger (C mi nus
A) to obtai n Transmi ssi on Output Operati ng Angl e.
(8) Rotate propel l er shaft 90 degrees and pl ace
I ncl i nometer on pi ni on yoke beari ng paral l el to the
shaft (Fi g. 6). Center bubbl e i n si ght gl ass and record
measurement.
Fig. 4 OUTPUT YOKE ANGLE (A)
1 - SLIP YOKE BEARING CAP
2 - INCLINOMETER
Fig. 5 PROPELLER SHAFT ANGLE (C)
1 - SHAFT YOKE BEARING CAP
2 - INCLINOMETER
3 - 4 PROPELLER SHAFT TJ
PROPELLER SHAFT (Continued)
NOTE: This measurement will give you the pinion
shaft or Input Yoke Angle (B).
(9) Subtract smal l er fi gure from l arger (C mi nus
B) to obtai n axl e I nput Operati ng Angl e.
Refer to rul es gi ven bel ow and the exampl e i n (Fi g.
7) for addi ti onal i nformati on.
• Good cancel l ati on of U-joi nt operati ng angl es
(wi thi n 1°).
• Operati ng angl es l ess than 3°.
• At l east 1/2 of one degree conti nuous operati ng
(propel l er shaft) angl e.
Fig. 7 UNIVERSAL JOINT ANGLE EXAMPLE
1 - 4.9°Angle (C)
2 - 3.2°Angle (B)
3 - Input Yoke
4 - 3.0°Angle (A)
5 - Output Yoke
Fig. 6 INPUT YOKE ANGLE (B)
1 - PINION YOKE BEARING CAP
2 - INCLINOMETER
TJ PROPELLER SHAFT 3 - 5
PROPELLER SHAFT (Continued)
ADJUSTMENTS
The pi ni on angl e of the front axl e can be adjusted
by the use of adjustment cams i n the l ower suspen-
si on arms (Fi g. 8). The pri mary functi on of the cams
i s to adjust caster angl e for al i gnment of the front
suspensi on. When usi ng the cams to adjust pi ni on
angl e, make sure that both cams are moved equal l y.
After pi ni on angl e i s adjusted, the front suspensi on
al i gnment shoul d be checked to ensure that si de-to-
si de caster i s wi th i n acceptabl e range. Havi ng the
correct pi ni on angl e does have pri ori ty over havi ng
the preferred caster angl e.
A cam ki t i s avai l abl e for the rear axl e upper sus-
pensi on arms i n order to provi de adjustabl i ty of the
pi ni on angl e. Fol l ow the procedures suppl i ed wi th the
ki t i n order to ensure a safe i nstal l ati on.
SPECIFICATIONS
PROPELLER SHAFT
TORQUE SPECIFICATIONS
DESCRIPTION N·m Ft. Lbs. In. Lbs.
Front Shaft Front Yoke
Bolts
19 14 -
Front Shaft Rear Flange
Bolts
27 20 -
Rear Saft Rear Yoke Bolts 19 14 -
Rear Shaft Transfer Case
Flange Bolts
115 85 -
Fig. 8 ADJUSTMENT CAM
1 - ADJUSTMENT CAM
2 - AXLE BRACKET
3 - BRACKET REINFORCEMENT
4 - LOWER SUSPENSION ARM
3 - 6 PROPELLER SHAFT TJ
PROPELLER SHAFT (Continued)
SPECIAL TOOLS
PROPELLER SHAFT - FRONT
REMOVAL
(1) Wi th vehi cl e i n neutral posi ton vehi cl e on hoi st.
(2) Remove ski d pl ate i f equi pped to gai n access to
the propel l er shaft.
(3) Mark a l i ne across the transfer case yoke, l i nk
yoke and propel l er shaft yoke for i nstal l ati on refer-
ence (Fi g. 9).
(4) Remove U-joi nt strap bol ts at the pi ni on shaft
yoke (Fi g. 10).
(5) Remove transfer case yoke bol ts.
(6) Push rear of propel l er shaft forward to cl ear
transfer case yoke.
(7) Remove propel l er shaft from vehi cl e.
INSTALLATION
(1) I nstal l propel l er shaft wi th reference marks
al i gned.
(2) Loosel y i nstal l bol ts to hol d uni versal joi nt to
transfer case yoke.
(3) I nstal l U-joi nt strap bol ts at the axl e yoke and
ti ghten to 19 N·m (14 ft. l bs.).
(4) I nstal l uni versal joi nt to transfer case bol ts and
ti ghten to 27 N·m (20 ft. l bs.).
PROPELLER SHAFT - REAR
REMOVAL
(1) Wi th vehi cl e i n neutral , posi ti on vehi cl e on
hoi st.
(2) Mark a l i ne across the shaft and at each end of
the propel l er shaft for i nstal l ati on reference.
(3) Remove U-joi nt strap bol ts, at pi ni on shaft
yoke.
(4) Pry open cl amp, hol di ng dust boot to propel l er
shaft yoke (Fi g. 11).
INCLINOMETER 7663
Fig. 9 YOKE REFERENCE MARKS
1 - REFERENCE MARKS
Fig. 10 FRONT PROPELLER SHAFT
1 - FRONT AXLE
2 - BOOT
3 - PROPELLER SHAFT
4 - CV-JOINT
5 - TRANSFER CASE
6 - BOOT
7 - SLINGER
8 - CLAMP
9 - YOKE
Fig. 11 DUST BOOT CLAMP
1 - SLINGER
2 - BOOT
3 - AWL
4 - TRANSFER CASE
TJ PROPELLER SHAFT 3 - 7
PROPELLER SHAFT (Continued)
(5) Sl i de sl i p yoke off of transmi ssi on/transfer case
output shaft and remove propel l er shaft (Fi g. 12).
INSTALLATION
(1) Sl i de sl i p yoke on transmi ssi on/transfer case
output shaft. Al i gn i nstal l ati on reference marks at
axl e yoke and i nstal l propel l er shaft.
(2) I nstal l U-joi nt strap bol ts at axl e yoke and
ti ghten to 19 N·m (14 ft. l bs.).
(3) Ti ghten cl amp wi th Cl amp Tool C-4975A to
hol d dust boot to propel l er shaft yoke (Fi g. 13).
PROPELLER SHAFT - REAR
RUBICON
REMOVAL
(1) Wi th vi hi cl e i n neutral , posti on vehi cl e on
hoi st.
(2) Mark reference l i nes across the pi ni on yoke,
transfer case fl ange and propel l er shaft for i nstal l a-
ti on reference.
(3) Remove transfer case fl ange bol ts (Fi g. 14) and
U-joi nt strap bol ts at the pi ni on shaft yoke.
(4) Remove propel l er shaft from vehi cl e.
Fig. 12 REAR PROPELLER SHAFT
1 - CLAMP
2 - YOKE
3 - PROPELLER SHAFT
4 - AXLE YOKE
5 - CLAMP
6 - OUTPUT SHAFT
7 - BOOT
Fig. 13 CRIMPING DUST BOOT CLAMP
1 - CLAMP TOOL
2 - SLINGER
3 - BOOT
4 - CLAMP
Fig. 14 TRANSFER CASE FLANGE
1 - REAR PROPELLER SHAFT
2 - REFERENCE MARK
3 - TRANSFER CASE FLANGE
3 - 8 PROPELLER SHAFT TJ
PROPELLER SHAFT - REAR (Continued)
INSTALLATION
(1) Al i gn i nstal l ati on reference marks at the pi ni on
yoke, transfer case fl ange and propel l er shaft.
(2) I nstal l U-joi nt strap and ti ghten bol ts to 19
N·m (14 ft. l bs.).
(3) I nstal l transfer case fl ange bol ts (Fi g. 15) and
ti ghten to 115 N·m (85 ft. l bs.).
SINGLE CARDAN UNIVERSAL
J OINTS
DISASSEMBLY
NOTE: Individual components of cardan universal
joints are not serviceable, they must be replaced as
an assembly.
(1) Tap the outsi de of the beari ng cap assembl y
wi th a dri ft to l oosen the snap ri ngs.
(2) Remove snap ri ngs from both si des of yoke
(Fi g. 16).
(3) Posi ti on a socket wi th a i nsi de di ameter l arge
enough to recei ve the beari ng cap beneath the yoke
on the press.
(4) Posi ti on yoke wi th the grease fi tti ng i f
equi pped, poi nti ng up.
(5) Pl ace another socket wi th an outsi de di ameter
smal l er than beari ng cap on the upper beari ng cap
and press the l ower cap through the yoke (Fi g. 17).
(6) Pul l beari ng cap of the yoke.
NOTE: If bearing cap will not come out, tap the
yoke ear near the bearing cap to dislodge the cap.
Fig. 15 TRANSFER CASE FLANGE BOLTS
1 - REAR PROPELLER SHAFT
2 - TRANSFER CASE FLANGE
Fig. 16 YOKE SNAP RING
1 - SNAP RING
Fig. 17 PRESS OUT BEARING CAP
1 - PRESS
2 - SOCKET
TJ PROPELLER SHAFT 3 - 9
PROPELLER SHAFT - REAR RUBICON (Continued)
(7) Turn yoke over and strai ghten the cross i n the
open hol e. Then careful l y press the end of the cross
unti l the other beari ng cap can be removed (Fi g. 18).
ASSEMBLY
CAUTION: Keep cross and bearing cap straight dur-
ing installation. Failure to heed caution may result
in damage.
(1) Appl y extreme pressure (EP) N.L.G.I . Grade 1
or 2 grease to i nsi de of yoke bores.
(2) Posi ti on cross i n the yoke wi th l ube fi tti ng i f
equi pped, poi nti ng up (Fi g. 19).
(3) Pl ace a beari ng cap over the trunni on and
al i gn cap wi th yoke bore (Fi g. 20).
(4) Press beari ng cap i nto the yoke bore enough to
cl ear snap ri ng groove.
(5) I nstal l a snap ri ng.
(6) Repeat Step 3 and Step 4 to i nstal l the other
beari ng cap.
NOTE: If joint is stiff or binding, strike the yoke with
a soft hammer to seat the needle bearings.
(7) Add grease to l ube fi tti ng, i f equi pped.
Fig. 18 PRESS OUT BEARING CAP
1 - CROSS
2 - BEARING CAP
Fig. 19 U-JOINT CROSS
1 - CROSS
2 - YOKE
Fig. 20 BEARING AND CROSS
1 - BEARING CAP
2 - TRUNNION
3 - 10 PROPELLER SHAFT TJ
SINGLE CARDAN UNIVERSAL J OINTS (Continued)
DOUBLE CARDAN UNIVERSAL
J OINTS
DISASSEMBLY
NOTE: Individual components of cardan universal
joints are not serviceable they must be replaced as
an assembly.
(1) Mark propel l er shaft yoke and l i nk yoke for
assembl y reference.
(2) Tap the outsi de of the beari ng cap assembl y
wi th dri ft to l oosen snap ri ngs.
(3) Remove al l beari ng cap snap ri ngs (Fi g. 21).
(4) Remove any grease fi tti ngs i f equi pped.
(5) Posi ti on a socket on the press wi th an i nsi de
di ameter l arge enough to recei ve the beari ng cap
under the l i nk yoke.
(6) Pl ace another socket wi th an outsi de di ameter
smal l er than the beari ng cap on the upper beari ng
cap.
(7) Press one beari ng cap from the outboard si de of
the l i nk yoke enough to grasp the cap wi th vi se jaws
(Fi g. 22).
(8) Grasp protrudi ng beari ng cap wi th vi se jaws
and tap l i nk yoke wi th a mal l et and dri ft to remove
beari ng cap (Fi g. 23).
Fig. 21 SNAP RINGS
Fig. 22 PRESS OUT BEARING
Fig. 23 REMOVE BEARING FROM YOKE
TJ PROPELLER SHAFT 3 - 11
(9) Fl i p assembl y and repeat Step 5, Step 6, Step 7
and Step 8 to remove the opposi te beari ng cap.
(10) Remove cross centeri ng ki t assembl y and
spri ng (Fi g. 24).
(11) Press remai ni ng beari ng caps out the other
end of the l i nk yoke, as descri bed above to compl ete
the di sassembl y.
ASSEMBLY
CAUTION: Alignment marks on link yoke and pro-
peller shaft yoke must be aligned during assem-
bled. Keep needle bearings upright in the bearing
cap. Failure to heed caution may result in damage.
(1) Appl y extreme pressure (EP) N.L.G.I . Grade 1
or 2 grease to i nsi de of yoke bores.
(2) Fi t a cross i nto propel l er shaft yoke (Fi g. 25).
(3) Pl ace a beari ng cap over the trunni on and
al i gn cap wi th the yoke bore (Fi g. 26).
(4) Press beari ng cap i nto the yoke bore enough to
cl ear snap ri ng groove (Fi g. 27).
(5) I nstal l a snap ri ng.
Fig. 24 CENTERING KIT
Fig. 25 INSTALL CROSS IN YOKE
Fig. 26 INSTALL BEARING CAP
Fig. 27 PRESS BEARING CAP
3 - 12 PROPELLER SHAFT TJ
DOUBLE CARDAN UNIVERSAL J OINTS (Continued)
(6) Fl i p propel l er shaft yoke and i nstal l other bear-
i ng cap onto the opposi te trunni on and i nstal l a snap
ri ng (Fi g. 28).
(7) Fi t l i nk yoke onto the remai ni ng trunni ons and
press both beari ng caps i nto pl ace and i nstal l snap
ri ngs (Fi g. 29).
(8) I nstal l centeri ng ki t assembl y i nsi de the l i nk
yoke (Fi g. 30).
NOTE: Making sure the spring is properly posi-
tioned.
(9) Pl ace two beari ng caps on opposi te trunni ons of
the remai ni ng cross. Fi t open trunni ons i nto the l i nk
yoke bores and the beari ng caps i nto the centeri ng
ki t (Fi g. 31).
Fig. 28 PRESS BEARING CAP
Fig. 29 INSTALL LINK YOKE
Fig. 30 CENTERING KIT
Fig. 31 REMAINING CROSS
TJ PROPELLER SHAFT 3 - 13
DOUBLE CARDAN UNIVERSAL J OINTS (Continued)
(10) Press remai ni ng two beari ng caps i nto pl ace
and i nstal l snap ri ngs (Fi g. 32).
(11) Tap snap ri ngs to seat them i nto the grooves
(Fi g. 33).
(12) Fl exi ng joi nt beyond center, the joi nt shoul d
snap over-center i n both di recti ons i f assembl ed cor-
rectl y (Fi g. 34).
Fig. 32 PRESS BEARING CAP
Fig. 33 SEAT SNAP RINGS
Fig. 34 VERIFY ASSEMBLY
3 - 14 PROPELLER SHAFT TJ
DOUBLE CARDAN UNIVERSAL J OINTS (Continued)
FRONT AXLE - 181FBI
TABLE OF CONTENTS
page page
FRONT AXLE - 181FBI
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . 15
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 19
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . 21
SPECIFICATIONS
FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . 29
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . 29
AXLE SHAFTS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 33
AXLE SHAFT SEALS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 33
SINGLE CARDAN UNIVERSAL JOINT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 35
PINION SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 35
COLLAPSIBLE SPACER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 37
DIFFERENTIAL COVER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 38
DIFFERENTIAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 40
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 41
DIFFERENTIAL CASE BEARINGS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 43
PINION GEAR/RING GEAR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 46
FRONT AXLE - 181FBI
DIAGNOSIS AND TESTING
GEAR NOISE
Axl e gear noi se can be caused by i nsuffi ci ent l ubri -
cant, i ncorrect backl ash, tooth contact, worn/damaged
gears or the carri er housi ng not havi ng the proper
offset and squareness.
Gear noi se usual l y happens at a speci fi c speed
range. The noi se can al so occur duri ng a speci fi c type
of dri vi ng condi ti on. These condi ti ons are accel era-
ti on, decel erati on, coast, or constant l oad.
When road testi ng, fi rst warm-up the axl e fl ui d by
dri vi ng the vehi cl e at l east 5 mi l es and then accel er-
ate the vehi cl e to the speed range where the noi se i s
the greatest. Shi ft out-of-gear and coast through the
peak-noi se range. I f the noi se stops or changes
greatl y:
• Check for i nsuffi ci ent l ubri cant.
• I ncorrect ri ng gear backl ash.
• Gear damage.
Di fferenti al si de gears and pi ni ons can be checked
by turni ng the vehi cl e. They usual l y do not cause
noi se duri ng strai ght-ahead dri vi ng when the gears
are unl oaded. The si de gears are l oaded duri ng vehi -
cl e turns. A worn pi ni on mate shaft can al so cause a
snappi ng or a knocki ng noi se.
BEARING NOISE
The axl e shaft, di fferenti al and pi ni on beari ngs can
al l produce noi se when worn or damaged. Beari ng
noi se can be ei ther a whi ni ng, or a growl i ng sound.
Pi ni on beari ngs have a constant-pi tch noi se. Thi s
noi se changes onl y wi th vehi cl e speed. Pi ni on beari ng
noi se wi l l be hi gher pi tched because i t rotates at a
faster rate. Dri ve the vehi cl e and l oad the di fferen-
ti al . I f beari ng noi se occurs, the rear pi ni on beari ng
i s the source of the noi se. I f the beari ng noi se i s
heard duri ng a coast, the front pi ni on beari ng i s the
source.
Worn or damaged di fferenti al beari ngs usual l y pro-
duce a l ow pi tch noi se. Di fferenti al beari ng noi se i s
si mi l ar to pi ni on beari ng noi se. The pi tch of di fferen-
ti al beari ng noi se i s al so constant and vari es onl y
wi th vehi cl e speed.
Axl e shaft beari ngs produce noi se and vi brati on
when worn or damaged. The noi se general l y changes
when the beari ngs are l oaded. Road test the vehi cl e.
Turn the vehi cl e sharpl y to the l eft and to the ri ght.
Thi s wi l l l oad the beari ngs and change the noi se
l evel . Where axl e beari ng damage i s sl i ght, the noi se
i s usual l y not noti ceabl e at speeds above 30 mph.
TJ FRONT AXLE - 181FBI 3 - 15
LOW SPEED KNOCK
Low speed knock i s general l y caused by a worn
U-joi nt or by worn si de-gear thrust washers. A worn
pi ni on shaft bore wi l l al so cause l ow speed knock.
VIBRATION
Vi brati on at the rear of the vehi cl e i s usual l y
caused by:
• Damaged dri ve shaft.
• Mi ssi ng dri ve shaft bal ance wei ght(s).
• Worn or out of bal ance wheel s.
• Loose wheel l ug nuts.
• Worn U-joi nt(s).
• Loose/broken spri ngs.
• Damaged axl e shaft beari ng(s).
• Loose pi ni on gear nut.
• Excessi ve pi ni on yoke run out.
• Bent axl e shaft(s).
Check for l oose or damaged front end components
or engi ne/transmi ssi on mounts. These components
can contri bute to what appears to be a rear end
vi brati on. Do not overl ook engi ne accessori es, brack-
ets and dri ve bel ts.
Al l dri vel i ne components shoul d be exami ned
before starti ng any repai r.
DRIVELINE SNAP
A snap or cl unk noi se when the vehi cl e i s shi fted
i nto gear (or the cl utch engaged) can be caused by:
• Hi gh engi ne i dl e speed.
• Transmi ssi on shi ft operati on.
• Loose engi ne/transmi ssi on/transfer case mounts.
• Worn U-joi nts.
• Loose spri ng mounts.
• Loose pi ni on gear nut and yoke.
• Excessi ve ri ng gear backl ash.
• Excessi ve si de gear to case cl earance.
The source of a snap or a cl unk noi se can be deter-
mi ned wi th the assi stance of a hel per. Rai se the vehi -
cl e on a hoi st wi th the wheel s free to rotate. I nstruct
the hel per to shi ft the transmi ssi on i nto gear. Li sten
for the noi se, a mechani cs stethoscope i s hel pful i n
i sol ati ng the source of a noi se.
DIAGNOSTIC CHART
Condition Possible Causes Correction
Wheel Noise 1. Wheel loose. 1. Tighten loose nuts.
2. Faulty, brinelled wheel bearing. 2. Replace bearing.
Axle Shaft Noise 1. Misaligned axle tube. 1. Inspect axle tube alignment.
Correct as necessary.
2. Bent or sprung axle shaft. 2. Inspect and correct as necessary.
3. End-play in pinion bearings. 3. Refer to pinion pre-load
information and correct as
necessary.
4. Excessive gear backlash
between the ring gear and pinion.
4. Check adjustment of the ring
gear and pinion backlash. Correct
as necessary.
5. Improper adjustment of pinion
gear bearings.
5. Adjust the pinion bearings
pre-load.
6. Loose pinion yoke nut. 6. Tighten the pinion yoke nut.
7. Scuffed gear tooth contact
surfaces.
7. Inspect and replace as
necessary.
3 - 16 FRONT AXLE - 181FBI TJ
FRONT AXLE - 181FBI (Continued)
Condition Possible Causes Correction
Axle Shaft Broke 1. Misaligned axle tube. 1. Replace the broken shaft after
correcting tube mis-alignment.
2 Vehicle overloaded. 2. Replace broken shaft and avoid
excessive weight on vehicle.
3. Erratic clutch operation. 3. Replace broken shaft and avoid
or correct erratic clutch operation.
4. Grabbing clutch. 4. Replace broken shaft and inspect
and repair clutch as necessary.
Differential Cracked 1. Improper adjustment of the
differential bearings.
1. Replace case and inspect gears
and bearings for further damage.
Set differential bearing pre-load
properly.
2. Excessive ring gear backlash. 2. Replace case and inspect gears
and bearings for further damage.
Set ring gear backlash properly.
3. Vehicle overloaded. 3. Replace case and inspect gears
and bearings for further damage.
Avoid excessive vehicle weight.
4. Erratic clutch operation. 4. Replace case and inspect gears
and bearings for further damage.
Avoid erratic use of clutch.
Differential Gears Scored 1. Insufficient lubrication. 1. Replace scored gears. Fill
differential with the correct fluid type
and quantity.
2. Improper grade of lubricant. 2. Replace scored gears. Fill
differential with the correct fluid type
and quantity.
3. Excessive spinning of one
wheel/tire.
3. Replace scored gears. Inspect all
gears, pinion bores, and shaft for
damage. Service as necessary.
Loss Of Lubricant 1. Lubricant level too high. 1. Drain lubricant to the correct
level.
2. Worn axle shaft seals. 2. Replace seals.
3. Cracked differential housing. 3. Repair as necessary.
4. Worn pinion seal. 4. Replace seal.
5. Worn/scored yoke. 5. Replace yoke and seal.
6. Axle cover not properly sealed. 6. Remove, clean, and re-seal
cover.
Axle Overheating 1. Lubricant level low. 1. Fill differential to correct level.
2. Improper grade of lubricant. 2. Fill differential with the correct
fluid type and quantity.
3. Bearing pre-loads too high. 3. Re-adjust bearing pre-loads.
4. Insufficient ring gear backlash. 4. Re-adjust ring gear backlash.
TJ FRONT AXLE - 181FBI 3 - 17
FRONT AXLE - 181FBI (Continued)
Condition Possible Causes Correction
Gear Teeth Broke 1. Overloading. 1. Replace gears. Examine other
gears and bearings for possible
damage.
2. Erratic clutch operation. 2. Replace gears and examine the
remaining parts for damage. Avoid
erratic clutch operation.
3. Ice-spotted pavement. 3. Replace gears and examine
remaining parts for damage.
4. Improper adjustments. 4. Replace gears and examine
remaining parts for damage. Ensure
ring gear backlash is correct.
Axle Noise 1. Insufficient lubricant. 1. Fill differential with the correct
fluid type and quantity.
2. Improper ring gear and pinion
adjustment.
2. Check ring gear and pinion
contact pattern.
3. Unmatched ring gear and pinion. 3. Replace gears with a matched
ring gear and pinion.
4. Worn teeth on ring gear and/or
pinion.
4. Replace ring gear and pinion.
5. Loose pinion bearings. 5. Adjust pinion bearing pre-load.
6. Loose differential bearings. 6. Adjust differential bearing
pre-load.
7. Mis-aligned or sprung ring gear. 7. Measure ring gear run-out.
Replace components as necessary.
8. Loose differential bearing cap
bolts.
8. Inspect differential components
and replace as necessary. Ensure
that the bearing caps are torqued
tot he proper specification.
9. Housing not machined properly. 9. Replace housing.
3 - 18 FRONT AXLE - 181FBI TJ
FRONT AXLE - 181FBI (Continued)
REMOVAL
(1) Wi th vehi cl e i n neutral , posi ti on vehi cl e on
hoi st.
(2) Posi ti on a l i ft under the axl e and secure to the
axl e.
(3) Remove brake components.
(4) Remove vent hose from axl e shaft tube.
(5) Remove propel l er shaft.
(6) Remove stabi l i zer bar l i nks at the axl e (Fi g. 1).
(7) Remove shock absorbers from axl e brackets
(Fi g. 2).
(8) Remove track bar from axl e bracket (Fi g. 3).
(9) Remove ti e rod and drag l i nk from steeri ng
knuckl e.
(10) Remove steeri ng damper from axl e bracket.
(11) Remove upper and l ower suspensi on arms
from axl e brackets.
(12) Lower l i ft enough to remove the axl e. The coi l
spri ngs wi l l drop wi th the axl e.
(13) Remove coi l spri ngs from the axl e.
INSTALLATION
CAUTION: The weight of the vehicle must be sup-
ported by the springs before suspension arms and
track bar fasteners can be tightened. Failure to
heed caution may result in damage.
(1) I nstal l spri ngs and retai ners and ti ghten
retai ner bol ts to 21 N·m (16 ft. l bs.).
(2) Posi ti on axl e under vehi cl e and al i gn i t wi th
the spri ng pads.
Fig. 1 STABILIZER BAR
1 - RETAINER
2 - STABILIZER BAR
3 - LINK
4 - BUSHING
Fig. 2 COIL SPRING & SHOCK ABSORBER
1 - RETAINER
2 - GROMMET
3 - SHOCK
4 - FRONT AXLE
Fig. 3 TRACK BAR
1 - TRACK BAR
2 - FRAME BRACKET
3 - FRONT AXLE
TJ FRONT AXLE - 181FBI 3 - 19
FRONT AXLE - 181FBI (Continued)
(3) I nstal l upper and l ower suspensi on arms i n the
axl e brackets and l oosel y i nstal l bol ts and nuts (Fi g.
4).
(4) Connect the vent hose to the axl e shaft tube.
(5) I nstal l track bar to the axl e bracket and l oosel y
i nstal l bol t (Fi g. 5).
(6) I nstal l shock absorbers and ti ghten the bol ts
(Fi g. 6) to torque speci fi cati on.
(7) I nstal l stabi l i zer bar l i nks to the axl e brackets
and ti ghten nuts (Fi g. 7) to torque speci fi cati on.
Fig. 4 UPPER & LOWER SUSPENSION ARMS
1 - UPPER SUSPENSION ARM
2 - FRONT AXLE
3 - LOWER SUSPENSION ARM
Fig. 5 TRACK BAR
1 - TRACK BAR
2 - FRAME BRACKET
3 - FRONT AXLE
Fig. 6 COIL SPRING & SHOCK ABSORBER
1 - RETAINER
2 - GROMMET
3 - SHOCK
4 - FRONT AXLE
Fig. 7 STABILIZER BAR
1 - RETAINER
2 - STABILIZER BAR
3 - LINK
4 - BUSHING
3 - 20 FRONT AXLE - 181FBI TJ
FRONT AXLE - 181FBI (Continued)
(8) I nstal l drag l i nk and ti e rod and ti ghten nut to
torque speci fi cati on
(9) I nstal l steeri ng damper to the axl e bracket and
ti ghten nut to torque speci fi cati on.
(10) I nstal l brake components.
(11) I nstal l propel l er shaft.
(12) Remove l i ft from the axl e and l ower vehi cl e.
(13) Ti ghten upper and l ower control arm nuts to
torque speci fi cati on.
(14) Ti ghten track bar bol t at the axl e bracket to
torque speci fi cati on.
(15) Check the front wheel al i gnment.
ADJUSTMENTS
Ri ng and pi ni on gears are suppl i ed as matched
sets onl y. The i denti fyi ng numbers for the ri ng and
pi ni on gear are etched/marked onto each gear (Fi g.
8). A pl us (+) number, mi nus (–) number or zero (0) i s
etched/marked on the pi ni on gear. Thi s number i s
the amount (i n thousandths of an i nch) the depth
vari es from the standard depth setti ng of a pi ni on
etched/marked wi th a (0). The standard setti ng from
the center l i ne of the ri ng gear to the back face of the
pi ni on i s 92.08 mm (3.625 i n.). The standard depth
provi des the best gear tooth contact pattern.
Compensati on for pi ni on depth vari ance i s
achi eved wi th a sel ect shi m/oi l sl i nger. The shi ms are
pl aced between the rear pi ni on beari ng and the pi n-
i on gear head (Fi g. 9).
I f a new gear set i s bei ng i nstal l ed, note the depth
vari ance etched i nto both the ori gi nal and repl ace-
ment pi ni on. Add or subtract thi s number from the
thi ckness of the ori gi nal depth shi m/oi l sl i nger to
compensate for the di fference i n the depth vari ances.
Refer to the Pi ni on Gear Depth Vari ance chart.
Note where Ol d and New Pi ni on Marki ng col umns
i ntersect. I ntersecti ng fi gure represents pl us or
mi nus the amount needed.
Note the etched number on the face of the pi ni on
gear head (–1, –2, 0, +1, +2, etc.). The numbers rep-
resent thousands of an i nch devi ati on from the stan-
dard. I f the number i s negati ve, add that val ue to the
requi red thi ckness of the depth shi ms. I f the number
i s posi ti ve, subtract that val ue from the thi ckness of
the depth shi m. I f the number i s 0 no change i s nec-
essary.
Fig. 8 PINION GEAR ID NUMBERS
1 - PRODUCTION NUMBERS
2 - PINION GEAR DEPTH VARIANCE
3 - GEAR MATCHING NUMBER
Fig. 9 SHIM LOCATIONS
1 - PINION GEAR DEPTH SHIM/OIL SLINGER
2 - DIFFERENTIAL BEARING SHIM
TJ FRONT AXLE - 181FBI 3 - 21
FRONT AXLE - 181FBI (Continued)
PINION GEAR DEPTH VARIANCE
Original Pinion
Gear Depth
Variance
Replacement Pinion Gear Depth Variance
Ϫ4 Ϫ3 Ϫ2 Ϫ1 0 +1 +2 +3 +4
+4 +0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0
+3 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 Ϫ0.001
+2 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 Ϫ0.001 Ϫ0.002
+1 +0.005 +0.004 +0.003 +0.002 +0.001 0 Ϫ0.001 Ϫ0.002 Ϫ0.003
0 +0.004 +0.003 +0.002 +0.001 0 Ϫ0.001 Ϫ0.002 Ϫ0.003 Ϫ0.004
Ϫ1 +0.003 +0.002 +0.001 0 Ϫ0.001 Ϫ0.002 Ϫ0.003 Ϫ0.004 Ϫ0.005
Ϫ2 +0.002 +0.001 0 Ϫ0.001 Ϫ0.002 Ϫ0.003 Ϫ0.004 Ϫ0.005 Ϫ0.006
Ϫ3 +0.001 0 Ϫ0.001 Ϫ0.002 Ϫ0.003 Ϫ0.004 Ϫ0.005 Ϫ0.006 Ϫ0.007
Ϫ4 0 Ϫ0.001 Ϫ0.002 Ϫ0.003 Ϫ0.004 Ϫ0.005 Ϫ0.006 Ϫ0.007 Ϫ0.008
PINION DEPTH MEASUREMENT AND ADJUSTMENT
Measurements are taken wi th pi ni on beari ng cups
and pi ni on beari ngs i nstal l ed i n the housi ng. Take
measurements wi th Pi ni on Gauge Set and Di al I ndi -
cator C-3339 (Fi g. 10).
(1) Assembl e Pi ni on Hei ght Bl ock 6739, Pi ni on
Bl ock 6733 and rear pi ni on beari ng onto Screw 6741
(Fi g. 10).
(2) I nsert assembl ed hei ght gauge components,
rear beari ng and screw i nto the housi ng through pi n-
i on beari ng cups (Fi g. 11).
(3) I nstal l front pi ni on beari ng and Cone-nut 6740
hand ti ght.
Fig. 10 PINION GEAR DEPTH GAUGE TOOLS
1 - DIAL INDICATOR
2 - ARBOR
3 - PINION HEIGHT BLOCK
4 - CONE
5 - SCREW
6 - PINION BLOCK
7 - SCOOTER BLOCK
8 - ARBOR DISC
Fig. 11 PINION HEIGHT BLOCK
1 - PINION BLOCK
2 - PINION HEIGHT BLOCK
3 - 22 FRONT AXLE - 181FBI TJ
FRONT AXLE - 181FBI (Continued)
(4) Pl ace Arbor Di sc 6732 on Arbor D-115-3 i n posi -
ti on i n axl e housi ng si de beari ng cradl es (Fi g. 12).
I nstal l di fferenti al beari ng caps on arbor di scs and
ti ghten cap bol ts to 41 N·m (30 ft. l bs.).
NOTE: Arbor Discs 6732 has different step diame-
ters to fit other axles. Choose proper step for axle
being serviced.
(5) Assembl e Di al I ndi cator C-3339 i nto Scooter
Bl ock D-115-2 and secure set screw.
(6) Posi ti on Scooter Bl ock/Di al I ndi cator fl ush on
the pi ni on hei ght bl ock. Hol d scooter bl ock and zero
the di al i ndi cator.
(7) Sl owl y sl i de the scooter bl ock across the pi ni on
hei ght bl ock over to the arbor (Fi g. 13). Move the
scooter bl ock ti l l the di al i ndi cator probe crests the
arbor and record the hi ghest readi ng.
(8) Sel ect a shi m/oi l baffl e equal to the di al i ndi ca-
tor readi ng pl us the pi ni on depth vari ance number
etched i n the face of the pi ni on (Fi g. 8). For exampl e,
i f the depth vari ance i s –2, add +0.002 i n. to the di al
i ndi cator readi ng.
DIFFERENTIAL SIDE BEARING PRELOAD AND
GEAR BACKLASH
Di fferenti al si de beari ng prel oad and gear backl ash
i s achi eved by sel ecti ve shi ms posi ti oned behi nd the
di fferenti al si de beari ng cones. The proper shi m
thi ckness can be determi ned usi ng sl i p-fi t Dummy
Beari ngs D-348 i n pl ace of the di fferenti al si de bear-
i ngs and a Di al I ndi cator C-3339. Before proceedi ng
wi th the di fferenti al beari ng prel oad and gear back-
l ash measurements, measure the pi ni on gear depth
and prepare the pi ni on for i nstal l ati on. Establ i shi ng
proper pi ni on gear depth i s essenti al to establ i shi ng
gear backl ash and tooth contact patterns. After the
overal l shi m thi ckness to take up di fferenti al si de
pl ay i s measured, the pi ni on i s i nstal l ed, and the
gear backl ash shi m thi ckness i s measured. The over-
al l shi m thi ckness i s the total of the di al i ndi cator
readi ng and the prel oad speci fi cati on added together.
The gear backl ash measurement determi nes the
thi ckness of the shi m used on the ri ng gear si de of
the di fferenti al case. Subtract the gear backl ash shi m
thi ckness from the total overal l shi m thi ckness and
sel ect that amount for the pi ni on gear si de of the di f-
ferenti al (Fi g. 14). Di fferenti al shi m measurements
are performed wi th spreader W-129-B removed.
Fig. 12 GAUGE TOOLS IN HOUSING
1 - ARBOR DISC
2 - PINION BLOCK
3 - ARBOR
4 - PINION HEIGHT BLOCK
Fig. 13 PINION DEPTH MEASUREMENT
1 - ARBOR
2 - SCOOTER BLOCK
3 - DIAL INDICATOR
Fig. 14 SHIM LOCATIONS
1 - PINION GEAR DEPTH SHIM/OIL SLINGER
2 - DIFFERENTIAL BEARING SHIM
TJ FRONT AXLE - 181FBI 3 - 23
FRONT AXLE - 181FBI (Continued)
PRELOAD SHIM SELECTION
NOTE: It is difficult to salvage the differential side
bearings during the removal procedure. Install
replacement bearings if necessary.
(1) Remove di fferenti al si de beari ngs from di ffer-
enti al case.
(2) Remove factory i nstal l ed shi ms from di fferen-
ti al case.
(3) I nstal l ri ng gear on di fferenti al case and
ti ghten bol ts to speci fi cati on.
(4) I nstal l dummy si de beari ngs D-348 on di fferen-
ti al case.
(5) I nstal l di fferenti al case i n the housi ng.
(6) I nstal l marked beari ng caps i n thei r correct
posi ti ons. I nstal l and snug the bol ts (Fi g. 15).
(7) Wi th a dead-bl ow hammer, seat the di fferenti al
dummy beari ngs to each si de of the housi ng (Fi g. 16)
and (Fi g. 17).
(8) Thread Pi l ot Stud C-3288-B i nto rear cover bol t
hol e bel ow ri ng gear (Fi g. 18).
(9) Attach the Di al I ndi cator C-3339 to pi l ot stud.
Posi ti on the di al i ndi cator pl unger on a fl at surface
between the ri ng gear bol t heads (Fi g. 18).
(10) Push and hol d di fferenti al case to pi ni on gear
si de of the housi ng and zero di al i ndi cator (Fi g. 19).
(11) Push and hol d di fferenti al case to ri ng gear
si de of the housi ng and record the di al i ndi cator
readi ng (Fi g. 20).
(12) Add 0.008 i n. (0.2 mm) to the zero end pl ay
total . Thi s new total represents the thi ckness of
shi ms to compress or prel oad the new beari ngs when
the di fferenti al i s i nstal l ed.
(13) Rotate di al i ndi cator out of the way on the
pi l ot stud.
(14) Remove di fferenti al case and dummy beari ngs
from the housi ng.
(15) I nstal l the pi ni on gear i n the housi ng. I nstal l
the pi ni on yoke and establ i sh the correct pi ni on
rotati ng torque.
(16) I nstal l di fferenti al case and dummy beari ngs
D-348 i n the housi ng (wi thout shi ms), i nstal l beari ng
caps and ti ghten bol ts snug.
(17) Seat ri ng gear si de dummy beari ng (Fi g. 17).
Fig. 15 BEARING CAP BOLTS
1 - BEARING CAP
2 - DIFFERENTIAL HOUSING
3 - DIFFERENTIAL CASE
Fig. 16 SEAT DUMMY BEARINGS PINION SIDE
1 - MALLET
2 - DIFFERENTIAL HOUSING
3 - DIFFERENTIAL CASE
Fig. 17 SEAT DUMMY BEARING RING GEAR SIDE
1 - DIFFERENTIAL HOUSING
2 - MALLET
3 - DIFFERENTIAL CASE
3 - 24 FRONT AXLE - 181FBI TJ
FRONT AXLE - 181FBI (Continued)
(18) Posi ti on the di al i ndi cator pl unger on a fl at
surface between the ri ng gear bol t heads (Fi g. 18).
(19) Push and hol d di fferenti al case toward pi ni on
gear and zero the di al i ndi cator (Fi g. 21).
Fig. 18 DIFFERENTIAL SIDE PLAY MEASUREMENT
1 - DIFFERENTIAL CASE
2 - DIFFERENTIAL HOUSING
3 - PILOT STUD
4 - DIAL INDICATOR
Fig. 19 DIAL INDICATOR LOCATION
1 - FORCE DIFFERENTIAL CASE TO PINION GEAR SIDE
2 - PILOT STUD
3 - DIAL INDICATOR
4 - ZERO DIAL INDICATOR FACE
Fig. 20 READ DIAL INDICATOR
1 - READ DIAL INDICATOR
2 - DIFFERENTIAL CASE TO RING GEAR SIDE
3 - DIFFERENTIAL HOUSING
Fig. 21 ZERO DIAL INDICATOR
1 - ZERO DIAL INDICATOR FACE
2 - FORCE DIFFERENTIAL CASE TO PINION GEAR SIDE
3 - PINION GEAR
4 - DIFFERENTIAL HOUSING
5 - DIFFERENTIAL CASE
TJ FRONT AXLE - 181FBI 3 - 25
FRONT AXLE - 181FBI (Continued)
(20) Push and hol d di fferenti al case to ri ng gear
si de of the housi ng and record di al i ndi cator readi ng
(Fi g. 22).
(21) Subtract 0.05 mm (0.002 i n.) from the di al
i ndi cator readi ng to compensate for backl ash between
ri ng and pi ni on gears. Thi s total i s the thi ckness
shi m requi red to achi eve proper backl ash.
(22) Subtract the backl ash shi m thi ckness from
the total prel oad shi m thi ckness. The remai nder i s
the shi m thi ckness requi red on the pi ni on si de of the
housi ng.
(23) Rotate di al i ndi cator out of the way on pi l ot
stud.
(24) Remove di fferenti al case and dummy beari ngs
from the housi ng.
(25) I nstal l the sel ected shi ms onto the di fferenti al
case hubs.
(26) I nstal l si de beari ngs and cups on di fferenti al
case.
(27) I nstal l spreader W-129-B and adaters from
Adapter Set 6987, onto housi ng. Spread the housi ng
to recei ve di fferenti al case.
(28) I nstal l di fferenti al case i nto the housi ng.
(29) Remove spreader from the housi ng.
(30) I nstal l beari ng caps and ti ghten bol ts to 61
N·m (45 ft. l bs.).
(31) Rotate the di fferenti al case several ti mes to
seat the si de beari ngs.
(32) Posi ti on the i ndi cator pl unger agai nst a ri ng
gear tooth (Fi g. 23).
(33) Push and hol d ri ng gear upward whi l e not
al l owi ng the pi ni on gear to rotate.
(34) Zero di al i ndi cator face to poi nter.
(35) Push and hol d ri ng gear downward whi l e not
al l owi ng the pi ni on gear to rotate. Di al i ndi cator
readi ng shoul d be between 0.12 mm - 0.20 mm (0.005
i n. - 0.008 i n.). I f backl ash i s not wi thi n speci fi cati ons
transfer the necessary amount of shi m thi ckness
from one si de of the housi ng to the other (Fi g. 24).
(36) Veri fy di fferenti al case and ri ng gear runout
by measuri ng ri ng to pi ni on gear backl ash at ei ght
l ocati ons around the ri ng gear. Readi ngs shoul d not
vary more than 0.05 mm (0.002 i n.). I f readi ngs vary
more than speci fi ed, the ri ng gear or the di fferenti al
case i s defecti ve.
After the proper backl ash i s achi eved, perform
Gear Contact Pattern procedure.
Fig. 22 DIFFERENTIAL CASE RING GEAR SIDE
1 - READ DIAL INDICATOR
2 - FORCE DIFFERENTIAL CASE TO RING GEAR SIDE
3 - PINION GEAR
4 - DIFFERENTIAL HOUSING
5 - DIFFERENTIAL CASE
Fig. 23 RING GEAR BACKLASH MEASUREMENT
1 - DIAL INDICATOR
Fig. 24 BACKLASH SHIM
3 - 26 FRONT AXLE - 181FBI TJ
FRONT AXLE - 181FBI (Continued)
GEAR CONTACT PATTERN
The ri ng gear and pi ni on teeth contact patterns
wi l l show i f the pi ni on depth i s correct i n the hous-
i ng. I t wi l l al so show i f the ri ng gear backl ash has
been adjusted correctl y. The backl ash can be adjusted
wi thi n speci fi cati ons to achi eve desi red tooth contact
patterns.
The TOP LAND of the gear tooth i s the top surface
of the tooth. The PROFI LE of the gear tooth i s the
depth of the tooth. The TOE of the gear i s the por-
ti on of the tooth surface at the end towards the cen-
ter. The HEEL of the gear i s the porti on of the tooth
at the outer-end. The ROOT of the gear tooth i s the
l owest porti on of the tooth (Fi g. 25).
NOTE: If the PROFILE across the tooth is the same
it is a 3 Axis cut gear. If the PROFILE across the
tooth is tapered it is a 2 Axis cut gear.
(1) Appl y a thi n coat of hydrated ferri c oxi de or equi va-
l ent to the dri ve and coast si de of the ri ng gear teeth.
(2) Wrap, twi st and hol d a shop towel around the pi ni on
yoke to i ncrease the turni ng resi stance of the pi ni on. Thi s
wi l l provi de a more di sti nct contact pattern.
(3) Wi th a boxed end wrench on the ri ng gear bol t,
rotate the di fferenti al case one compl ete revol uti on i n
both di recti ons whi l e a l oad i s bei ng appl i ed from
shop towel .
The areas on the ri ng gear teeth wi th the greatest
degree of contact agai nst the pi ni on teeth wi l l
squeeze the compound to the areas wi th the l east
amount of contact. Note and compare patterns on the
ri ng gear teeth to Gear Tooth Contact Patterns chart
(Fi g. 26) and (Fi g. 27) and adjust pi ni on depth and
gear backl ash as necessary.
Fig. 26 PATTERN INTERPRETATION (GEAR CUT 2 AXIS)
Fig. 25 GEAR DESCRIPTION
1 - TOP LAND
2 - PROFILE
3 - TOE
4 - HEEL
5 - ROOT
TJ FRONT AXLE - 181FBI 3 - 27
FRONT AXLE - 181FBI (Continued)
DIFFERENTIAL BEARING PRELOAD CHECK
The fi nal check on the di fferenti al assembl y before
i nstal l i ng the axl es i s torque to rotate pi ni on and di f-
ferenti al combi ned. Thi s wi l l veri fy the correct di ffer-
enti al beari ng prel oad.
Torque to rotate the di fferenti al and pi ni on shoul d
be the torque to rotate the pi ni on pl us 0.79-1.24 N·m
(7-11 i n. l bs.).
Fig. 27 PATTERN INTERPRETATION (GEAR CUT 3 AXIS)
3 - 28 FRONT AXLE - 181FBI TJ
FRONT AXLE - 181FBI (Continued)
SPECIFICATIONS
FRONT AXLE
AXLE SPECIFICATIONS
DESCRIPTION SPECIFICATION
Axle Ratio 3.07, 3.73, 4.10, 4.56
Ring Gear Backlash 0.12-0.20 mm (0.005-0.008 in.)
Pinion Bearing Preload - Original Bearings 1.13-2.26 N·m (10-20 in. lbs.)
Pinion Bearing Preload - New Bearings 2-3.4 N·m (15-30 in. lbs.)
TORQUE SPECIFICATIONS
DESCRIPTION N·m Ft. Lbs. In. Lbs.
Fill Hole Plug 34 25 -
Differential Cover Bolts 41 30 -
Bearing Cap Bolts 61 45 -
Ring Gear Bolts 108 80 -
Pinion Bearing Nut Min -
Max
217 - 678 160 - 500 -
Axle Nut 237 175 -
Hub Bearing Bolts 102 75 -
SPECIAL TOOLS
PULLER C-293-PA
ADAPTER C-293-39
WRENCH C-3281
PILOT STUD C-3288-B
TJ FRONT AXLE - 181FBI 3 - 29
FRONT AXLE - 181FBI (Continued)
DIAL INDICATOR C-3339
INSTALLER C-3716-A
INSTALLER C-3972-A
HANDLE C-4171
REMOVER C-4345
PULLER C-452
INSTALLER D-130
INSTALLER D-146
REMOVER D-149
DUMMY BEARINGS D-348
3 - 30 FRONT AXLE - 181FBI TJ
FRONT AXLE - 181FBI (Continued)
PLUG SP-3289
SPREADER W-129-B
INSTALLER W-162-D
INSTALLER W-262
PINION DEPTH SET 6774
TURNBUCKLE 6797
SPANNER WRENCH 6958
ADAPTER KIT 6987B
CUP 8109
INSTALLER DISCS 8110
TJ FRONT AXLE - 181FBI 3 - 31
FRONT AXLE - 181FBI (Continued)
AXLE SHAFTS
REMOVAL
(1) Wi th vehi cl e i n neutral , posi ti on vehi cl e on
hoi st.
(2) Remove brake components.
(3) Remove cotter pi n, nut retai ner and axl e hub nut.
(4) Remove hub beari ng bol ts (Fi g. 28).
(5) Remove hub beari ng from steeri ng knuckl e.
(6) Remove axl e shaft assembl y (Fi g. 29) from axl e
(7) Remove brake rotor shi el d from the hub bear-
i ng or knuckl e.
Fig. 30 HUB BEARING & KNUCKLE
1 - BRAKE SHIELD
2 - WASHER
3 - RETAINER
4 - COTTER PIN
5 - NUT
6 - HUB AND BEARING ASSEMBLY
7 - STEERING KNUCKLE
8 - BOLT
9 - TONE WHEEL (ABS)
Fig. 28 HUB BEARING BOLTS
1 - AXLE SHAFT
2 - AXLE
3 - KNUCKLE
4 - HUB BEARING
Fig. 29 HUB BEARING AND AXLE ASSEMBLY
1 - AXLE
2 - KNUCKLE
3 - HUB BEARING
4 - AXLE SHAFT
3 - 32 FRONT AXLE - 181FBI TJ
INSTALLATION
(1) Cl ean axl e shaft and appl y a thi n fi l m of
Mopar Wheel Beari ng Grease or equi val ent to the
shaft spl i nes, seal contact surface and hub bore.
(2) I nstal l brake rotor shi el d on knuckl e.
(3) I nstal l axl e shaft i nto di fferenti al si de gears.
(4) I nstal l hub beari ng and ti ghten bol ts to 102
N·m (75 ft. l bs.).
(5) I nstal l axl e washer and nut. Ti ghten nut to 237
N·m (175 ft. l bs.) and i nstal l nut retai ner and cotter
pi n (Fi g. 30).
(6) I nstal l brake components.
AXLE SHAFT SEALS
REMOVAL
(1) Wi th vehi cl e i n neutral , posi ti on vehi cl e on
hoi st.
(2) Remove axl e shafts (Fi g. 31).
(3) Remove di fferenti al assembl y (Fi g. 32).
(4) Remove i nner axl e shaft seal s wi th a pry bar.
INSTALLATION
(1) Remove any seal er remai ni ng from ori gi nal
seal s.
(2) I nstal l oi l seal s wi th Di scs 8110 and Turn-
buckl e 6797 (Fi g. 33). Ti ghten tool unti l di sc bottoms
i n housi ng.
(3) I nstal l di fferenti al and axl e shafts.
Fig. 31 HUB BEARING AND AXLE ASSEMBLY
1 - AXLE
2 - KNUCKLE
3 - HUB BEARING
4 - AXLE SHAFT
Fig. 32 DIFFERENTIAL CASE
1 - AXLE HOUSING
2 - DIFFERENTIAL CASE
3 - BEARING CUPS
Fig. 33 AXLE SEAL INSTALLATION
1 - TURNBUCKLE
2 - DISCS
TJ FRONT AXLE - 181FBI 3 - 33
AXLE SHAFTS (Continued)
SINGLE CARDAN UNIVERSAL
J OINT
REMOVAL
CAUTION: Clamp only the narrow forged portion of
the yoke in the vise. Failure to heed caution may
result in damage.
(1) Remove axl e shaft.
(2) Remove beari ng cap retai ni ng snap ri ngs (Fi g.
34).
NOTE: Saturate the bearing caps with penetrating
oil prior to removal.
(3) Pl ace a socket (recei ver) wi th an i nsi de di ame-
ter l arger than the beari ng cap agai nst the yoke and
the peri meter of the beari ng cap to be removed.
(4) Pl ace a socket (dri ver) wi th an outsi de di ame-
ter smal l er than the beari ng cap agai nst the opposi te
beari ng cap.
(5) Posi ti on yoke wi th the sockets i n a vi se (Fi g.
35).
(6) Ti ghten vi se jaws, to force beari ng cap i nto the
socket (recei ver).
(7) Rel ease vi se jaws. Remove sockets and beari ng
cap forced out of the yoke.
(8) Repeat above procedure for the remai ni ng bear-
i ng cap and remove cross from propel l er shaft yoke.
Fig. 34 AXLE SHAFT OUTER U-JOINT
1 - SHAFT YOKE
2 - BEARING CAP
3 - SNAP RINGS
4 - BEARING CAP
5 - SPINDLE YOKE
6 - BEARING
7 - BEARING CAP
8 - SNAP RINGS
9 - BEARING CAP
Fig. 35 YOKE BEARING CAP REMOVAL
1 - LARGE-DIAMETER SOCKET
2 - VISE
3 - SMALL-DIAMETER SOCKET
3 - 34 FRONT AXLE - 181FBI TJ
INSTALLATION
CAUTION: Keep cross and bearing cap straight dur-
ing installation. Failure to heed caution may result
in damage.
(1) Pack beari ng caps 1/3 ful l of wheel beari ng
l ubri cant (Fi g. 36). Appl y extreme pressure (EP), l i th-
i um-base l ubri cant to ai d i n i nstal l ati on.
(2) Posi ti on cross i n the yoke. I nsert seal s and
beari ngs, then tap beari ng caps i nto the yoke bores
far enough to hol d spi der i n posi ti on.
(3) Pl ace socket (dri ver) agai nst one beari ng cap.
Posi ti on yoke wi th the socket i n a vi se.
(4) Ti ghten vi se to force beari ng caps i nto the
yoke. Force the caps enough to i nstal l retai ni ng cl i ps.
(5) I nstal l beari ng cap retai ni ng cl i ps.
(6) I nstal l axl e shaft.
PINION SEAL
REMOVAL
(1) Wi th vehi cl e i n neutral , posi ti on vehi cl e on
hoi st.
(2) Remove brake rotors and cal i pers.
(3) Remove propel l er shaft from the yoke.
(4) Rotate pi ni on gear three or four ti mes.
(5) Record rotati ng torque of the pi ni on gear wi th
an i nch pound torque wrench, for i nstal l ati on refer-
ence.
(6) Hol d pi ni on yoke wi th Wrench 6958 and
remove pi ni on nut and washer.
(7) Remove pi ni on yoke wi th Remover C-452 and
Wrench C-3281 (Fi g. 37).
(8) Remove seal wi th a pry tool or a sl i de hammer
mounted screw.
INSTALLATION
(1) Appl y a l i ght coati ng of gear l ubri cant on the
l i p of pi ni on seal . I nstal l seal wi th an appropri ate
i nstal l er (Fi g. 38).
Fig. 36 AXLE SHAFT OUTER U-JOINT
1 - SHAFT YOKE
2 - BEARING CAP
3 - SNAP RINGS
4 - BEARING CAP
5 - SPINDLE YOKE
6 - BEARING
7 - BEARING CAP
8 - SNAP RINGS
9 - BEARING CAP
Fig. 37 PINION YOKE REMOVER
1 - WRENCH
2 - PINION YOKE
3 - REMOVER
Fig. 38 PINION SEAL INSTALLER
1 - HANDLE
2 - INSTALLER
TJ FRONT AXLE - 181FBI 3 - 35
SINGLE CARDAN UNIVERSAL J OINT (Continued)
(2) I nstal l yoke on pi ni on gear wi th I nstal l er
W-162-D, Cup 8109 and Hol der 6958 (Fi g. 39).
CAUTION: Do not exceed the minimum tightening
torque when installing the pinion yoke retaining nut
at this point. Failure to heed caution may result in
damage
(3) I nstal l pi ni on washer and a new nut on the
pi ni on gear shaft.
NOTE: Tighten nut only enough to remove the shaft
end play.
(4) Ti ghten pi ni on nut to 217 N·m (160 ft. l bs.).
(5) Rotate pi ni on shaft usi ng an i nch pound torque
wrench. Rotati ng torque shoul d be equal to the read-
i ng recorded duri ng removal , pl us an addi ti onal 0.56
N·m (5 i n. l bs.) (Fi g. 40).
(6) I f rotati ng torque i s l ow, use Spanner 6958
(Fi g. 41) to hol d the pi ni on yoke and ti ghten pi ni on
shaft nut i n 6.8 N·m (5 ft. l bs.) i ncrements unti l
proper rotati ng torque i s achi eved.
(7) I nstal l propel l er shaft wi th reference marks
al i gned.
(8) I nstal l brake rotors and cal i pers.
Fig. 39 PINION YOKE INSTALLER
1 - INSTALLER
2 - PINION YOKE
3 - SPANNER WRENCH
Fig. 40 PINION ROTATING TORQUE
1 - TORQUE WRENCH
2 - PINION YOKE
Fig. 41 YOKE HOLDER
1 - PINION YOKE
2 - SPANNER WRENCH
3 - PIPE
3 - 36 FRONT AXLE - 181FBI TJ
PINION SEAL (Continued)
COLLAPSIBLE SPACER
REMOVAL
(1) Wi th vehi cl e i n neutral , posi ti on vehi cl e on
hoi st.
(2) Remove brake rotors and cal i pers.
(3) Remove propel l er shaft from axl e yoke.
(4) Rotate pi ni on gear three or four ti mes.
(5) Record rotati ng torque of the pi ni on gear wi th
an i nch pound torque wrench.
(6) Hol d pi ni on yoke wi th Spanner Wrench 6958
and remove pi ni on nut and washer.
(7) Remove pi ni on yoke wi th Remover C-452 and
Fl ange Wrench C-3281 (Fi g. 42).
(8) Remove pi ni on seal wi th a sui tabl e pry tool or
a sl i de hammer mounted screw.
(9) Remove front pi ni on beari ng off pi ni on gear
shaft, wi th a pai r of pi ck tool s. I f beari ng becomes
bound on the shaft, l i ghtl y tap the end of the pi ni on
gear wi th a rubber hammer.
(10) Remove col l apsi bl e spacer.
INSTALLATION
(1) I nstal l new col l apsi bl e spacer on pi ni on shaft.
(2) I nstal l front pi ni on beari ng.
(3) Appl y a l i ght coati ng of gear l ubri cant on the
l i p of pi ni on seal and i nstal l seal wi th an appropri ate
i nstal l er (Fi g. 43).
(4) I nstal l yoke wi th I nstal l er W-162-D, Cup 8109
and Spanner Wrench 6958 (Fi g. 44).
(5) I nstal l pi ni on washer and new nut and ti ghten
nut to 217 N·m (160 ft. l bs.).
CAUTION: Never loosen pinion gear nut to decrease
pinion gear bearing rotating torque and never
exceed specified preload torque. Failure to heed
caution may result in damage.
Fig. 42 PINION YOKE REMOVER
1 - WRENCH
2 - PINION YOKE
3 - REMOVER
Fig. 43 PINION SEAL INSTALLER
1 - HANDLE
2 - INSTALLER
Fig. 44 PINION YOKE INSTALLER
1 - INSTALLER
2 - PINION YOKE
3 - SPANNER WRENCH
TJ FRONT AXLE - 181FBI 3 - 37
(6) Wi th yoke Spanner Wrench 6958 and a torque
wrench set at 678 N·m (500 ft. l bs.), sl owl y ti ghten
nut (Fi g. 45) i n 6.8 N·m (5 ft. l bs.) i ncrements unti l
rotati ng torque i s achi eved. Measure rotati ng torque
wi th i nch pound torque wrench frequentl y to avoi d
over crushi ng the col l apsi bl e spacer (Fi g. 46).
CAUTION: If more than 687 N·m (500 ft. lbs.) torque
is required to crush the collapsible spacer, the
spacer is defective and must be replaced. Failure to
heed caution may result in damage.
(7) Rotati ng torque shoul d be the recorded readi ng
duri ng removal , pl us an addi ti onal 0.56 N·m (5 i n.
l bs.).
(8) I nstal l propel l er shaft.
(9) I nstal l brake rotors and cal i pers.
DIFFERENTIAL COVER
REMOVAL
(1) Wi th vehi cl e i n neutral , posi ti on vehi cl e on
hoi st.
(2) Remove drai n pl ug.
(3) Remove cover bol ts.
(4) Remove cover and drai n l ubri cant.
INSTALLATION
(1) Appl y a 6.35mm (1/4 i n.) bead of Mopar Si l i -
cone Rubber Seal ant or equi val ent to the housi ng
cover (Fi g. 47).
Fig. 45 YOKE SPANNER WRENCH
1 - PINION YOKE
2 - SPANNER WRENCH
3 - PIPE
Fig. 46 PINION ROTATING TORQUE
1 - TORQUE WRENCH
2 - PINION YOKE
Fig. 47 HOUSING COVER - TYPICAL
1 - SEALANT SURFACE
2 - SEALANT
3 - SEALANT THICKESS
3 - 38 FRONT AXLE - 181FBI TJ
COLLAPSIBLE SPACER (Continued)
CAUTION: If housing cover is not installed within 3
to 5 minutes, the cover must be cleaned and new
RTV applied. Failure to heed caution may result in
damage.
(2) I nstal l cover and i denti fi cati on tag. Ti ghten
cover bol ts i n a cri ss-cross pattern to 41 N·m (30 ft.
l bs.).
(3) Fi l l di fferenti al to speci fi cati ons.
(4) I nstal l fi l l pl ug and ti ghten to 34 N·m (25 ft.
l bs.).
DIFFERENTIAL
REMOVAL
(1) Remove di fferenti al cover and fl ui d to drai n.
(2) Remove hub beari ngs and axl e shafts.
(3) Note the i nstal l ati on reference l etters stamped
on the beari ng caps and housi ng machi ned seal i ng
surface (Fi g. 48).
(4) Loosen the di fferenti al beari ng cap bol ts.
(5) Posi ti on Spreader W-129-B and Adapter from
Ki t 6987, wi th the tool dowel pi ns seated i n the l ocat-
i ng hol es (Fi g. 49). I nstal l hol ddown cl amps and
ti ghten the tool turnbuckl e fi nger-ti ght.
(6) I nstal l Pi l ot Stud C-3288-B at the l eft si de of
the di fferenti al housi ng. Attach Di al I ndi cator C-3339
to gui de pi n. Load i ndi cator pl unger agai nst the
opposi te si de of the housi ng (Fi g. 50) and zero i ndi -
cator.
Fig. 48 BEARING CAP IDENTIFICATION
1 - INSTALLATION REFERENCE LETTERS
2 - INSTALLATION REFERENCE LETTERS
Fig. 49 SPREADER LOCATION
1 - AXLE HOUSING
2 - DOWEL
3 - SAFETY HOLD DOWN
4 - SPREADER
5 - TURNBUCKLE
Fig. 50 DIAL INDICATOR LOCATION
1 - INDICATOR CLAMP
2 - DIAL INDICATOR
3 - LEVER ADAPTER
4 - SPREADER
5 - PILOT STUD
TJ FRONT AXLE - 181FBI 3 - 39
DIFFERENTIAL COVER (Continued)
(7) Spread housi ng whi l e measuri ng the di stance
wi th the di al i ndi cator (Fi g. 51).
CAUTION: Do not spread over 0.50 mm (0.020 in).
Failure to heed caution may result in damage.
(8) Remove di al i ndi cator.
(9) Hol d di fferenti al case i n posi ti on whi l e remov-
i ng di fferenti al beari ng caps.
(10) Remove di fferenti al from the housi ng (Fi g.
52).
(11) Remove spreader from housi ng.
(12) Cl ean housi ng cavi ty wi th a fl ushi ng oi l , l i ght
engi ne oi l or l i nt free cl oth.
NOTE: Do not use water, steam, kerosene or gaso-
line for cleaning.
DISASSEMBLY
(1) Remove ri ng gear.
(2) Dri ve out rol l pi n hol di ng pi ni on gear mate
shaft wi th a punch (Fi g. 53).
(3) Remove pi ni on gear mate shaft from the di ffer-
enti al case and pi ni on mate gears.
Fig. 51 SPREAD DIFFERENTIAL HOUSING
1 - INDICATOR
2 - SPREADER
Fig. 52 DIFFERENTIAL CASE
1 - AXLE HOUSING
2 - DIFFERENTIAL CASE
3 - BEARING CUPS
Fig. 53 MATE SHAFT ROLL PIN
1 - DRIFT
2 - LOCKPIN
3 - MATE SHAFT
3 - 40 FRONT AXLE - 181FBI TJ
DIFFERENTIAL (Continued)
(4) Rotate di fferenti al si de gears and remove pi n-
i on mate gears and thrust washers (Fi g. 54).
(5) Remove di fferenti al si de gears and thrust
washers.
ASSEMBLY
(1) I nstal l di fferenti al si de gears and thrust wash-
ers.
(2) I nstal l pi ni on mate gears and thrust washers.
(3) I nstal l pi ni on gear mate shaft. Al i gn rol l pi n
hol es i n shaft and the di fferenti al case.
(4) I nstal l pi ni on mate shaft rol l pi n i n the di ffer-
enti al case (Fi g. 55).
(5) I nstal l the ri ng gear.
INSTALLATION
NOTE: If replacement differential bearings or differ-
ential case are being installed, differential side
bearing shim requirements may change. Refer to
Adjustments (Differential Bearing Preload and Gear
Backlash) to determine the proper shim selection.
(1) Posi ti on Spreader W-129-B and Adapter Ki t
6987, wi th the tool dowel pi ns seated i n the l ocati ng
hol es (Fi g. 56). I nstal l hol ddown cl amps and ti ghten
turnbuckl e fi nger-ti ght.
Fig. 54 PINION MATE GEAR
1 - THRUST WASHER
2 - SIDE GEAR
3 - PINION MATE GEAR
Fig. 55 MATE SHAFT ROLL PIN
1 - PUNCH
2 - PINION MATE SHAFT
3 - MATE SHAFT LOCKPIN
Fig. 56 SPREADER LOCATION
1 - AXLE HOUSING
2 - DOWEL
3 - SAFETY HOLD DOWN
4 - SPREADER
5 - TURNBUCKLE
TJ FRONT AXLE - 181FBI 3 - 41
DIFFERENTIAL (Continued)
(2) I nstal l a Pi l ot Stud C-3288-B at the l eft si de of
the di fferenti al housi ng. Attach Di al I ndi cator C-3339
to pi l ot stud. Load the l ever adapter agai nst the
opposi te si de of the housi ng (Fi g. 57) and zero i ndi -
cator.
(3) Spread housi ng whi l e measuri ng the di stance
wi th the di al i ndi cator (Fi g. 58).
CAUTION: Do not spread over 0.50 mm (0.020 in).
Failure to heed caution may result in damage.
(4) Remove di al i ndi cator.
(5) I nstal l di fferenti al case i n the housi ng. Tap di f-
ferenti al case to seat beari ngs cups i n the housi ng.
(6) I nstal l beari ng caps at thei r ori gi nal l ocati ons
(Fi g. 59).
(7) Loosel y i nstal l di fferenti al beari ng cap bol ts.
(8) Remove axl e housi ng spreader.
(9) Ti ghten beari ng cap bol ts to 61 N·m (45 ft.
l bs.).
(10) I nstal l hub beari ngs and axl e shafts.
(11) I nstal l di fferenti al cover.
Fig. 57 DIAL INDICATOR LOCATION
1 - CLAMP
2 - DIAL INDICATOR
3 - LEVER ADAPTER
4 - SPREADER
5 - PILOT STUD
Fig. 58 SPREAD DIFFERENTIAL HOUSING
1 - INDICATOR
2 - SPREADER
Fig. 59 BEARING CAP IDENTIFICATION
1 - INSTALLATION REFERENCE LETTERS
2 - INSTALLATION REFERENCE LETTERS
3 - 42 FRONT AXLE - 181FBI TJ
DIFFERENTIAL (Continued)
DIFFERENTIAL CASE
BEARINGS
REMOVAL
(1) Remove beari ngs from the di fferenti al case
wi th Pul l er/Press C-293-PA, C-293-39 Adapter and
Pl ug SP-3289 (Fi g. 60).
INSTALLATION
NOTE: If replacement differential side bearings or
differential case are being installed, differential side
bearing shim requirements may change. Refer to
Adjustments (Differential Bearing Preload and Gear
Backlash) to determine the proper shim selection.
(1) I nstal l di fferenti al si de beari ng shi ms onto di f-
ferenti al case hubs.
(2) I nstal l di fferenti al si de beari ngs wi th I nstal l er
C-3716-A and Handl e C-4171 (Fi g. 61).
Fig. 60 DIFFERENTIAL BEARING
1 - ADAPTERS
2 - BEARING
3 - DIFFERENTIAL
4 - PLUG
5 - PULLER
Fig. 61 DIFFERENTIAL CASE BEARING
1 - INSTALLER
2 - HANDLE
TJ FRONT AXLE - 181FBI 3 - 43
PINION GEAR/RING GEAR
REMOVAL
NOTE: The ring and pinion gears are serviced as a
matched set. Never replace one gear without replac-
ing the other matched gear.
(1) Remove di fferenti al from axl e housi ng.
(2) Secure di fferenti al case i n a vi se wi th soft
metal jaw (Fi g. 62).
(3) Remove ri ng gear bol ts from the di fferenti al
case.
(4) Dri ve ri ng gear off the di fferenti al case wi th a
dead-bl ow hammer (Fi g. 62).
(5) Hol d yoke wi th Spanner Wrench 6958 and
remove the pi ni on nut and washer (Fi g. 63).
(6) Remove pi ni on yoke wi th Remover C-452 and
Fl ange Wrench C-3281 (Fi g. 64).
Fig. 62 RING GEAR
1 - DIFFERENTAIL CASE
2 - RING GEAR
3 - HAMMER
Fig. 63 YOKE SPANNER WRENCH
1 - PINION YOKE
2 - SPANNER WRENCH
3 - PIPE
Fig. 64 PINION YOKE
1 - FLANGE WRENCH
2 - PINION YOKE
3 - REMOVER
3 - 44 FRONT AXLE - 181FBI TJ
(7) Remove pi ni on and col l apsi bl e spacer from the
housi ng (Fi g. 65).
(8) Remove front pi ni on beari ng cup, beari ng, oi l
sl i nger and pi ni on seal wi th Remover C-4345 and
Handl e C-4171 (Fi g. 66).
(9) Remove rear pi ni on beari ng cup from the hous-
i ng (Fi g. 67) wi th Remover D-149 and Handl e
C-4171.
(10) Remove col l apsi bl e spacer from pi ni on shaft
(Fi g. 68).
Fig. 65 PINION GEAR
1 - DEAD-BLOW HAMMER
Fig. 66 FRONT BEARING CUP
1 - REMOVER
2 - HANDLE
Fig. 67 REAR BEARING CUP
1 - REMOVER
2 - HANDLE
Fig. 68 COLLAPSIBLE SPACER
1 - COLLAPSIBLE SPACER
2 - SHOULDER
3 - PINION
4 - PINION DEPTH SHIM
5 - REAR BEARING
TJ FRONT AXLE - 181FBI 3 - 45
PINION GEAR/RING GEAR (Continued)
(11) Remove rear pi ni on beari ng wi th Pul l er/Press
C-293-PA and Adapters C-293-39 (Fi g. 69).
(12) Remove pi ni on depth shi m/oi l sl i nger from the
pi ni on shaft and record thi ckness.
INSTALLATION
NOTE: A pinion depth shim/oil slinger is placed
between the rear pinion bearing cone and the pin-
ion head to achieve proper ring gear and pinion
mesh. If ring gear and pinion are reused, the pinion
depth shim/oil slinger should not require replace-
ment. Refer to Adjustment (Pinion Gear Depth) to
select the proper thickness shim/oil slinger if ring
and pinion gears are replaced.
(1) Appl y Mopar௡ Door Ease or equi val ent l ubri -
cant to outsi de surface of the pi ni on beari ng cups.
I nstal l rear beari ng cup wi th I nstal l er D-146 and
Dri ver Handl e C-4171 (Fi g. 70) and veri fy cup i s
seated.
(2) I nstal l front beari ng cup wi th I nstal l er D-130
and Handl e C-4171 (Fi g. 71) and veri fy cup i s seated.
Fig. 69 REAR PINION BEARING
1 - PULLER
2 - VISE
3 - ADAPTERS
4 - PINION GEAR SHAFT
Fig. 70 REAR PINION BEARING CUP
1 - INSTALLER
2 - HANDLE
Fig. 71 FRONT PINION BEARING CUP
1 - INSTALLER
2 - HANDLE
3 - 46 FRONT AXLE - 181FBI TJ
PINION GEAR/RING GEAR (Continued)
(3) I nstal l front pi ni on beari ng, and oi l sl i nger.
(4) Appl y a l i ght coati ng of gear l ubri cant on the
l i p of pi ni on seal and i nstal l seal wi th an appropri ate
i nstal l er (Fi g. 72).
(5) I nstal l rear pi ni on depth shi m/oi l sl i nger and
beari ng on the pi ni on shaft wi th I nstal l er W-262 and
a press (Fi g. 73).
(6) I nstal l new col l apsi bl e spacer on pi ni on shaft
and i nstal l pi ni on i nto the housi ng (Fi g. 74).
(7) I nstal l yoke wi th I nstal l er W-162-B, Cup 8109
and Spanner Wrench 6958 (Fi g. 75).
(8) I nstal l pi ni on washer and a new nut onto the
pi ni on. Ti ghten the nut to 216 N·m (160 ft. l bs.).
Fig. 72 PINION SEAL INSTALLER
1 - HANDLE
2 - INSTALLER
Fig. 73 REAR PINION BEARING
1 - PRESS
2 - INSTALLATER
3 - PINION DEPTH SHIM/OIL SLINGER
4 - DRIVE PINION
5 - REAR PINION BEARING
Fig. 74 COLLAPSIBLE PRELOAD SPACER
1 - COLLAPSIBLE SPACER
2 - SHOULDER
3 - PINION GEAR
4 - OIL SLINGER
5 - REAR BEARING
Fig. 75 PINION YOKE INSTALLER
1 - INSTALLER
2 - PINION YOKE
3 - SPANNER WRENCH
TJ FRONT AXLE - 181FBI 3 - 47
PINION GEAR/RING GEAR (Continued)
CAUTION: Never loosen the pinion nut to decrease
pinion bearing rotating torque and never exceed
specified preload torque. Failure to heed caution
may result in damage.
(9) Usi ng Spanner Wrench 6958 and torque
wrench set at 678 N·m (500 ft. l bs.) (Fi g. 76). Sl owl y
ti ghten the nut i n 6.8 N·m (5 ft. l b.) i ncrements unti l
the rotati ng torque i s achi eved. Measure rotati ng
torque frequentl y to avoi d over crushi ng the col l aps-
i bl e spacer (Fi g. 77).
CAUTION: If more than 678 N·m (500 ft. lbs.) torque
is required to crush the collapsible spacer, the
spacer is defective and must be replaced. Failure to
heed caution may result in damage.
(10) Check beari ng rotati ng torque wi th an i nch
pound torque wrench (Fi g. 77). The torque necessary
to rotate the pi ni on shoul d be:
• Ori gi nal Beari ngs: 1.13 to 2.26 N·m (10 to 20 i n.
l bs.).
• New Beari ngs: 1.7 to 3.4 N·m (15 to 30 i n. l bs.).
(11) I nvert the di fferenti al case and start two ri ng
gear bol ts. Thi s wi l l provi de case-to-ri ng gear bol t
hol e al i gnment.
(12) I nvert the di fferenti al case i n the vi se and
i nstal l new ri ng gear bol ts and al ternatel y ti ghten to
108 N·m (80 ft. l bs.) (Fi g. 78).
CAUTION: Never reuse ring gear bolts. Failure to
heed caution may result in damage.
(13) I nstal l di fferenti al and veri fy di fferenti al bear-
i ng prel oad, gear mesh and contact pattern.
Fig. 76 YOKE SPANNER WRENCH
1 - PINION YOKE
2 - SPANNER WRENCH
3 - PIPE
Fig. 77 PINION ROTATION TORQUE
1 - TORQUE WRENCH
2 - PINION YOKE
Fig. 78 RING GEAR BOLT
1 - TORQUE WRENCH
2 - RING GEAR BOLT
3 - RING GEAR
4 - CASE
3 - 48 FRONT AXLE - 181FBI TJ
PINION GEAR/RING GEAR (Continued)
FRONT AXLE - 216FBI
TABLE OF CONTENTS
page page
FRONT AXLE - 216FBI
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . 49
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 53
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . 55
SPECIFICATIONS
FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . 63
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . 63
AXLE SHAFTS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 67
AXLE SHAFT SEALS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 67
SINGLE CARDAN UNIVERSAL JOINT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 68
PINION SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 69
DIFFERENTIAL COVER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 70
DIFFERENTIAL - TRU-LOK
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 71
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . 71
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 75
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 76
DIFFERENTIAL - TRU-LOK PUMP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 78
PINION GEAR/RING GEAR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 81
FRONT AXLE - 216FBI
DIAGNOSIS AND TESTING
GEAR NOISE
Axl e gear noi se can be caused by i nsuffi ci ent l ubri -
cant, i ncorrect backl ash, tooth contact, worn/damaged
gears or the carri er housi ng not havi ng the proper
offset and squareness.
Gear noi se usual l y happens at a speci fi c speed
range. The noi se can al so occur duri ng a speci fi c type
of dri vi ng condi ti on. These condi ti ons are accel era-
ti on, decel erati on, coast, or constant l oad.
When road testi ng, fi rst warm-up the axl e fl ui d by
dri vi ng the vehi cl e at l east 5 mi l es and then accel er-
ate the vehi cl e to the speed range where the noi se i s
the greatest. Shi ft out-of-gear and coast through the
peak-noi se range. I f the noi se stops or changes
greatl y:
• Check for i nsuffi ci ent l ubri cant.
• I ncorrect ri ng gear backl ash.
• Gear damage.
Di fferenti al si de gears and pi ni ons can be checked
by turni ng the vehi cl e. They usual l y do not cause
noi se duri ng strai ght-ahead dri vi ng when the gears
are unl oaded. The si de gears are l oaded duri ng vehi -
cl e turns. A worn pi ni on mate shaft can al so cause a
snappi ng or a knocki ng noi se.
BEARING NOISE
The axl e shaft, di fferenti al and pi ni on beari ngs can
al l produce noi se when worn or damaged. Beari ng
noi se can be ei ther a whi ni ng, or a growl i ng sound.
Pi ni on beari ngs have a constant-pi tch noi se. Thi s
noi se changes onl y wi th vehi cl e speed. Pi ni on beari ng
noi se wi l l be hi gher pi tched because i t rotates at a
faster rate. Dri ve the vehi cl e and l oad the di fferen-
ti al . I f beari ng noi se occurs, the rear pi ni on beari ng
i s the source of the noi se. I f the beari ng noi se i s
heard duri ng a coast, the front pi ni on beari ng i s the
source.
Worn or damaged di fferenti al beari ngs usual l y pro-
duce a l ow pi tch noi se. Di fferenti al beari ng noi se i s
si mi l ar to pi ni on beari ng noi se. The pi tch of di fferen-
ti al beari ng noi se i s al so constant and vari es onl y
wi th vehi cl e speed.
Axl e shaft beari ngs produce noi se and vi brati on
when worn or damaged. The noi se general l y changes
when the beari ngs are l oaded. Road test the vehi cl e.
Turn the vehi cl e sharpl y to the l eft and to the ri ght.
Thi s wi l l l oad the beari ngs and change the noi se
l evel . Where axl e beari ng damage i s sl i ght, the noi se
i s usual l y not noti ceabl e at speeds above 30 mph.
TJ FRONT AXLE - 216FBI 3 - 49
LOW SPEED KNOCK
Low speed knock i s general l y caused by a worn
U-joi nt or by worn si de-gear thrust washers. A worn
pi ni on shaft bore wi l l al so cause l ow speed knock.
VIBRATION
Vi brati on at the rear of the vehi cl e i s usual l y
caused by:
• Damaged dri ve shaft.
• Mi ssi ng dri ve shaft bal ance wei ght(s).
• Worn or out of bal ance wheel s.
• Loose wheel l ug nuts.
• Worn U-joi nt(s).
• Loose/broken spri ngs.
• Damaged axl e shaft beari ng(s).
• Loose pi ni on gear nut.
• Excessi ve pi ni on yoke run out.
• Bent axl e shaft(s).
Check for l oose or damaged front end components
or engi ne/transmi ssi on mounts. These components
can contri bute to what appears to be a rear end
vi brati on. Do not overl ook engi ne accessori es, brack-
ets and dri ve bel ts.
Al l dri vel i ne components shoul d be exami ned
before starti ng any repai r.
DRIVELINE SNAP
A snap or cl unk noi se when the vehi cl e i s shi fted
i nto gear (or the cl utch engaged) can be caused by:
• Hi gh engi ne i dl e speed.
• Transmi ssi on shi ft operati on.
• Loose engi ne/transmi ssi on/transfer case mounts.
• Worn U-joi nts.
• Loose spri ng mounts.
• Loose pi ni on gear nut and yoke.
• Excessi ve ri ng gear backl ash.
• Excessi ve si de gear to case cl earance.
The source of a snap or a cl unk noi se can be deter-
mi ned wi th the assi stance of a hel per. Rai se the vehi -
cl e on a hoi st wi th the wheel s free to rotate. I nstruct
the hel per to shi ft the transmi ssi on i nto gear. Li sten
for the noi se, a mechani cs stethoscope i s hel pful i n
i sol ati ng the source of a noi se.
DIAGNOSTIC CHART
Condition Possible Causes Correction
Wheel Noise 1. Wheel loose. 1. Tighten loose nuts.
2. Faulty, brinelled wheel bearing. 2. Replace bearing.
Axle Shaft Noise 1. Misaligned axle tube. 1. Inspect axle tube alignment.
Correct as necessary.
2. Bent or sprung axle shaft. 2. Inspect and correct as necessary.
3. End-play in pinion bearings. 3. Refer to pinion pre-load
information and correct as
necessary.
4. Excessive gear backlash
between the ring gear and pinion.
4. Check adjustment of the ring
gear and pinion backlash. Correct
as necessary.
5. Improper adjustment of pinion
gear bearings.
5. Adjust the pinion bearings
pre-load.
6. Loose pinion yoke nut. 6. Tighten the pinion yoke nut.
7. Scuffed gear tooth contact
surfaces.
7. Inspect and replace as
necessary.
3 - 50 FRONT AXLE - 216FBI TJ
FRONT AXLE - 216FBI (Continued)
Condition Possible Causes Correction
Axle Shaft Broke 1. Misaligned axle tube. 1. Replace the broken shaft after
correcting tube mis-alignment.
2 Vehicle overloaded. 2. Replace broken shaft and avoid
excessive weight on vehicle.
3. Erratic clutch operation. 3. Replace broken shaft and avoid
or correct erratic clutch operation.
4. Grabbing clutch. 4. Replace broken shaft and inspect
and repair clutch as necessary.
Differential Cracked 1. Improper adjustment of the
differential bearings.
1. Replace case and inspect gears
and bearings for further damage.
Set differential bearing pre-load
properly.
2. Excessive ring gear backlash. 2. Replace case and inspect gears
and bearings for further damage.
Set ring gear backlash properly.
3. Vehicle overloaded. 3. Replace case and inspect gears
and bearings for further damage.
Avoid excessive vehicle weight.
4. Erratic clutch operation. 4. Replace case and inspect gears
and bearings for further damage.
Avoid erratic use of clutch.
Differential Gears Scored 1. Insufficient lubrication. 1. Replace scored gears. Fill
differential with the correct fluid type
and quantity.
2. Improper grade of lubricant. 2. Replace scored gears. Fill
differential with the correct fluid type
and quantity.
3. Excessive spinning of one
wheel/tire.
3. Replace scored gears. Inspect all
gears, pinion bores, and shaft for
damage. Service as necessary.
Loss Of Lubricant 1. Lubricant level too high. 1. Drain lubricant to the correct
level.
2. Worn axle shaft seals. 2. Replace seals.
3. Cracked differential housing. 3. Repair as necessary.
4. Worn pinion seal. 4. Replace seal.
5. Worn/scored yoke. 5. Replace yoke and seal.
6. Axle cover not properly sealed. 6. Remove, clean, and re-seal
cover.
Axle Overheating 1. Lubricant level low. 1. Fill differential to correct level.
2. Improper grade of lubricant. 2. Fill differential with the correct
fluid type and quantity.
3. Bearing pre-loads too high. 3. Re-adjust bearing pre-loads.
4. Insufficient ring gear backlash. 4. Re-adjust ring gear backlash.
TJ FRONT AXLE - 216FBI 3 - 51
FRONT AXLE - 216FBI (Continued)
Condition Possible Causes Correction
Gear Teeth Broke 1. Overloading. 1. Replace gears. Examine other
gears and bearings for possible
damage.
2. Erratic clutch operation. 2. Replace gears and examine the
remaining parts for damage. Avoid
erratic clutch operation.
3. Ice-spotted pavement. 3. Replace gears and examine
remaining parts for damage.
4. Improper adjustments. 4. Replace gears and examine
remaining parts for damage. Ensure
ring gear backlash is correct.
Axle Noise 1. Insufficient lubricant. 1. Fill differential with the correct
fluid type and quantity.
2. Improper ring gear and pinion
adjustment.
2. Check ring gear and pinion
contact pattern.
3. Unmatched ring gear and pinion. 3. Replace gears with a matched
ring gear and pinion.
4. Worn teeth on ring gear and/or
pinion.
4. Replace ring gear and pinion.
5. Loose pinion bearings. 5. Adjust pinion bearing pre-load.
6. Loose differential bearings. 6. Adjust differential bearing
pre-load.
7. Mis-aligned or sprung ring gear. 7. Measure ring gear run-out.
Replace components as necessary.
8. Loose differential bearing cap
bolts.
8. Inspect differential components
and replace as necessary. Ensure
that the bearing caps are torqued
tot he proper specification.
9. Housing not machined properly. 9. Replace housing.
3 - 52 FRONT AXLE - 216FBI TJ
FRONT AXLE - 216FBI (Continued)
REMOVAL
(1) Wi th vehi cl e i n neutral , posi ti on vehi cl e on
hoi st.
(2) Posi ti on a l i ft under the axl e and secure to the
axl e.
(3) Remove brake components.
(4) Remove vent hose from axl e shaft tube.
(5) Remove propel l er shaft.
(6) Remove stabi l i zer bar l i nks at the axl e (Fi g. 1).
(7) Remove shock absorbers from axl e brackets
(Fi g. 2).
(8) Remove track bar from axl e bracket (Fi g. 3).
(9) Remove ti e rod and drag l i nk from steeri ng
knuckl e.
(10) Remove steeri ng damper from axl e bracket.
(11) Remove upper and l ower suspensi on arms
from axl e brackets.
(12) Lower l i ft enough to remove the axl e. The coi l
spri ngs wi l l drop wi th the axl e.
(13) Remove coi l spri ngs from the axl e.
INSTALLATION
CAUTION: The weight of the vehicle must be sup-
ported by the springs before suspension arms and
track bar fasteners can be tightened. Failure to
heed caution may result in damage.
(1) I nstal l spri ngs and retai ners and ti ghten
retai ner bol ts to 21 N·m (16 ft. l bs.).
(2) Posi ti on axl e under vehi cl e and al i gn i t wi th
the spri ng pads.
Fig. 1 STABILIZER BAR
1 - RETAINER
2 - STABILIZER BAR
3 - LINK
4 - BUSHING
Fig. 2 COIL SPRING AND SHOCK ABSORBER
1 - RETAINER
2 - GROMMET
3 - SHOCK
4 - FRONT AXLE
Fig. 3 TRACK BAR
1 - TRACK BAR
2 - FRAME BRACKET
3 - FRONT AXLE
TJ FRONT AXLE - 216FBI 3 - 53
FRONT AXLE - 216FBI (Continued)
(3) I nstal l upper and l ower suspensi on arms i n the
axl e brackets and l oosel y i nstal l bol ts and nuts (Fi g.
4).
(4) Connect the vent hose to the axl e shaft tube.
(5) I nstal l track bar to the axl e bracket and l oosel y
i nstal l bol t (Fi g. 5).
(6) I nstal l shock absorbers and ti ghten the bol ts
(Fi g. 6) to torque speci fi cati on.
(7) I nstal l stabi l i zer bar l i nks to the axl e brackets
and ti ghten nuts (Fi g. 7) to torque speci fi cati on.
(8) I nstal l drag l i nk and ti e rod and ti ghten nut to
torque speci fi cati on
(9) I nstal l steeri ng damper to the axl e bracket and
ti ghten nut to torque speci fi cati on.
(10) I nstal l brake components.
(11) I nstal l propel l er shaft.
(12) Remove l i ft from the axl e and l ower vehi cl e.
(13) Ti ghten upper and l ower control arm nuts to
torque speci fi cati on.
(14) Ti ghten track bar bol t at the axl e bracket to
torque speci fi cati on.
(15) Check the front wheel al i gnment.
Fig. 4 UPPER AND LOWER SUSPENSION ARMS
1 - UPPER SUSPENSION ARM
2 - FRONT AXLE
3 - LOWER SUSPENSION ARM
Fig. 5 TRACK BAR
1 - TRACK BAR
2 - FRAME BRACKET
3 - FRONT AXLE
Fig. 6 COIL SPRING AND SHOCK ABSORBER
1 - RETAINER
2 - GROMMET
3 - SHOCK
4 - FRONT AXLE
Fig. 7 STABILIZER BAR
1 - RETAINER
2 - STABILIZER BAR
3 - LINK
4 - BUSHING
3 - 54 FRONT AXLE - 216FBI TJ
FRONT AXLE - 216FBI (Continued)
ADJUSTMENTS
Ri ng and pi ni on gears are suppl i ed as matched
sets onl y. The i denti fyi ng numbers for the ri ng and
pi ni on gear are etched i nto the face of each gear (Fi g.
8). A pl us (+) number, mi nus (–) number or zero (0) i s
etched i nto the face of the pi ni on gear. Thi s number
i s the amount (i n thousandths of an i nch) the depth
vari es from the standard depth setti ng of a pi ni on
etched wi th a (0). The standard depth provi des the
best gear tooth contact pattern. Refer to Backl ash
and Contact Pattern i n thi s secti on for addi ti onal
i nformati on.
Compensati on for pi ni on depth vari ance i s
achi eved wi th a sel ect shi m/oi l sl i nger. The shi ms are
pl aced between the rear pi ni on beari ng and the pi n-
i on gear head (Fi g. 9).
I f a new gear set i s bei ng i nstal l ed, note the depth
vari ance etched i nto both the ori gi nal and repl ace-
ment pi ni on. Add or subtract thi s number from the
thi ckness of the ori gi nal depth shi m/oi l sl i nger to
compensate for the di fference i n the depth vari ances.
Refer to the Depth Vari ance chart.
Note where Ol d and New Pi ni on Marki ng col umns
i ntersect. I ntersecti ng fi gure represents pl us or
mi nus the amount needed.
Note the etched number on the face of the pi ni on
gear head (–1, –2, 0, +1, +2, etc.). The numbers rep-
resent thousands of an i nch devi ati on from the stan-
dard. I f the number i s negati ve, add that val ue to the
requi red thi ckness of the depth shi ms. I f the number
i s posi ti ve, subtract that val ue from the thi ckness of
the depth shi m. I f the number i s 0 no change i s nec-
essary.
Fig. 8 PINION GEAR ID NUMBERS
1 - PRODUCTION NUMBERS
2 - PINION GEAR DEPTH VARIANCE
3 - GEAR MATCHING NUMBER
Fig. 9 PINION PRELOAD SHIMS
1 - PRELOAD SHIMS
2 - FRONT BEARING CUP
3 - SLINGER
4 - PINION YOKE
5 - WASHER
6 - PINION NUT
7 - PINION OIL SEAL
8 - FRONT PINION BEARING
TJ FRONT AXLE - 216FBI 3 - 55
FRONT AXLE - 216FBI (Continued)
PINION GEAR DEPTH VARIANCE
Original Pinion
Gear Depth
Variance
Replacement Pinion Gear Depth Variance
Ϫ4 Ϫ3 Ϫ2 Ϫ1 0 +1 +2 +3 +4
+4 +0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0
+3 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 Ϫ0.001
+2 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 Ϫ0.001 Ϫ0.002
+1 +0.005 +0.004 +0.003 +0.002 +0.001 0 Ϫ0.001 Ϫ0.002 Ϫ0.003
0 +0.004 +0.003 +0.002 +0.001 0 Ϫ0.001 Ϫ0.002 Ϫ0.003 Ϫ0.004
Ϫ1 +0.003 +0.002 +0.001 0 Ϫ0.001 Ϫ0.002 Ϫ0.003 Ϫ0.004 Ϫ0.005
Ϫ2 +0.002 +0.001 0 Ϫ0.001 Ϫ0.002 Ϫ0.003 Ϫ0.004 Ϫ0.005 Ϫ0.006
Ϫ3 +0.001 0 Ϫ0.001 Ϫ0.002 Ϫ0.003 Ϫ0.004 Ϫ0.005 Ϫ0.006 Ϫ0.007
Ϫ4 0 Ϫ0.001 Ϫ0.002 Ϫ0.003 Ϫ0.004 Ϫ0.005 Ϫ0.006 Ϫ0.007 Ϫ0.008
PINION DEPTH MEASUREMENT AND ADJUSTMENT
Measurements are taken wi th pi ni on beari ng cups
and pi ni on beari ngs i nstal l ed i n the housi ng. Take
measurements wi th Pi ni on Gauge Set and Di al I ndi -
cator C-3339 (Fi g. 10).
(1) Assembl e Pi ni on Hei ght Bl ock 6739, Pi ni on
Bl ock 6734 and rear pi ni on beari ng onto Screw 6741
(Fi g. 10).
(2) I nsert assembl ed hei ght gauge components,
rear beari ng and screw i nto the housi ng through pi n-
i on beari ng cups (Fi g. 11).
(3) I nstal l front pi ni on beari ng and Cone-nut 6740
hand ti ght.
Fig. 10 PINION GEAR DEPTH GAUGE TOOLS
1 - DIAL INDICATOR
2 - ARBOR
3 - PINION HEIGHT BLOCK
4 - CONE
5 - SCREW
6 - PINION BLOCK
7 - SCOOTER BLOCK
8 - ARBOR DISC
Fig. 11 PINION HEIGHT BLOCK
1 - PINION BLOCK
2 - PINION HEIGHT BLOCK
3 - 56 FRONT AXLE - 216FBI TJ
FRONT AXLE - 216FBI (Continued)
(4) Pl ace Arbor Di sc 6732 on Arbor D-115-3 i n posi -
ti on i n the housi ng si de beari ng cradl es (Fi g. 12).
NOTE: Arbor Discs 6732 has different step diame-
ters to fit other axles. Choose proper step for axle
being serviced.
(5) I nstal l di fferenti al beari ng caps on arbor di scs
and i nstal l beari ng cap bol ts. Ti ghten beari ng cap
bol ts to 108 N·m (80 ft. l bs.).
(6) Assembl e Di al I ndi cator C-3339 i nto Scooter
Bl ock D-115-2 and secure set screw.
(7) Posi ti on Scooter Bl ock/Di al I ndi cator fl ush on
the pi ni on hei ght bl ock. Hol d scooter bl ock and zero
the di al i ndi cator.
(8) Sl owl y sl i de the scooter bl ock across the pi ni on
hei ght bl ock over to the arbor (Fi g. 13). Move the
scooter bl ock ti l l di al i ndi cator crests the arbor, then
record the hi ghest readi ng.
(9) Sel ect a shi m/oi l sl i nger equal to the di al i ndi -
cator readi ng pl us the pi ni on depth vari ance number
etched i n the face of the pi ni on (Fi g. 8). For exampl e,
i f the depth vari ance i s –2, add +0.002 i n. to the di al
i ndi cator readi ng.
PRELOAD SHIM SELECTION
Di fferenti al si de beari ng prel oad and gear backl ash i s
achi eved by sel ecti ve shi ms posi ti oned between the di f-
ferenti al si de beari ng cups and the housi ng. The proper
shi m thi ckness i s determi ned usi ng sl i p-fi t Dummy
Beari ngs D-345 i n pl ace of the di fferenti al si de beari ngs
and a Di al I ndi cator C-3339. Before proceedi ng wi th the
di fferenti al beari ng prel oad and gear backl ash measure-
ments, measure the pi ni on gear depth and prepare the
pi ni on for i nstal l ati on. Establ i shi ng proper pi ni on gear
depth i s essenti al to establ i shi ng gear backl ash and
tooth contact patterns. After the overal l shi m thi ckness
to take up di fferenti al si de pl ay i s measured, the pi ni on
i s i nstal l ed, and the gear backl ash shi m thi ckness i s
measured. The overal l shi m thi ckness i s the total of the
di al i ndi cator readi ng and the prel oad speci fi cati on
added together. The gear backl ash measurement deter-
mi nes the thi ckness of the shi m used on the ri ng gear
si de of the di fferenti al case. Subtract the gear backl ash
shi m thi ckness from the total overal l shi m thi ckness
and sel ect that amount for the pi ni on gear si de of the
di fferenti al (Fi g. 14). Di fferenti al shi m measurements
are performed wi th spreader W-129-B removed.
Fig. 12 GAUGE TOOLS IN HOUSING
1 - ARBOR DISC
2 - PINION BLOCK
3 - ARBOR
4 - PINION HEIGHT BLOCK
Fig. 13 PINION DEPTH MEASUREMENT
1 - ARBOR
2 - SCOOTER BLOCK
3 - DIAL INDICATOR
Fig. 14 SHIM LOCATION
1. PINION DEPTH SHIM
2. DIFFERENTIAL SHIM PINION GEAR SIDE
3. RING GEAR
4. DIFFERENTIAL SHIM RING GEAR SIDE
TJ FRONT AXLE - 216FBI 3 - 57
FRONT AXLE - 216FBI (Continued)
NOTE: It is difficult to salvage the differential side
bearings during the removal procedure. Install
replacement bearings if necessary.
(1) Remove di fferenti al si de beari ngs from di ffer-
enti al case.
(2) Remove factory i nstal l ed shi ms from di fferen-
ti al case.
(3) I nstal l ri ng gear on di fferenti al case and
ti ghten bol ts to speci fi cati on.
(4) I nstal l dummy si de beari ngs D-345 on di fferen-
ti al case.
(5) I nstal l di fferenti al case i n the housi ng.
(6) I nstal l the marked beari ng caps i n thei r correct
posi ti ons and snug the bol ts (Fi g. 15).
(7) Wi th a dead-bl ow hammer, seat the di fferenti al
dummy beari ngs to each si de of the housi ng (Fi g. 16)
and (Fi g. 17).
(8) Thread Pi l ot Stud C-3288-B i nto rear cover bol t
hol e bel ow ri ng gear (Fi g. 18).
Fig. 15 BEARING CAP BOLTS
1 - BEARING CAP
2 - DIFFERENTIAL HOUSING
3 - DIFFERENTIAL CASE
Fig. 16 SEAT DUMMY BEARING PINION SIDE
1 - DEAD-BLOW HAMMER
2 - DIFFERENTIAL HOUSING
3 - DIFFERENTIAL CASE
Fig. 17 SEAT DUMMY BEARING RING GEAR SIDE
1 - DIFFERENTIAL HOUSING
2 - DEAD-BLOW HAMMER
3 - DIFFERENTIAL CASE
3 - 58 FRONT AXLE - 216FBI TJ
FRONT AXLE - 216FBI (Continued)
(9) Attach the Di al I ndi cator C-3339 to pi l ot stud.
Posi ti on the di al i ndi cator pl unger on a fl at surface
between the ri ng gear bol t heads (Fi g. 18).
(10) Push and hol d di fferenti al case to pi ni on gear
si de of the housi ng and zero di al i ndi cator (Fi g. 19).
(11) Push and hol d di fferenti al case to ri ng gear
si de of the housi ng and record di al i ndi cator readi ng
(Fi g. 20).
(12) Add 0.25 mm (0.010 i n.) to the zero end pl ay
total . Thi s total represents the thi ckness of shi ms
needed to prel oad the new beari ngs when the di ffer-
enti al i s i nstal l ed.
(13) Rotate di al i ndi cator out of the way on the
pi l ot stud.
(14) Remove di fferenti al case and dummy beari ngs
from the housi ng.
(15) I nstal l the pi ni on gear i n the housi ng. I nstal l
the pi ni on yoke and establ i sh the correct pi ni on
rotati ng torque.
(16) I nstal l di fferenti al case and dummy beari ngs
D-345 i n the housi ng (wi thout shi ms), i nstal l beari ng
caps and ti ghten bol ts snug.
(17) Seat ri ng gear si de dummy beari ng (Fi g. 17).
(18) Posi ti on the di al i ndi cator pl unger on a fl at
surface between the ri ng gear bol t heads (Fi g. 18).
Fig. 18 DIFFERENTIAL SIDE PLAY MEASUREMENT
1 - DIFFERENTIAL CASE
2 - DIFFERENTIAL HOUSING
3 - PILOT STUD
4 - DIAL INDICATOR
Fig. 19 DIAL INDICATOR LOCATION
1 - DIFFERENTIAL CASE TO PINION GEAR SIDE
2 - PILOT STUD
3 - DIAL INDICATOR ARM
4 - DIAL INDICATOR FACE
Fig. 20 RECORD DIAL INDICATOR READING
1 - DIAL INDICATOR
2 - DIFFERENTIAL CASE TO RING GEAR SIDE
3 - DIFFERENTIAL HOUSING
TJ FRONT AXLE - 216FBI 3 - 59
FRONT AXLE - 216FBI (Continued)
(19) Push and hol d di fferenti al case toward pi ni on
gear and zero di al i ndi cator (Fi g. 21).
(20) Push and hol d di fferenti al case to ri ng gear
si de of the housi ng and record di al i ndi cator readi ng
(Fi g. 22). Subtract 0.05 mm (0.002 i n.) from thi s
readi ng. Thi s i s the shi m thi ckness for the ri ng gear
si de.
NOTE: This is the shim needed on the ring gear
side for proper backlash.
(21) Subtract the backl ash shi m thi ckness from
the total prel oad shi m thi ckness. The remai nder i s
the shi m thi ckness requi red on the pi ni on si de of the
housi ng.
(22) Rotate di al i ndi cator out of the way on pi l ot
stud.
(23) Remove di fferenti al case and dummy beari ngs
from the housi ng.
(24) I nstal l the sel ected shi ms onto the di fferenti al
case hubs.
(25) I nstal l si de beari ngs on di fferenti al case hubs
wi th I nstal l C-3716-A and Handl e C-4171.
(26) I nstal l beari ng cups on di fferenti al .
(27) I nstal l Spreader W-129-B and some i tems
from Adapter Set 6987 on the housi ng and spread
open enough to recei ve di fferenti al case.
CAUTION: Do not spread housing over 0.38 mm
(0.015 in.). Failure to heed caution may result in
damage.
(28) I nstal l di fferenti al case i nto the housi ng.
(29) Remove spreader from the housi ng.
(30) Rotate the di fferenti al case several ti mes to
seat the si de beari ngs.
(31) Posi ti on the i ndi cator pl unger agai nst a ri ng
gear tooth (Fi g. 23).
(32) Push and hol d ri ng gear upward whi l e not
al l owi ng the pi ni on gear to rotate.
(33) Zero di al i ndi cator face to poi nter.
(34) Push and hol d ri ng gear downward whi l e not
al l owi ng the pi ni on gear to rotate. Di al i ndi cator
readi ng shoul d be between 0.12 mm - 0.20 mm (0.005
i n. - 0.008 i n.). I f backl ash i s not wi thi n speci fi cati ons
transfer the necessary amount of shi m thi ckness
from one si de of the housi ng to the other (Fi g. 24).
Fig. 21 ZERO DIAL INDICATOR
1 - DIAL INDICATOR FACE
2 - DIFFERENTIAL CASE TO PINION GEAR SIDE
3 - PINION GEAR
4 - DIFFERENTIAL HOUSING
5 - DIFFERENTIAL CASE
Fig. 22 RECORD DIAL INDICATOR READING
1 - DIAL INDICATOR
2 - DIFFERENTIAL CASE TO RING GEAR SIDE
3 - PINION GEAR
4 - DIFFERENTIAL HOUSING
5 - DIFFERENTIAL CASE
Fig. 23 RING GEAR BACKLASH MEASUREMENT
1 - DIAL INDICATOR
3 - 60 FRONT AXLE - 216FBI TJ
FRONT AXLE - 216FBI (Continued)
(35) Veri fy di fferenti al case and ri ng gear runout
by measuri ng ri ng to pi ni on gear backl ash at ei ght
l ocati ons around the ri ng gear. Readi ngs shoul d not
vary more than 0.05 mm (0.002 i n.). I f readi ngs vary
more than speci fi ed, the ri ng gear or the di fferenti al
case i s defecti ve.
After the proper backl ash i s achi eved, perform
Gear Contact Pattern Anal ysi s procedure.
GEAR CONTACT PATTERN
The ri ng gear and pi ni on teeth contact patterns
wi l l show i f the pi ni on depth i s correct i n the hous-
i ng. I t wi l l al so show i f the ri ng gear backl ash has
been adjusted correctl y. The backl ash can be adjusted
wi thi n speci fi cati ons to achi eve desi red tooth contact
patterns.
The TOP LAND of the gear tooth i s the top surface
of the tooth. The PROFI LE of the gear tooth i s the
depth of the tooth. The TOE of the gear i s the por-
ti on of the tooth surface at the end towards the cen-
ter. The HEEL of the gear i s the porti on of the tooth
at the outer-end. The ROOT of the gear tooth i s the
l owest porti on of the tooth (Fi g. 25).
NOTE: If the PROFILE across the tooth is the same
it is a 3 Axis cut gear. If the PROFILE across the
tooth is tapered it is a 2 Axis cut gear.
(1) Appl y a thi n coat of hydrated ferri c oxi de or
equi val ent to the dri ve and coast si de of the ri ng gear
teeth.
(2) Wrap, twi st and hol d a shop towel around the
pi ni on yoke to i ncrease the turni ng resi stance of the
pi ni on. Thi s wi l l provi de a more di sti nct contact pat-
tern.
(3) Wi th a boxed end wrench on the ri ng gear bol t,
rotate the di fferenti al case one compl ete revol uti on i n
both di recti ons whi l e a l oad i s bei ng appl i ed from
shop towel .
The areas on the ri ng gear teeth wi th the greatest
degree of contact agai nst the pi ni on teeth wi l l squee-
gee the compound to the areas wi th the l east amount
of contact. Note and compare patterns on the ri ng
gear teeth to Gear Tooth Contact Patterns chart (Fi g.
26) and (Fi g. 27) and adjust pi ni on depth and gear
backl ash as necessary.
DIFFERENTIAL BEARING PRELOAD CHECK
The fi nal check on the di fferenti al assembl y before
i nstal l i ng the axl es i s torque to rotate pi ni on and di f-
ferenti al combi ned. Thi s wi l l veri fy the correct di ffer-
enti al beari ng prel oad.
Torque to rotate the di fferenti al and pi ni on shoul d
be the torque to rotate the pi ni on pl us 0.79-1.24 N·m
(7-11 i n. l bs.).
Fig. 24 BACKLASH SHIM
Fig. 25 GEAR DESCRIPTION
1 - TOP LAND
2 - PROFILE
3 - TOE
4 - HEEL
5 - ROOT
TJ FRONT AXLE - 216FBI 3 - 61
FRONT AXLE - 216FBI (Continued)
Fig. 26 PATTERN INTERPRETATION (GEAR CUT 2 AXIS)
Fig. 27 PATTERN INTERPRETATION (GEAR CUT 3 AXIS)
3 - 62 FRONT AXLE - 216FBI TJ
FRONT AXLE - 216FBI (Continued)
SPECIFICATIONS
FRONT AXLE
AXLE SPECIFICATIONS
DESCRIPTION SPECIFICATION
Axle Ratio 4.10
Ring Gear Backlash 0.12-0.20 mm (0.005-0.008 in.)
Pinion Bearing Preload - Original Bearing 1-2 N·m (10-20 in. lbs.)
Pinion Bearing Preload - New Bearing 2.3-4.5 N·m (20-40 in. lbs.)
TORQUE SPECIFICATIONS
DESCRIPTION N·m Ft. Lbs. In. Lbs.
Fill Plug 34 25 -
Drain Plug 34 25 -
Differential Cover Bolts 41 30 -
Bearing Cap Bolts 108 80 -
Pinion Nut 217-271 160-200 -
Ring Gear Bolts 136 100 -
Axle Nut 237 175 -
SPECIAL TOOLS
PULLER- C-293-PA
PLUG C-293-3
ADAPTERS C-293-39
TJ FRONT AXLE - 216FBI 3 - 63
FRONT AXLE - 216FBI (Continued)
FLANGE WRENCH C-3281
PILOT STUDS C-3288-B
DIAL INDICATOR C-3339
HANDLE C-4171
REMOVER C-452
INSTALLER D-144
INSTALLER D-146
REMOVER D-147
REMOVER D-148
INSTALLER D-156
3 - 64 FRONT AXLE - 216FBI TJ
FRONT AXLE - 216FBI (Continued)
DUMMY BEARINGS D-345
SPREADER W-129-B
INSTALLER W-162-D
INSTALLER W-262
PULLER 6444
JAWS 6447
HOLDER YOKE 6719A
PINION DEPTH SET 6730
TURNBUCKLE 6797
INSTALLER DISCS 8110
TJ FRONT AXLE - 216FBI 3 - 65
FRONT AXLE - 216FBI (Continued)
AXLE SHAFTS
REMOVAL
(1) Wi th vehi cl e i n neutral , posi ti on vehi cl e on hoi st.
(2) Remove brake components.
(3) Remove cotter pi n, nut retai ner and axl e hub nut.
(4) Remove hub beari ng bol ts (Fi g. 28).
(5) Remove hub beari ng from steeri ng knuckl e.
(6) Remove axl e shaft assembl y (Fi g. 29) from axl e
(7) Remove brake rotor shi el d from the hub bear-
i ng or knuckl e.
Fig. 30 HUB BEARING AND KNUCKLE
1 - BRAKE SHIELD
2 - WASHER
3 - RETAINER
4 - COTTER PIN
5 - NUT
6 - HUB AND BEARING ASSEMBLY
7 - STEERING KNUCKLE
8 - BOLT
9 - TONE WHEEL (ABS)
Fig. 28 HUB BEARING BOLTS
1 - AXLE SHAFT
2 - AXLE
3 - KNUCKLE
4 - HUB BEARING
Fig. 29 HUB BEARING AND AXLE
1 - AXLE
2 - KNUCKLE
3 - HUB BEARING
4 - AXLE SHAFT
3 - 66 FRONT AXLE - 216FBI TJ
INSTALLATION
(1) Cl ean axl e shaft and appl y a thi n fi l m of
Mopar Wheel Beari ng Grease or equi val ent to the
shaft spl i nes, seal contact surface and hub bore.
(2) I nstal l brake rotor shi el d on knuckl e.
(3) I nstal l axl e shaft i nto di fferenti al si de gears.
(4) I nstal l hub beari ng and ti ghten bol ts to 102
N·m (75 ft. l bs.).
(5) I nstal l axl e washer and nut. Ti ghten nut to 237
N·m (175 ft. l bs.) and i nstal l nut retai ner and cotter
pi n (Fi g. 30).
(6) I nstal l brake components.
AXLE SHAFT SEALS
REMOVAL
(1) Wi th vehi cl e i n neutral , posi ti on vehi cl e on
hoi st.
(2) Remove axl e shafts (Fi g. 31).
(3) Remove di fferenti al assembl y (Fi g. 32).
(4) Remove i nner axl e shaft seal s wi th a pry bar.
INSTALLATION
(1) Remove any seal er remai ni ng from ori gi nal
seal s.
(2) I nstal l oi l seal s wi th Di scs 8110 and Turn-
buckl e 6797 (Fi g. 33). Ti ghten tool unti l di sc bottoms
i n housi ng.
(3) I nstal l di fferenti al and axl e shafts.
Fig. 31 HUB BEARING AND AXLE ASSEMBLY
1 - AXLE
2 - KNUCKLE
3 - HUB BEARING
4 - AXLE SHAFT
Fig. 32 DIFFERENTIAL CASE
1 - AXLE HOUSING
2 - DIFFERENTIAL CASE
3 - BEARING CUPS
Fig. 33 AXLE SEAL INSTALLER
1 - TURNBUCKLE
2 - DISCS
TJ FRONT AXLE - 216FBI 3 - 67
AXLE SHAFTS (Continued)
SINGLE CARDAN UNIVERSAL
J OINT
REMOVAL
CAUTION: Clamp only the narrow forged portion of
the yoke in the vise. Failure to heed caution may
result in damage.
(1) Remove axl e shaft.
(2) Remove beari ng cap retai ni ng snap ri ngs (Fi g.
34).
NOTE: Saturate the bearing caps with penetrating
oil prior to removal.
(3) Pl ace a socket (recei ver) wi th an i nsi de di ame-
ter l arger than the beari ng cap agai nst the yoke and
the peri meter of the beari ng cap to be removed.
(4) Pl ace a socket (dri ver) wi th an outsi de di ame-
ter smal l er than the beari ng cap agai nst the opposi te
beari ng cap.
(5) Posi ti on yoke wi th the sockets i n a vi se (Fi g.
35).
(6) Ti ghten vi se jaws, to force beari ng cap i nto the
socket (recei ver).
(7) Rel ease vi se jaws. Remove sockets and beari ng
cap forced out of the yoke.
(8) Repeat above procedure for the remai ni ng bear-
i ng cap and remove cross from propel l er shaft yoke.
INSTALLATION
CAUTION: Keep cross and bearing cap straight dur-
ing installation. Failure to heed caution may result
in damage.
(1) Pack beari ng caps 1/3 ful l of wheel beari ng
l ubri cant (Fi g. 36). Appl y extreme pressure (EP), l i th-
i um-base l ubri cant to ai d i n i nstal l ati on.
(2) Posi ti on cross i n the yoke. I nsert seal s and
beari ngs, then tap beari ng caps i nto the yoke bores
far enough to hol d spi der i n posi ti on.
(3) Pl ace socket (dri ver) agai nst one beari ng cap.
Posi ti on yoke wi th the socket i n a vi se.
(4) Ti ghten vi se to force beari ng caps i nto the
yoke. Force the caps enough to i nstal l retai ni ng cl i ps.
(5) I nstal l beari ng cap retai ni ng cl i ps.
(6) I nstal l axl e shaft.
Fig. 34 AXLE SHAFT OUTER U-JOINT
1 - SHAFT YOKE
2 - BEARING CAP
3 - SNAP RINGS
4 - BEARING CAP
5 - SPINDLE YOKE
6 - BEARING
7 - BEARING CAP
8 - SNAP RINGS
9 - BEARING CAP
Fig. 35 YOKE BEARING CAP
1 - LARGE-DIAMETER SOCKET
2 - VISE
3 - SMALL-DIAMETER SOCKET
3 - 68 FRONT AXLE - 216FBI TJ
PINION SEAL
REMOVAL
(1) Mark the propel l er shaft and pi ni on yoke for
i nstal l ati on reference.
(2) Remove propel l er shaft from the yoke.
(3) Rotate pi ni on gear three or four ti mes and ver-
i fy i t rotates smoothl y.
(4) Remove pi ni on yoke nut and washer wi th
Remover C-452 and Fl ange Wrench C-3281 (Fi g. 37).
(5) Remove pi ni on shaft seal wi th a pry tool or
sl i de hammer mounted screw.
INSTALLATION
(1) Appl y a l i ght coati ng of gear l ubri cant on the
l i p of pi ni on seal . I nstal l seal wi th an appropri ate
i nstal l er (Fi g. 38).
(2) I nstal l yoke on the pi ni on gear wi th I nstal l er
W-162-D and Spanner Wrench 6958 (Fi g. 39).
(3) I nstal l a new nut on the pi ni on gear and
ti ghten the nut to 217-271 N·m (160-200 i n. l bs.)
(Fi g. 40).
(4) I nstal l ati on propel l er shaft wi th reference
marks al i gned.
(5) Check and add gear l ubri cant to axl e i f neces-
sary.
Fig. 36 AXLE SHAFT OUTER U-JOINT
1 - SHAFT YOKE
2 - BEARING CAP
3 - SNAP RINGS
4 - BEARING CAP
5 - SPINDLE YOKE
6 - BEARING
7 - BEARING CAP
8 - SNAP RINGS
9 - BEARING CAP
Fig. 37 PINION YOKE REMOVER
1 - WRENCH
2 - YOKE
3 - PULLER
Fig. 38 PINION SEAL INSTALLER
1 - HANDLE
2 - INSTALLER
TJ FRONT AXLE - 216FBI 3 - 69
SINGLE CARDAN UNIVERSAL J OINT (Continued)
DIFFERENTIAL COVER
REMOVAL
(1) Wi th vehi cl e i n neutral , posi ti on vehi cl e on
hoi st.
(2) Remove drai n pl ug.
(3) Di sconnect i ndi cator swi tch harness and
remove connector from di fferenti al cover (Fi g. 41).
(4) Remove cover bol ts.
(5) Remove cover and drai n l ubri cant.
INSTALLATION
(1) Appl y a 6.35mm (1/4 i n.) bead of Mopar Si l i -
cone Rubber Seal ant or equi val ent to the housi ng
cover (Fi g. 42).
CAUTION: If housing cover is not installed within 3
to 5 minutes, the cover must be cleaned and new
RTV applied. Failure to heed caution may result in
damage.
(2) I nstal l cover, i denti fi cati on tag and i ndi cator
swi tch connector (Fi g. 43). Ti ghten cover bol ts i n a
cri ss-cross pattern to 41 N·m (30 ft. l bs.).
(3) Connect i ndi cator swi tch harness.
(4) Fi l l di fferenti al to speci fi cati ons.
(5) I nstal l fi l l pl ug and ti ghten to 34 N·m (25 ft.
l bs.).
Fig. 39 PINION YOKE INSTALLER
1 - INSTALLER
2 - PINION YOKE
3 - SPANNER WRENCH
Fig. 40 PINION SHAFT NUT
1 - PINION FLANGE
2 - HOLDING TOOL
3 - DIFFERENTIAL HOUSING
Fig. 41 INDICATOR SWITCH CONNECTOR
1 - CONNECTOR
2 - DIFFERENTIAL COVER
3 - 70 FRONT AXLE - 216FBI TJ
PINION SEAL (Continued)
DIFFERENTIAL - TRU-LOK
DESCRIPTION
The di fferenti al i s a l ocki ng di fferenti al , that pro-
vi des a posi ti ve mechani cal connecti on between the
ri ght and l eft axl e when engauged. The di fferenti al
uses a dog cl utch to connecti on the ri ght and l eft
axl e.
OPERATION
The Tru-l ok di fferenti al i s acti vated by the axl e
l ock swi tch l ocated on the dash panel . When the
swi tch i s acti vated, an ai r pump wi th a bui l t-i n pres-
sure regul ator sends 5 PSI of ai r pressure to a accua-
tor di aphragm i n the di fferenti al housi ng. The
di aphragm then engages a dog cl utch and a posi ti on
swi tch. The dog cl utch has one gear attached to the
di fferenti al case and another gear attached to a di f-
ferenti al si de gear. When the dog cl utch i s engaged
the ri ght and l eft wheel s turn at the same speed. The
posi ti on swi tch l i ghts a l amp on the dash to i ndi cate
the system has been engaged. The di fferenti al works
as standard di fferenti al when not engaged.
NOTE: The differential is serviced as an assembly,
the diaphragm and indicator switch are serviced
separately. The differential case must be removed
to service the diaphragm actuator and indicator
switch.
DIAGNOSIS AND TESTING
UNLOCKED
(1) Bl ock ti res opposi te the axl e to be tested to pre-
vent the vehi cl e from rol l i ng.
(2) Pl ace transfer case i n 4WD Low and automan-
ti c transmi ssi on i n Park (1st gear i f manual trans-
mi ssi on).
(3) Rai se both wheel s of the axl e to be tested off
the ground.
(4) Turn i gni ti on to the ON posi ti on and dash
swi tch to the OFF posi ti on.
(5) Rotate one ti re by hand. The other ti re shoul d
spi n i n the opposi te di recti on.
NOTE: If wheel cannot be rotated the differential
must be repaired/replaced.
Fig. 42 HOUSING COVER - TYPICAL
1 - SEALANT SURFACE
2 - SEALANT
3 - SEALANT THICKESS
Fig. 43 INDICATOR SWITCH CONNECTOR
1 - CONNECTOR
2 - DIFFERENTIAL COVER
TJ FRONT AXLE - 216FBI 3 - 71
DIFFERENTIAL COVER (Continued)
LOCKED
(1) Bl ock ti res opposi te the axl e to be tested to pre-
vent the vehi cl e from rol l i ng.
(2) Pl ace transfer case i n 4WD Low and automan-
ti c transmi ssi on i n Park (1st gear i f manual trans-
mi ssi on).
(3) Rai se both wheel s of the axl e to be tested off
the ground.
(4) Turn i gni ti on to the ON posi ti on and dash
swi tch to the ON posi ti on.
(5) Try to rotate one ti re by hand. You shoul d not
be abl e to rotate the ti re.
NOTE: If wheel does rotate verify locker pump oper-
ation. If the pump is operating properly the differen-
tial must be repaired/replaced.
TRU-LOK INDICATOR SWITCH
(1) Turn i gni ti on swi tch off.
(2) Di sconnect i ndi cator swi tch harness (Fi g. 44)
from the di fferenti al housi ng.
(3) Measure el ectri cal conti nui ty across the swi tch
termi nal s. Ci rcui t shoul d be cl osed (zero resi stance).
NOTE: If circuit is not closed remove differential
and replace locker indicator switch.
TRU-LOK PUMPS
(1) Connect a pressure gauge to the front pump.
(2) Pl ace transfer case i n 4WD Low and automati c
transmi ssi on i n Park (1st gear i f manual transmi s-
si on).
(3) Turn i gni ti on to the ON posi ti on and push the
dash swi tch twi ce to acti vate the front pump.
NOTE: If pump is not running, verify pump has (Fig.
45) 12 volts and a ground.
(4) Wi th the pump runni ng the pressure gauge
shoul d show 5 psi ..
NOTE: If pump does not produce 5 psi. replace the
pump.
REMOVAL
(1) Remove drai n pl ug from the di fferenti al hous-
i ng.
(2) Di sconnect i ndi cator swi tch harness and
remove connector from di fferenti al cover (Fi g. 46).
(3) Remove di fferenti al housi ng cover.
Fig. 44 INDICATOR SWITCH CONNECTOR
1 - CONNECTOR
2 - DIFFERENTIAL COVER
Fig. 45 PUMP CONNECTORS
1 - REAR PUMP CONNECTOR
2 - FRONT PUMP CONNECTOR
3 - AXLE HARNESS
Fig. 46 INDICATOR SWITCH CONNECTOR
1 - CONNECTOR
2 - DIFFERENTIAL COVER
3 - 72 FRONT AXLE - 216FBI TJ
DIFFERENTIAL - TRU-LOK (Continued)
(4) Remove axl e shafts.
(5) Remove pressure hose from actuator assembl y
(Fi g. 47).
(6) Note the reference l etters stamped on the bear-
i ng caps and housi ng machi ned seal i ng surface (Fi g.
48).
(7) Loosen di fferenti al beari ng cap bol ts.
(8) Posi ti on Spreader W-129-B wi th Adapter Ki t
6987B on di fferenti al l ocati ng hol es (Fi g. 49). I nstal l
hol d-down cl amps and ti ghten the turnbuckl e fi nger-
ti ght.
(9) I nstal l a Pi l ot Stud C-3288-B at the l eft si de of
the di fferenti al housi ng. Attach Di al I ndi cator C-3339
to pi l ot stud (Fi g. 50). Load i ndi cator pl unger agai nst
the opposi te si de of the housi ng and zero the i ndi ca-
tor.
CAUTION: Never spread the housing over 0.38 mm
(0.015 in). Failure to heed caution may result in
damage.
Fig. 47 PRESSURE HOSE
1 - PRESSURE HOSE
2 - BEARING CAP
3 - PRESSURE HOSE CLAMP
Fig. 48 BEARING CAP REFERENCE MARKS
1 - REFERENCE MARKS
2 - REFERENCE MARKS
Fig. 49 SPREADER LOCATION
1 - DIFFERENTIAL CASE
2 - ADAPTER
3 - HOLD DOWN
4 - SPREADER
5 - TURNBUCKLE
Fig. 50 DIAL INDICATOR LOCATION
1 - DIAL INDICATOR
2 - PILOT STUD
TJ FRONT AXLE - 216FBI 3 - 73
DIFFERENTIAL - TRU-LOK (Continued)
(10) Spread housi ng whi l e measuri ng the di stance
wi th the di al i ndi cator (Fi g. 51).
(11) Remove di al i ndi cator.
(12) Remove di fferenti al beari ng cap bol ts and ri ng
gear si de beari ng cap.
(13) Remove di fferenti al from housi ng wi th pi ni on
gear si de beari ng cap (Fi g. 52) and tag di fferenti al
beari ng cups and prel oad shi ms to i ndi cate l ocati on.
CAUTION: Do not bend actuator mounting tabs,
during differential removal. Failure to heed caution
may result in damage.
(14) Remove spreader from housi ng.
(15) Remove i ndi cator swi tch (Fi g. 53) from di ffer-
enti al housi ng.
(16) Cl ean the housi ng cavi ty wi th fl ushi ng oi l ,
l i ght engi ne oi l or l i nt free cl oth.
NOTE: Do not use water, steam, kerosene or gaso-
line for cleaning.
Fig. 51 SPREAD DIFFERENTIAL CASE
1 - DIAL INDICATOR
2 - SPREADER
Fig. 52 DIFFERENTIAL
1 - DIFFERENTIAL
2 - BEARING CAP
Fig. 53 LOCKER INDICATOR SWITCH
1 - DIFFERENTIAL CASE
2 - SWITCH
3 - 74 FRONT AXLE - 216FBI TJ
DIFFERENTIAL - TRU-LOK (Continued)
DISASSEMBLY
(1) I nstal l Pl ug C-293-3 i nto the di fferenti al axl e
shaft hol e.
(2) Remove di fferenti al case beari ngs wi th Pul l er
6444, Pul l er Rods 6444-3 and Pul l er Fl ange 6444-1.
Posi ti on pul l er (Fi g. 54) on the di fferenti al .
(3) Posi ti on Pul l er Jaws 6444-7 (Fi g. 55) around
the case beari ng and pul l er fl ange.
(4) Posi ti on Pul l er Col l ar 6444-8 (Fi g. 56) around
the pul l er jaws.
Fig. 55 PULLER AND JAWS
1 - PULLER
2 - ROD
3 - PLUG
4 - JAW
Fig. 56 PULLER AND COLLAR
1 - PULLER
2 - ROD
3 - PLUG
4 - COLLAR
Fig. 54 PULLER AND FLANGE
1 - PULLER
2 - ROD
3 - PLUG
4 - FLANGE
TJ FRONT AXLE - 216FBI 3 - 75
DIFFERENTIAL - TRU-LOK (Continued)
(5) Ti ghten the pul l er nut and remove di fferenti al
case beari ng.
(6) Remove actuator (Fi g. 57).
ASSEMBLY
(1) Veri fy pressure pl ate tabs (Fi g. 58) are seated
on the dog cl utch sl ots.
(2) Pl ace actuator on the pressure pl ate and case
beari ng on the case (Fi g. 59).
(3) I nstal l di fferenti al case beari ngs wi th I nstal l er
D-156 and Handl e C-4171.
INSTALLATION
NOTE: If replacement differential bearings or differ-
ential case are being installed, differential side
bearing shim requirements may change. Refer
Adjustments (Differential Bearing Preload and Gear
Backlash) to determine the proper shim selection.
(1) I nstal l i ndi cator swi tch i nto the housi ng.
(2) Posi ti on Spreader W-129-B and adapters from
Adapter set 6987, wi th the tool dowel pi ns seated i n
the l ocati ng hol es (Fi g. 60). I nstal l hol d-down cl amps
and ti ghten the tool turnbuckl e fi nger-ti ght.
(3) I nstal l Pi l ot Stud C-3288-B at the l eft si de of
the di fferenti al housi ng. Attach Di al I ndi cator C-3339
to pi l ot stud. Load i ndi cator pl unger agai nst the
opposi te si de of the housi ng and zero i ndi cator.
(4) Spread housi ng whi l e measuri ng the di stance
wi th the di al i ndi cator.
CAUTION: Never spread over 0.38 mm (0.015 in).
Failure to heed caution may result in damage.
(5) Remove di al i ndi cator.
(6) I nstal l di fferenti al case wi th pi ni on gear si de
beari ng cap and di fferenti al prel oad shi ms i n the
Fig. 57 LOCKING ACTUATOR
1 - ACTUATOR
2 - PRESSURE PLATE
Fig. 58 PRESSURE PLATE
1 - PLATE
2 - PLATE TABS
Fig. 59 ACTUATOR AND CASE BEARING
1 - CASE BEARING
2 - ACTUATOR
3 - 76 FRONT AXLE - 216FBI TJ
DIFFERENTIAL - TRU-LOK (Continued)
housi ng. Tap di fferenti al case to seat beari ngs cups
i n the housi ng.
CAUTION: Ensure indicator switch plunger head is
positioned under the actuator. Failure to heed cau-
tion may result in damage.
(7) I nstal l ri ng gear si de beari ng cap wi th refer-
ence marks al i gned (Fi g. 61).
(8) Loosel y i nstal l di fferenti al beari ng cap bol ts.
(9) Remove axl e housi ng spreader.
(10) Ti ghten beari ng cap bol ts to 108 N·m (80 ft.
l bs.).
(11) Wi th a 1/4 i nch dri l l bi t check the cl earance
between the actuator and actuator pressure pl ate at
the top and the bottom.
CAUTION: If clearance is not correct, indicator
switch plunger may be on top of the actuator or
actuator mounting tabs may be bent. Failure to
heed caution may result in damage.
(12) I nstal l pressure hose on the actuator assem-
bl y.
(13) I nstal l axl e shafts.
(14) I nstal l di fferenti al cover, i denti fi cati on tag
and i ndi cator swi tch connector (Fi g. 62).
DIFFERENTIAL - TRU-LOK
PUMP
REMOVAL
(1) Di sconnect pumps and axl e harness connectors
(Fi g. 63).
(2) Remove pressure hoses from the front and rear
pumps.
(3) Remove pump mounti ng bracket bol ts (Fi g. 64).
(4) Remove pumps and bracket assembl y from the
vehi cl e.
(5) Remove pump connectors from the mounti ng
bracket.
Fig. 60 SPREADER LOCATION
1 - DIFFERENTIAL CASE
2 - ADAPTER
3 - HOLD DOWN
4 - SPREADER
5 - TURNBUCKLE
Fig. 61 BEARING CAP REFERENCE MARKS
1 - REFERENCE MARKS
2 - REFERENCE MARKS
Fig. 62 INDICATOR SWITCH CONNECTOR
1 - CONNECTOR
2 - DIFFERENTIAL COVER
TJ FRONT AXLE - 216FBI 3 - 77
DIFFERENTIAL - TRU-LOK (Continued)
(6) Remove pump mounti ng screws (Fi g. 65) from
the bracket and remove pump/pumps.
INSTALLATION
(1) Al i gn pump wi th screw hol es i n pump bracket.
(2) I nstal l and ti ghten pump mounti ng screws
(Fi g. 66).
(3) I nstal l pump bracket assembl y on the cross-
member/ski d pl ate and i nstal l pump bracket mount-
i ng bol ts (Fi g. 67).
(4) Ti ghten pump bracket bol ts to 14 N·m (125 i n.
l bs.).
Fig. 63 PUMP CONNECTORS
1 - REAR PUMP CONNECTOR
2 - FRONT PUMP CONNECTOR
3 - AXLE HARNESS
Fig. 64 PUMP BRACKET
1 - PUMP BRACKET
2 - CROSSMEMBER/SKID PLATE
Fig. 65 PUMP SCREWS
1 - REAR PUMP SCREWS
2 - FRONT PUMP SCREWS
Fig. 66 PUMP SCREWS
1 - REAR PUMP SCREWS
2 - FRONT PUMP SCREWS
Fig. 67 PUMP BRACKET
1 - PUMP BRACKET
2 - CROSSMEMBER/SKID PLATE
3 - 78 FRONT AXLE - 216FBI TJ
DIFFERENTIAL - TRU-LOK PUMP (Continued)
(5) Connector pump and axl e harness connectors
(Fi g. 68).
(6) I nstal l pressure hoses on the pumps.
(7) Veri fy pump operati on.
PINION GEAR/RING GEAR
REMOVAL
NOTE: The ring and pinion gears are serviced as a
matched set. Never replace one gear without replac-
ing the other gear.
(1) Remove di fferenti al from housi ng.
(2) Secure di fferenti al case i n a vi se wi th soft
metal jaw.
(3) Remove ri ng gear bol ts from the di fferenti al
case.
(4) Dri ve ri ng gear off the di fferenti al case wi th a
dead-bl ow hammer (Fi g. 69).
(5) Hol d yoke wi th Hol der 6719A and remove pi n-
i on nut and washer.
(6) Remove pi ni on yoke from the pi ni on shaft wi th
Pul l er C-452 and Fl ange Wrench C-3281 (Fi g. 70).
Fig. 68 PUMP CONNECTORS
1 - REAR PUMP CONNECTOR
2 - FRONT PUMP CONNECTOR
3 - AXLE HARNESS
Fig. 69 RING GEAR REMOVAL
1 - CASE
2 - RING GEAR
3- HAMMER
Fig. 70 PINION YOKE REMOVAL
1 - FLANGER WRENCH
2 - YOKE
3 - PULLER
TJ FRONT AXLE - 216FBI 3 - 79
DIFFERENTIAL - TRU-LOK PUMP (Continued)
(7) Remove pi ni on gear and prel oad shi ms from
housi ng (Fi g. 71).
(8) Remove pi ni on seal wi th a pry bar or sl i de
hammer mounted screw.
(9) Remove front pi ni on beari ng cup wi th Remover
D-147 and Handl e C-4171 (Fi g. 72).
(10) Remove rear beari ng cup (Fi g. 73) wi th
Remover D-148 and Handl e C-4171.
(11) Remove rear pi ni on beari ng wi th Pul l er
C-293-PA and Adapters C-293-39 (Fi g. 74).
Fig. 71 REMOVE PINION GEAR
1 - DEAD-BLOW HAMMER
Fig. 72 FRONT BEARING CUP REMOVAL
1 - REMOVER
2 - HANDLE
Fig. 73 REAR BEARING CUP REMOVAL
1 - DRIVER
2 - HANDLE
Fig. 74 REAR BEARING REMOVAL
1 - PULLER
2 - VISE
3 - ADAPTERS
4 - PINION SHAFT
3 - 80 FRONT AXLE - 216FBI TJ
PINION GEAR/RING GEAR (Continued)
(12) Remove pi ni on depth shi m/oi l sl i nger from
pi ni on shaft and record thi ckness.
INSTALLATION
NOTE: Pinion depth shims are placed between the
rear pinion bearing cone and pinion gear to achieve
proper ring and pinion gear mesh. If ring and pinion
gears are reused, the original pinion depth shim
can be used. Refer to Adjustments (Pinion Gear
Depth) to select the proper shim thickness if ring
and pinion gears are replaced.
(1) Appl y Mopar Door Ease sti ck or equi val ent
l ubri cant to outsi de surface of beari ng cups.
(2) I nstal l rear pi ni on beari ng cup wi th I nstal l er
D-146 and Handl e C-4171 (Fi g. 75).
(3) I nstal l front pi ni on beari ng cup wi th I nstal l er
D-144 and Handl e C-4171 (Fi g. 76).
(4) I nstal l pi ni on front beari ng, oi l sl i nger. Appl y a
l i ght coati ng of gear l ubri cant on the l i p of pi ni on
seal .
(5) I nstal l pi ni on seal wi th an appropri ate i nstal l er
(Fi g. 77).
(6) I nstal l proper thi ckness depth shi m on the pi n-
i on gear.
Fig. 75 REAR PINION BEARING CUP
1 - INSTALLER
2 - HANDLE
Fig. 76 FRONT PINION BEARING CUP INSTALLER
1 - INSTALLER
2 - HANDLE
Fig. 77 PINION SEAL INSTALLER
1 - HANDLE
2 - INSTALLER
TJ FRONT AXLE - 216FBI 3 - 81
PINION GEAR/RING GEAR (Continued)
(7) I nstal l rear beari ng and oi l sl i nger, i f equi pped
on pi ni on gear wi th I nstal l er W-262 (Fi g. 78).
(8) I nstal l pi ni on gear i n housi ng.
(9) I nstal l pi ni on prel oad shi ms (Fi g. 79)
(10) I nstal l yoke wi th I nstal l er W-162-D and Yoke
Hol der 6719A (Fi g. 80).
(11) I nstal l yoke washer and a new nut on the
pi ni on gear. Ti ghten the nut to speci fi cati on (Fi g. 81).
Fig. 78 REAR PINION BEARING
1 - PRESS
2 - INSTALLER
3 - PINION GEAR
4 - PINION BEARING
Fig. 79 PINION PRELOAD SHIMS
1 - PRELOAD SHIMS
2 - FRONT BEARING CUP
3 - SLINGER
4 - PINION YOKE
5 - WASHER
6 - PINION NUT
7 - PINION OIL SEAL
8 - FRONT PINION BEARING
Fig. 80 PINION YOKE INSTALLER
1 - INSTALLER
2 - YOKE HOLDER
Fig. 81 TIGHTENING PINION NUT
1 - PINION YOKE
2 - YOKE HOLDING
3 - DIFFERENTIAL HOUSING
3 - 82 FRONT AXLE - 216FBI TJ
PINION GEAR/RING GEAR (Continued)
(12) Check beari ng prel oad torque wi th an i nch
pound torque wrench (Fi g. 82). The torque to rotate
the pi ni on gear shoul d be:
• Ori gi nal Beari ngs: 1 to 2 N·m (10 to 20 i n. l bs.).
• New Beari ngs: 2.3 to 4.5 N·m (20 to 40 i n. l bs.).
(13) I nvert di fferenti al case i n a vi se and start two
ri ng gear bol ts. Thi s wi l l provi de case-to-ri ng gear
bol t hol e al i gnment.
(14) I nstal l new ri ng gear bol ts and al ternatel y
ti ghten to 136 N·m (100 ft. l bs.). (Fi g. 83).
CAUTION: Never reuse the ring gear bolts. Failure
to heed caution may result in damage.
(15) I nstal l di fferenti al i n axl e housi ng and veri fy
gear mesh and contact pattern. Refer to Adjustments
(Gear Contact Pattern).
Fig. 82 PINION ROTATION TORQUE
1 - PINION YOKE
2 - INCH POUND TORQUE WRENCH
Fig. 83 RING GEAR INSTALLATION
1 - TORQUE WRENCH
2 - RING GEAR BOLT
3 - RING GEAR
4 - CASE
TJ FRONT AXLE - 216FBI 3 - 83
PINION GEAR/RING GEAR (Continued)
REAR AXLE - 194RBI
TABLE OF CONTENTS
page page
REAR AXLE - 194RBI
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . 84
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 88
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . 89
SPECIFICATIONS
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . 96
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . 97
AXLE SHAFTS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 100
AXLE SHAFT SEALS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 100
AXLE BEARINGS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 101
PINION SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 102
COLLAPSIBLE SPACER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 103
DIFFERENTIAL COVER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 105
DIFFERENTIAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 106
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 107
DIFFERENTIAL - TRAC-LOK
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 108
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 108
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . 108
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 109
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
DIFFERENTIAL CASE BEARINGS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 113
PINION GEAR/RING GEAR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 115
REAR AXLE - 194RBI
DIAGNOSIS AND TESTING
GEAR NOISE
Axl e gear noi se can be caused by i nsuffi ci ent l ubri -
cant, i ncorrect backl ash, i ncorrect pi ni on depth, tooth
contact, worn/damaged gears, or the carri er housi ng
not havi ng the proper offset and squareness.
Gear noi se usual l y happens at a speci fi c speed
range. The noi se can al so occur duri ng a speci fi c type
of dri vi ng condi ti on. These condi ti ons are accel era-
ti on, decel erati on, coast, or constant l oad.
When road testi ng, fi rst warm-up the axl e fl ui d by
dri vi ng the vehi cl e at l east 5 mi l es and then accel er-
ate the vehi cl e to the speed range where the noi se i s
the greatest. Shi ft out-of-gear and coast through the
peak-noi se range. I f the noi se stops or changes
greatl y:
• Check for i nsuffi ci ent l ubri cant.
• I ncorrect ri ng gear backl ash.
• Gear damage.
Di fferenti al si de gears and pi ni ons can be checked
by turni ng the vehi cl e. They usual l y do not cause
noi se duri ng strai ght-ahead dri vi ng when the gears
are unl oaded. The si de gears are l oaded duri ng vehi -
cl e turns. A worn pi ni on shaft can al so cause a snap-
pi ng or a knocki ng noi se.
BEARING NOISE
The axl e shaft, di fferenti al and pi ni on beari ngs can
al l produce noi se when worn or damaged. Beari ng
noi se can be ei ther a whi ni ng, or a growl i ng sound.
Pi ni on beari ngs have a constant-pi tch noi se. Thi s
noi se changes onl y wi th vehi cl e speed. Pi ni on beari ng
noi se wi l l be hi gher pi tched because i t rotates at a
faster rate. Dri ve the vehi cl e and l oad the di fferen-
ti al . I f beari ng noi se occurs, the rear pi ni on beari ng
i s the source of the noi se. I f the beari ng noi se i s
heard duri ng a coast, the front pi ni on beari ng i s the
source.
Worn or damaged di fferenti al beari ngs usual l y pro-
duce a l ow pi tch noi se. Di fferenti al beari ng noi se i s
si mi l ar to pi ni on beari ng noi se. The pi tch of di fferen-
ti al beari ng noi se i s al so constant and vari es onl y
wi th vehi cl e speed.
Axl e shaft beari ngs produce noi se and vi brati on
when worn or damaged. The noi se general l y changes
when the beari ngs are l oaded. Road test the vehi cl e.
Turn the vehi cl e sharpl y to the l eft and to the ri ght.
Thi s wi l l l oad the beari ngs and change the noi se
3 - 84 REAR AXLE - 194RBI TJ
l evel . Where axl e beari ng damage i s sl i ght, the noi se
i s usual l y not noti ceabl e at speeds above 30 mph.
LOW SPEED KNOCK
Low speed knock i s general l y caused by a worn
U-joi nt or by worn si de–gear thrust washers. A worn
pi ni on shaft bore wi l l al so cause l ow speed knock.
VIBRATION
Vi brati on at the rear of the vehi cl e i s usual l y
caused by a:
• Damaged dri ve shaft.
• Mi ssi ng dri ve shaft bal ance wei ght(s).
• Worn or out-of-bal ance wheel s.
• Loose wheel l ug nuts.
• Worn U-joi nt(s).
• Loose/broken spri ngs.
• Damaged axl e shaft beari ng(s).
• Loose pi ni on gear nut.
• Excessi ve pi ni on yoke run out.
• Bent axl e shaft(s).
Check for l oose or damaged front-end components
or engi ne/transmi ssi on mounts. These components
can contri bute to what appears to be a rearend vi bra-
ti on. Do not overl ook engi ne accessori es, brackets
and dri ve bel ts.
NOTE: All driveline components should be exam-
ined before starting any repair.
DRIVELINE SNAP
A snap or cl unk noi se when the vehi cl e i s shi fted
i nto gear (or the cl utch engaged), can be caused by:
• Hi gh engi ne i dl e speed.
• Transmi ssi on shi ft operati on.
• Loose engi ne/transmi ssi on/transfer case mounts.
• Worn U-joi nts.
• Loose spri ng mounts.
• Loose pi ni on gear nut and yoke.
• Excessi ve ri ng gear backl ash.
• Excessi ve si de gear to case cl earance.
The source of a snap or a cl unk noi se can be deter-
mi ned wi th the assi stance of a hel per. Rai se the vehi -
cl e on a hoi st wi th the wheel s free to rotate. I nstruct
the hel per to shi ft the transmi ssi on i nto gear. Li sten
for the noi se, a mechani cs stethoscope i s hel pful i n
i sol ati ng the source of a noi se.
DIAGNOSTIC CHART
Condition Possible Causes Correction
Wheel Noise 1. Wheel loose. 1. Tighten loose nuts.
2. Faulty, brinelled wheel bearing. 2. Replace bearing.
Axle Shaft Noise 1. Misaligned axle tube. 1. Inspect axle tube alignment.
Correct as necessary.
2. Bent or sprung axle shaft. 2. Inspect and correct as necessary.
Axle Shaft Broke 1. Misaligned axle tube. 1. Replace the broken shaft after
correcting tube mis-alignment.
2 Vehicle overloaded. 2. Replace broken shaft and avoid
excessive weight on vehicle.
3. Erratic clutch operation. 3. Replace broken shaft and avoid
or correct erratic clutch operation.
4. Grabbing clutch. 4. Replace broken shaft and inspect
and repair clutch as necessary.
TJ REAR AXLE - 194RBI 3 - 85
REAR AXLE - 194RBI (Continued)
Condition Possible Causes Correction
Differential Cracked 1. Improper adjustment of the
differential bearings.
1. Replace case and inspect gears
and bearings for further damage.
Set differential bearing pre-load
properly.
2. Excessive ring gear backlash. 2. Replace case and inspect gears
and bearings for further damage.
Set ring gear backlash properly.
3. Vehicle overloaded. 3. Replace case and inspect gears
and bearings for further damage.
Avoid excessive vehicle weight.
4. Erratic clutch operation. 4. Replace case and inspect gears
and bearings for further damage.
Avoid erratic use of clutch.
Differential Gears Scored 1. Insufficient lubrication. 1. Replace scored gears. Fill
differential with the correct fluid type
and quantity.
2. Improper grade of lubricant. 2. Replace scored gears. Fill
differential with the correct fluid type
and quantity.
3. Excessive spinning of one
wheel/tire.
3. Replace scored gears. Inspect all
gears, pinion bores, and shaft for
damage. Service as necessary.
Loss Of Lubricant 1. Lubricant level too high. 1. Drain lubricant to the correct
level.
2. Worn axle shaft seals. 2. Replace seals.
3. Cracked differential housing. 3. Repair as necessary.
4. Worn pinion seal. 4. Replace seal.
5. Worn/scored yoke. 5. Replace yoke and seal.
6. Axle cover not properly sealed. 6. Remove, clean, and re-seal
cover.
Axle Overheating 1. Lubricant level low. 1. Fill differential to correct level.
2. Improper grade of lubricant. 2. Fill differential with the correct
fluid type and quantity.
3. Bearing pre-loads too high. 3. Re-adjust bearing pre-loads.
4. Insufficient ring gear backlash. 4. Re-adjust ring gear backlash.
3 - 86 REAR AXLE - 194RBI TJ
REAR AXLE - 194RBI (Continued)
Condition Possible Causes Correction
Gear Teeth Broke 1. Overloading. 1. Replace gears. Examine other
gears and bearings for possible
damage.
2. Erratic clutch operation. 2. Replace gears and examine the
remaining parts for damage. Avoid
erratic clutch operation.
3. Ice-spotted pavement. 3. Replace gears and examine
remaining parts for damage.
4. Improper adjustments. 4. Replace gears and examine
remaining parts for damage. Ensure
ring gear backlash is correct.
Axle Noise 1. Insufficient lubricant. 1. Fill differential with the correct
fluid type and quantity.
2. Improper ring gear and pinion
adjustment.
2. Check ring gear and pinion
contact pattern. Adjust backlash or
pinion depth.
3. Unmatched ring gear and pinion. 3. Replace gears with a matched
ring gear and pinion.
4. Worn teeth on ring gear and/or
pinion.
4. Replace ring gear and pinion.
5. Loose pinion bearings. 5. Adjust pinion bearing pre-load.
6. Loose differential bearings. 6. Adjust differential bearing
pre-load.
7. Mis-aligned or sprung ring gear. 7. Measure ring gear run-out.
Replace components as necessary.
8. Loose differential bearing cap
bolts.
8. Inspect differential components
and replace as necessary. Ensure
that the bearing caps are torqued
tot he proper specification.
9. Housing not machined properly. 9. Replace housing.
TJ REAR AXLE - 194RBI 3 - 87
REAR AXLE - 194RBI (Continued)
REMOVAL
(1) Wi th vehi cl e i n neutral , posi ti on vehi cl e on
hoi st.
(2) Posi ti on a l i ft devi ce under the axl e and secure
axl e to devi ce.
(3) Remove brake components.
(4) Di sconnect the vent hose from the axl e shaft
tube.
(5) Remove propel l er shaft.
(6) Di sconnect stabi l i zer bar l i nks (Fi g. 1).
(7) Remove shock absorbers from axl e bracket (Fi g.
2).
(8) Remove track bar from axl e bracket (Fi g. 3).
(9) Remove upper and l ower control arms from
axl e brackets.
(10) Lower axl e and remove spri ngs.
INSTALLATION
CAUTION: The weight of the vehicle must be sup-
ported by the springs before suspension arms and
track bar fasteners can be tightened. Failure to
heed caution may result in damage.
(1) Rai se axl e and al i gn the spri ng centeri ng bol ts
wi th mati ng hol es i n the axl e spri ng perch.
(2) I nstal l upper and l ower control arms i n the
axl e brackets (Fi g. 4) and l oosel y i nstal l the mount-
i ng bol ts.
Fig. 1 STABILIZER BAR
1 - LINK
2 - RETAINER
3 - STABILIZER BAR
4 - AXLE MOUNT
Fig. 2 SHOCK ABSORBER
1 - AXLE BRACKET
2 - SHOCK
Fig. 3 REAR TRACK BAR
1 - TRACK BAR
2 - FRAME BRACKET
3 - REAR AXLE
Fig. 4 UPPER AND LOWER SUSPENSION ARMS
1 - UPPER SUSPENSION ARM
2 - REAR AXLE
3 - LOWER SUSPENSION ARM
3 - 88 REAR AXLE - 194RBI TJ
REAR AXLE - 194RBI (Continued)
(3) I nstal l shock absorbers and ti ghten nuts to
torque speci fi cati on.
(4) I nstal l stabi l i zer bar l i nks and ti ghten nuts to
torque speci fi cati on.
(5) I nstal l brake components.
(6) I nstal l axl e vent hose.
(7) I nstal l propel l er shaft (Fi g. 5).
(8) Ti ghten upper and l ower control arms nuts to
torque speci fi cati on.
ADJUSTMENTS
RING AND PINION GEAR
Ri ng and pi ni on gears are suppl i ed as matched
sets onl y. The i denti fyi ng numbers for the ri ng and
pi ni on gear are etched i nto the face of each gear (Fi g.
6). A pl us (+) number, mi nus (–) number or zero (0) i s
etched i nto the face of the pi ni on gear. Thi s number
i s the amount (i n thousandths of an i nch) the depth
vari es from the standard depth setti ng of a pi ni on
etched wi th a (0). The standard depth provi des the
best teeth contact pattern. Refer to Backl ash and
Contact Pattern Anal ysi s Paragraph i n thi s secti on
for addi ti onal i nformati on.
Compensati on for pi ni on depth vari ance i s
achi eved wi th sel ect shi ms. The shi ms are pl aced
under the i nner pi ni on beari ng cone (Fi g. 7).
I f a new gear set i s bei ng i nstal l ed, note the depth
vari ance etched i nto both the ori gi nal and repl ace-
ment pi ni on gear. Add or subtract the thi ckness of
the ori gi nal depth shi ms to compensate for the di ffer-
ence i n the depth vari ances. Refer to the Depth Vari -
ance charts.
Note where Ol d and New Pi ni on Marki ng col umns
i ntersect. I ntersecti ng fi gure represents pl us or
mi nus amount needed.
Note the etched number on the face of the dri ve
pi ni on gear (–1, –2, 0, +1, +2, etc.). The numbers rep-
resent thousands of an i nch devi ati on from the stan-
dard. I f the number i s negati ve, add that val ue to the
requi red thi ckness of the depth shi m(s). I f the num-
ber i s posi ti ve, subtract that val ue from the thi ckness
of the depth shi m(s). I f the number i s 0 no change i s
necessary. Refer to the Pi ni on Gear Depth Vari ance
Chart.
Fig. 5 REAR PROPELLER SHAFT
1 - CLAMP
2 - YOKE
3 - PROPELLER SHAFT
4 - AXLE YOKE
5 - CLAMP
6 - OUTPUT SHAFT
7 - BOOT
Fig. 6 PINION GEAR ID NUMBERS
1 - PRODUCTION NUMBERS
2 - DRIVE PINION GEAR DEPTH VARIANCE
3 - GEAR MATCHING NUMBER
Fig. 7 ADJUSTMENT SHIM LOCATIONS
1 - PINION GEAR DEPTH SHIM
2 - DIFFERENTIAL SHIM-PINION GEAR SIDE
3 - RING GEAR
4 - DIFFERENTIAL SHIM-RING GEAR SIDE
5 - COLLAPSIBLE SPACER
TJ REAR AXLE - 194RBI 3 - 89
REAR AXLE - 194RBI (Continued)
PINION GEAR DEPTH VARIANCE
Original Pinion
Gear Depth
Variance
Replacement Pinion Gear Depth Variance
Ϫ4 Ϫ3 Ϫ2 Ϫ1 0 +1 +2 +3 +4
+4 +0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0
+3 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 Ϫ0.001
+2 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 Ϫ0.001 Ϫ0.002
+1 +0.005 +0.004 +0.003 +0.002 +0.001 0 Ϫ0.001 Ϫ0.002 Ϫ0.003
0 +0.004 +0.003 +0.002 +0.001 0 Ϫ0.001 Ϫ0.002 Ϫ0.003 Ϫ0.004
Ϫ1 +0.003 +0.002 +0.001 0 Ϫ0.001 Ϫ0.002 Ϫ0.003 Ϫ0.004 Ϫ0.005
Ϫ2 +0.002 +0.001 0 Ϫ0.001 Ϫ0.002 Ϫ0.003 Ϫ0.004 Ϫ0.005 Ϫ0.006
Ϫ3 +0.001 0 Ϫ0.001 Ϫ0.002 Ϫ0.003 Ϫ0.004 Ϫ0.005 Ϫ0.006 Ϫ0.007
Ϫ4 0 Ϫ0.001 Ϫ0.002 Ϫ0.003 Ϫ0.004 Ϫ0.005 Ϫ0.006 Ϫ0.007 Ϫ0.008
PINION DEPTH MEASUREMENT
Measurements are taken wi th pi ni on cups and pi n-
i on beari ngs i nstal l ed i n the housi ng. Take measure-
ments wi th a Pi ni on Gauge Set, Pi ni on Bl ock 6735,
Arbor Di scs 6732 and Di al I ndi cator C-3339 (Fi g. 8).
(1) Assembl e Pi ni on Hei ght Bl ock 6739, Pi ni on
Bl ock 6735 and rear pi ni on beari ng onto Screw 6741
(Fi g. 8).
(2) I nsert assembl ed hei ght gauge components,
rear beari ng and screw i nto the housi ng through pi n-
i on beari ng cups (Fi g. 9).
(3) I nstal l front pi ni on beari ng and Cone 6740
hand ti ght.
Fig. 8 PINION GEAR DEPTH TOOLS
1 - DIAL INDICATOR
2 - ARBOR
3 - PINION HEIGHT BLOCK
4 - CONE
5 - SCREW
6 - PINION BLOCK
7 - SCOOTER BLOCK
8 - ARBOR DISC
Fig. 9 PINION HEIGHT BLOCK
1 - PINION BLOCK
2 - PINION HEIGHT BLOCK
3 - 90 REAR AXLE - 194RBI TJ
REAR AXLE - 194RBI (Continued)
(4) Pl ace Arbor Di sc 6732 on Arbor D-115-3 i n posi -
ti on i n the housi ng si de beari ng cradl es (Fi g. 10).
I nstal l di fferenti al beari ng caps on Arbor Di scs and
ti ghten cap bol ts. Refer to the Torque Speci fi cati ons
i n thi s secti on.
NOTE: Arbor Discs 6732 have different step diame-
ters to fit other axle sizes. Pick correct size step for
axle being serviced.
(5) Assembl e Di al I ndi cator C-3339 i nto Scooter
Bl ock D-115-2 and secure set screw.
(6) Posi ti on Scooter Bl ock/Di al I ndi cator fl ush on
the pi ni on hei ght bl ock. Hol d scooter bl ock and zero
the di al i ndi cator.
(7) Sl owl y sl i de the scooter bl ock across the pi ni on
hei ght bl ock over to the arbor (Fi g. 11). Move the
scooter bl ock ti l l the di al i ndi cator probe crests the
arbor, then record the hi ghest readi ng.
(8) Sel ect a shi m equal to the di al i ndi cator read-
i ng pl us the dri ve pi ni on gear depth vari ance number
etched i n the face of the pi ni on gear (Fi g. 6) usi ng
the opposi te si gn on the vari ance number. For exam-
pl e, i f the depth vari ance i s –2, add +0.002 i n. to the
di al i ndi cator readi ng.
(9) Remove the pi ni on depth gauge components
from the housi ng
DIFFERENTIAL BEARING PRELOAD
Di fferenti al si de beari ng prel oad and gear backl ash
i s achi eved by sel ecti ve shi ms i nserted between the
beari ng cup and the housi ng. The proper shi m thi ck-
ness can be determi ned usi ng sl i p-fi t Dummy Bear-
i ngs D-348 i n pl ace of the di fferenti al si de beari ngs
and a Di al I ndi cator C-3339. Before proceedi ng wi th
the di fferenti al beari ng prel oad and gear backl ash
measurements, measure the pi ni on gear depth and
prepare the pi ni on gear for i nstal l ati on. Establ i shi ng
proper pi ni on gear depth i s essenti al to establ i shi ng
gear backl ash and tooth contact patterns. After the
overal l shi m thi ckness to take up di fferenti al si de
pl ay i s measured, the pi ni on gear i s i nstal l ed and the
gear backl ash shi m thi ckness i s measured. The over-
al l shi m thi ckness i s the total of the di al i ndi cator
readi ng, starti ng poi nt shi m thi ckness and the pre-
l oad speci fi cati on added together. The gear backl ash
measurement determi nes the thi ckness of the shi m
used on the ri ng gear si de of the di fferenti al case.
Subtract the gear backl ash shi m thi ckness from the
total overal l shi m thi ckness and sel ect that amount
for the pi ni on gear si de of the di fferenti al (Fi g. 12).
Fig. 10 GAUGE TOOLS IN HOUSING
1 - ARBOR DISC
2 - PINION BLOCK
3 - ARBOR
4 - PINION HEIGHT BLOCK
Fig. 11 PINION GEAR DEPTH MEASUREMENT
1 - ARBOR
2 - SCOOTER BLOCK
3 - DIAL INDICATOR
Fig. 12 SHIM LOCATIONS
1 - PINION GEAR DEPTH SHIM
2 - DIFFERENTIAL SHIM-PINION GEAR SIDE
3 - RING GEAR
4 - DIFFERENTIAL SHIM-RING GEAR SIDE
5 - COLLAPSIBLE SPACER
TJ REAR AXLE - 194RBI 3 - 91
REAR AXLE - 194RBI (Continued)
PRELOAD SHIM SELECTION
NOTE: It is difficult to salvage the differential side
bearings during the removal procedure. Install
replacement bearings if necessary.
(1) Remove si de beari ngs from di fferenti al case.
(2) I nstal l ri ng gear, i f necessary, on di fferenti al
case and ti ghten bol ts to speci fi cati on.
(3) I nstal l Dummy Beari ngs D-348 on di fferenti al
case.
(4) I nstal l di fferenti al case i n the housi ng.
(5) I nsert Dummy Shi ms 8107 ( 3.0 mm /0.118 i n.)
starti ng poi nt shi ms between the dummy beari ng
and the housi ng (Fi g. 13).
(6) I nstal l beari ng caps i n thei r correct posi ti ons
and snug the bol ts.
(7) Usi ng a dead-bl ow hammer to seat the di ffer-
enti al dummy beari ngs to each si de of the housi ng
(Fi g. 14) and (Fi g. 15).
Fig. 13 DUMMY SHIM LOCATION
1 - DUMMY SHIM
2 - DIFFERENTIAL HOUSING
3 - DIFFERENTIAL CASE
4 - DUMMY BEARING
Fig. 14 SEAT DUMMY BEARING PINION GEAR SIDE
1 - MALLET
2 - DIFFERENTIAL HOUSING
3 - DIFFERENTIAL CASE
Fig. 15 SEAT DUMMY BEARING RING GEAR SIDE
1 - DIFFERENTIAL HOUSING
2 - MALLET
3 - DIFFERENTIAL CASE
3 - 92 REAR AXLE - 194RBI TJ
REAR AXLE - 194RBI (Continued)
(8) Thread Pi l ot Stud C-3288-B i nto rear cover bol t
hol e bel ow ri ng gear (Fi g. 16).
(9) Attach Di al I ndi cator C-3339 to the pi l ot stud
and posi ti on i ndi cator pl unger on a fl at surface of the
ri ng gear bol t head (Fi g. 16).
(10) Push di fferenti al case to the pi ni on gear si de
of the housi ng (Fi g. 17) and zero di al i ndi cator.
(11) Push di fferenti al case to the ri ng gear si de
and record di al i ndi cator readi ng (Fi g. 18).
(12) Add the di al i ndi cator readi ng to the starti ng
poi nt shi m thi ckness to determi ne total shi m thi ck-
ness to achi eve zero di fferenti al end pl ay.
(13) Add 0.008 i n. (0.2 mm) to the zero end pl ay
total . Thi s new total represents the thi ckness of
shi ms to compress or prel oad the new beari ngs when
the di fferenti al i s i nstal l ed.
(14) Rotate di al i ndi cator out of the way.
(15) Remove di fferenti al case, dummy beari ngs
and starti ng poi nt shi ms from the housi ng.
(16) I nstal l pi ni on gear i n the housi ng. I nstal l the
yoke and establ i sh the correct pi ni on rotati ng torque.
(17) I nstal l di fferenti al case and dummy beari ngs
i n the housi ng (wi thout shi ms) and ti ghten retai ni ng
cap bol ts.
(18) Posi ti on the di al i ndi cator pl unger on a fl at
surface between the ri ng gear bol t heads (Fi g. 16).
(19) Push and hol d di fferenti al case toward pi ni on
gear.
(20) Zero di al i ndi cator face to poi nter.
(21) Push and hol d di fferenti al case to ri ng gear
si de of the housi ng and record di al i ndi cator readi ng.
(22) Subtract 0.002 i n. (0.05 mm) from the di al
i ndi cator readi ng to compensate for backl ash between
ri ng and pi ni on gears. Thi s total i s the thi ckness of
shi m requi red to achi eve proper backl ash.
(23) Subtract the backl ash shi m thi ckness from
the total prel oad shi m thi ckness. The remai nder i s
the shi m thi ckness requi red on the pi ni on si de of the
housi ng.
(24) Rotate di al i ndi cator out of the way on pi l ot
stud.
(25) Remove di fferenti al case and dummy beari ngs
from the housi ng.
Fig. 16 DIFFERENTIAL SIDE PLAY MEASUREMENT
1 - DIFFERENTIAL CASE
2 - DIFFERENTIAL HOUSING
3 - PILOT STUD
4 - DIAL INDICATOR
Fig. 17 ZERO DIAL INDICATOR
1 - DIFFERENTIAL CASE TO PINION GEAR SIDE
2 - PILOT STUD
3 - DIAL INDICATOR EXTENSION
4 - ZERO DIAL INDICATOR FACE
Fig. 18 RECORD DIAL INDICATOR READING
1 - READ DIAL INDICATOR
2 - DIFFERENTIAL CASE TO RING GEAR SIDE
3 - DIFFERENTIAL HOUSING
TJ REAR AXLE - 194RBI 3 - 93
REAR AXLE - 194RBI (Continued)
(26) I nstal l new si de beari ng cones and cups on
di fferenti al case.
(27) I nstal l spreader W-129-B and some compo-
nents of Adapter Set 6987 on di fferenti al housi ng and
spread axl e openi ng enough to recei ve di fferenti al
case.
(28) Pl ace si de beari ng shi ms i nto the housi ng
agai nst the di fferenti al beari ng bore.
(29) I nstal l di fferenti al case i n the housi ng.
(30) Rotate the di fferenti al case several ti mes to
seat the si de beari ngs.
(31) Posi ti on the i ndi cator pl unger agai nst a ri ng
gear tooth (Fi g. 19).
(32) Push and hol d ri ng gear upward whi l e not
al l owi ng the pi ni on gear to rotate.
(33) Zero di al i ndi cator face to poi nter.
(34) Push and hol d ri ng gear downward whi l e not
al l owi ng the pi ni on gear to rotate. Di al i ndi cator
readi ng shoul d be between 0.12 mm - 0.20 mm (0.005
i n. - 0.008 i n.). I f backl ash i s not wi thi n speci fi cati ons
transfer the necessary amount of shi m thi ckness
from one si de of the di fferenti al housi ng to the other
(Fi g. 20).
(35) Veri fy di fferenti al case and ri ng gear runout
by measuri ng ri ng to pi ni on gear backl ash at ei ght
l ocati ons around the ri ng gear. Readi ngs shoul d not
vary more than 0.05 mm (0.002 i n.). I f readi ngs vary
more than speci fi ed, the ri ng gear or the di fferenti al
case i s defecti ve.
After the proper backl ash i s achi eved, perform the
Gear Contact Pattern Anal ysi s procedure.
GEAR CONTACT PATTERN
The ri ng gear and pi ni on teeth contact patterns
wi l l show i f the pi ni on depth i s correct i n the hous-
i ng. I t wi l l al so show i f the ri ng gear backl ash has
been adjusted correctl y. The backl ash can be adjusted
wi thi n speci fi cati ons to achi eve desi red tooth contact
patterns.
The TOP LAND of the gear tooth i s the top surface
of the tooth. The PROFI LE of the gear tooth i s the
depth of the tooth. The TOE of the gear i s the por-
ti on of the tooth surface at the end towards the cen-
ter. The HEEL of the gear i s the porti on of the tooth
at the outer-end. The ROOT of the gear tooth i s the
l owest porti on of the tooth (Fi g. 21).
NOTE: If the PROFILE across the tooth is the same
it is a 3 Axis cut gear. If the PROFILE across the
tooth is tapered it is a 2 Axis cut gear.
Fig. 19 RING GEAR BACKLASH
1 - DIAL INDICATOR
Fig. 20 BACKLASH SHIM ADJUSTMENT
Fig. 21 GEAR DESCRIPTION
1 - TOP LAND
2 - PROFILE
3 - TOE
4 - HEEL
5 - ROOT
3 - 94 REAR AXLE - 194RBI TJ
REAR AXLE - 194RBI (Continued)
(1) Appl y a thi n coat of hydrated ferri c oxi de or
equi val ent to the dri ve and coast si de of the ri ng gear
teeth.
(2) Wrap, twi st, and hol d a shop towel around the
pi ni on yoke to i ncrease the turni ng resi stance of the
pi ni on. Thi s wi l l provi de a more di sti nct contact pat-
tern.
(3) Wi th a boxed end wrench on a ri ng gear bol t,
rotate the di fferenti al case one compl ete revol uti on i n
both di recti ons whi l e a l oad i s bei ng appl i ed from
shop towel .
The areas on the ri ng gear teeth wi th the greatest
degree of contact agai nst the pi ni on teeth wi l l
squeeze the compound to the areas wi th the l east
amount of contact. Note and compare patterns on the
ri ng gear teeth to Gear Tooth Contact Patterns
charts (Fi g. 22) and (Fi g. 23) and adjust pi ni on depth
and gear backl ash as necessary.
DIFFERENTIAL BEARING PRELOAD CHECK
The fi nal check on the di fferenti al assembl y before
i nstal l i ng the axl es i s torque to rotate pi ni on and di f-
ferenti al combi ned. Thi s wi l l veri fy the correct di ffer-
enti al beari ng prel oad.
Torque to rotate the di fferenti al and pi ni on shoul d
be the torque to rotate the pi ni on pl us 0.79-1.24 N·m
(7-11 i n. l bs.).
Fig. 22 PATTERN INTERPRETATION (GEAR CUT 2 AXIS)
TJ REAR AXLE - 194RBI 3 - 95
REAR AXLE - 194RBI (Continued)
SPECIFICATIONS
REAR AXLE
AXLE SPECIFICATIONS
DESCRIPTION SPECIFICATION
Axle Ratio 3.07, 3.73, 4.10, 4.56
Ring Gear Backlash 0.12-0.20 mm (0.005-0.008 in.)
Pinion Bearing Preload - Original Bearings 1-2 N·m (10-20 in. lbs.)
Pinion Bearing Preload - New Bearings 2-4 N·m (20-35 in. lbs.)
TORQUE SPECIFICATIONS
DESCRIPTION N·m Ft. Lbs. In. Lbs.
Differential Cover Bolts 41 30 -
Bearing Cap Bolts 77 57 -
Ring Gear Bolts 136 100 -
Pinion Nut Min / Max 271-475 200-350 -
Pinion Mate Shaft Screw 16.25 12 -
Fig. 23 PATTERN INTERPRETATION (GEAR CUT 3 AXIS)
3 - 96 REAR AXLE - 194RBI TJ
REAR AXLE - 194RBI (Continued)
SPECIAL TOOLS
PULLER C-293-PA
ADAPTER C-293-39
ADAPTER C-293-40
PILOT STUDS C-3288-B
DIAL INDICATOR C-3339
WRENCH C-3281
INSTALLER C-3716-A
HANDLE C-4171
REMOVER C-4345
PULLER C-452
TJ REAR AXLE - 194RBI 3 - 97
REAR AXLE - 194RBI (Continued)
INSTALLER D-130
INSTALLER D-146
REMOVER D-149
DUMMY BEARINGS D-348
ADAPTER PLUG SP-3289
SPREADER W-129-B
INSTALLER W-262
BEARING REMOVER 6310
INSTALLER 6436
INSTALLER 6437
3 - 98 REAR AXLE - 194RBI TJ
REAR AXLE - 194RBI (Continued)
PINION DEPTH 6774
HUB PULLER 6790
WRENCH SPANNER 6958
TRAC-LOK TOOLS 6960
HOLDER FIXTURE 6965
ADAPTER KIT 6987
PULLER 7794-A
SHIM DUMMY 8107
CUP 8109
INSTALLER SCREW 8112
TJ REAR AXLE - 194RBI 3 - 99
REAR AXLE - 194RBI (Continued)
AXLE SHAFTS
REMOVAL
(1) Wi th vehi cl e i n neutral , posi ti on vehi cl e on
hoi st.
(2) Remove brake drum.
(3) Remove di fferenti al cover and drai n fl ui d.
(4) Rotate di fferenti al case to access pi ni on mate
gear shaft l ock screw. Remove l ock screw and shaft
from di fferenti al case (Fi g. 24).
(5) Push axl e shaft i nward and remove axl e C-cl i p
l ock (Fi g. 25).
(6) Remove axl e shaft.
INSTALLATION
(1) Lubri cate beari ng bore and seal l i p wi th gear
l ubri cant. I nsert axl e shaft through seal , beari ng,
and engage i t i nto si de gear spl i nes.
(2) I nstal l C-cl i p l ock on the axl e shaft, then push
axl e outward to seat C-cl i p l ock i n si de gear.
(3) I nsert pi ni on mate shaft i nto di fferenti al case
and through thrust washers and pi ni on gears.
(4) Al i gn hol e i n shaft wi th hol e i n the di fferenti al
case and i nstal l l ock screw wi th Locti te௡ on the
threads. Ti ghten l ock screw to 19 N·m (14 ft. l bs.).
(5) I nstal l di fferenti al cover.
AXLE SHAFT SEALS
REMOVAL
(1) Remove the axl e shaft.
(2) Remove axl e shaft seal from the end of the axl e
shaft tube wi th a smal l pry bar.
(3) I nspect the axl e shaft tube bore for roughness
and burrs and remove as necessary.
INSTALLATION
(1) Wi pe the axl e shaft tube bore cl ean.
(2) I nstal l new axl e shaft seal wi th I nstal l er 6437
and Handl e C-4171 (Fi g. 26).
(3) I nstal l the axl e shaft.
Fig. 24 MATE SHAFT LOCK SCREW
1 - LOCK SCREW
2 - PINION GEAR MATE SHAFT
Fig. 25 AXLE SHAFT C-CLIP
1 - C-CLIP LOCK
2 - AXLE SHAFT
3 - SIDE GEAR
Fig. 26 AXLE SHAFT SEAL
1 - INSTALLER
2 - SEAL
3 - AXLE SHAFT TUBE
4 - HANDLE
3 - 100 REAR AXLE - 194RBI TJ
AXLE BEARINGS
REMOVAL
(1) Remove axl e shaft.
(2) Remove axl e shaft seal from axl e shaft tube
wi th a smal l pry bar.
(3) Remove axl e shaft beari ng from the axl e tube
wi th Beari ng Removal Tool Set 6310 and Adapter
Foot 6310-5 (Fi g. 27).
INSTALLATION
(1) Wi pe axl e shaft tube bore cl ean.
(2) I nstal l axl e shaft beari ng wi th I nstal l er 6436
and Handl e C-4171.
NOTE: Part number on the bearing must be against
the installer.
(3) I nstal l new axl e shaft seal wi th I nstal l er 6437
and Handl e C-4171 (Fi g. 28).
(4) I nstal l axl e shaft.
PINION SEAL
REMOVAL
(1) Wi th vehi cl e i n neutral , posi ti on vehi cl e on hoi st.
(2) Remove brake drums.
(3) Remove propel l er shaft from the yoke.
(4) Rotate pi ni on gear three or four ti mes.
(5) Record torque necessary to rotate the pi ni on
gear wi th an i nch pound di al -type torque wrench.
(6) Hol d the yoke wi th Wrench 6958 and remove
pi ni on nut and washer.
(7) Remove pi ni on yoke wi th Remover C-452 and
Wrench C-3281 (Fi g. 29).
(8) Remove pi ni on seal wi th a pry tool or sl i de
hammer mounted screw.
Fig. 27 AXLE SHAFT BEARING TOOLS
1 - AXLE SHAFT TUBE
2 - NUT
3 - GUIDE PLATE
4 - GUIDE
5 - THREADED ROD
6 - ADAPTER
7 - FOOT
Fig. 28 AXLE SHAFT SEAL INSTALLER
1 - INSTALLER
2 - SEAL
3 - AXLE SHAFT TUBE
4 - HANDLE
Fig. 29 PINION YOKE REMOVER
1 - WRENCH
2 - YOKE
3 - REMOVER
TJ REAR AXLE - 194RBI 3 - 101
INSTALLATION
(1) Appl y a l i ght coati ng of gear l ubri cant on the
l i p of pi ni on seal and i nstal l seal wi th an appropri ate
i nstal l er (Fi g. 30).
(2) I nstal l pi ni on yoke Screw 8112, Cup 8109 and
Spanner Wrench 6958 (Fi g. 31).
CAUTION: Do not exceed the minimum tightening
torque 271 N·m (200 ft. lbs.) when installing the pin-
ion yoke at this point. Failure to heed caution may
result in damage.
(3) I nstal l yoke washer and new nut on pi ni on
gear and ti ghten nut unti l there i s zero beari ng end-
pl ay.
(4) Ti ghten pi ni on nut to 271 N·m (200 ft. l bs.).
CAUTION: Never loosen pinion gear nut to decrease
pinion gear bearing rotating torque and never
exceed specified preload torque. Failure to heed
caution may result in damage.
(5) Rotate pi ni on shaft usi ng an i nch pound torque
wrench. Rotati ng torque shoul d be equal to the read-
i ng recorded duri ng removal pl us an addi ti onal 0.56
N·m (5 i n. l bs.) (Fi g. 32).
Fig. 30 PINION SEAL INSTALLER
1 - HANDLE
2 - INSTALLER
Fig. 31 PINION YOKE INSTALLER
1 - INSTALLER
2 - PINION YOKE
3 - SPANNER WRENCH
Fig. 32 PINION ROTATING TORQUE
1 - TORQUE WRENCH
2 - PINION YOKE
3 - 102 REAR AXLE - 194RBI TJ
PINION SEAL (Continued)
(6) I f rotati ng torque i s l ow, use Wrench 6958 to
hol d pi ni on yoke (Fi g. 33), and ti ghten pi ni on nut i n
6.8 N·m (5 ft. l bs.) i ncrements unti l proper rotati ng
torque i s achi eved.
CAUTION: If maximum tightening torque 475 N·m
(350 ft. lbs.) is reached prior to reaching the
required rotating torque, the collapsible spacer may
have been damaged. Failure to heed caution may
result in damage.
(7) I nstal l propel l er shaft.
(8) I nstal l the brake drums.
COLLAPSIBLE SPACER
REMOVAL
(1) Wi th vehi cl e i n neutral , posi ti on vehi cl e on
hoi st.
(2) Remove rear brake drums.
(3) Remove propel l er shaft.
(4) Rotate pi ni on gear three or four ti mes.
(5) Record torque to rotate the pi ni on gear wi th an
i nch pound di al -type torque wrench.
(6) Hol d pi ni on yoke wi th Spanner Wrench 6958
and remove pi ni on nut and washer.
(7) Remove pi ni on yoke wi th Remover C-452 and
Fl ange Wrench C-3281 (Fi g. 34).
(8) Remove pi ni on shaft seal wi th a pry tool or a
sl i de hammer mounted screw.
(9) Remove front pi ni on beari ng usi ng a pai r of
pi ck tool s to pul l the beari ng strai ght off the pi ni on
gear shaft.
NOTE: If bearing becomes bound on pinion shaft,
lightly tap the pinion shaft with a rawhide/rubber
hammer.
(10) Remove col l apsi bl e spacer.
INSTALLATION
(1) I nstal l a new col l apsi bl e prel oad spacer on pi n-
i on shaft.
(2) I nstal l pi ni on front beari ng.
(3) Appl y a l i ght coati ng of gear l ubri cant on the
l i p of pi ni on seal and i nstal l seal wi th an appropri ate
i nstal l er (Fi g. 35).
Fig. 33 YOKE HOLDER
1 - PINION YOKE
2 - SPANNER WRENCH
3 - PIPE
Fig. 34 PINION YOKE REMOVER
1 - WRENCH
2 - YOKE
3 - REMOVER
Fig. 35 PINION SEAL INSTALLER
1 - HANDLE
2 - INSTALLER
TJ REAR AXLE - 194RBI 3 - 103
PINION SEAL (Continued)
(4) I nstal l yoke wi th Screw 8112, Cup 8109 and
Spanner Wrench 6958 (Fi g. 36).
(5) I nstal l yoke washer and new nut on the pi ni on
gear. Ti ghten the nut to 271 N·m (200 ft. l bs.).
CAUTION: Never loosen pinion gear nut to decrease
pinion gear bearing rotating torque and never
exceed specified preload torque. Failure to heed
caution may result in damage.
(6) Usi ng yoke wi th Spanner Wrench 6958 and a
torque wrench set at 475 N·m (350 ft. l bs.), (Fi g. 37)
sl owl y ti ghten the nut i n 6.8 N·m (5 ft. l bs.) i ncre-
ments unti l the rotati ng torque i s achi eved. Measure
rotati ng torque frequentl y to avoi d over crushi ng the
col l apsi bl e spacer (Fi g. 38).
CAUTION: If more than 475 N·m (350 ft. lbs.) torque
is required to crush the collapsible spacer, the
spacer is defective and must be replaced. Failure to
heed caution may result in damage.
(7) Check rotati ng torque wi th an i nch pound
torque wrench (Fi g. 38). The rotati ng torque of the
pi ni on shoul d be, the readi ng recorded duri ng
removal pl us an addi ti onal 0.56 N·m (5 i n. l bs.).
(8) I nstal l propel l er shaft.
(9) I nstal l rear brake drums.
Fig. 36 PINION YOKE INSTALLER
1 - INSTALLER
2 - PINION YOKE
3 - SPANNER WRENCH
Fig. 37 YOKE HOLDER
1 - PINION YOKE
2 - SPANNER WRENCH
3 - PIPE
Fig. 38 PINION ROTATING TORQUE
1 - TORQUE WRENCH
2 - PINION YOKE
3 - 104 REAR AXLE - 194RBI TJ
COLLAPSIBLE SPACER (Continued)
DIFFERENTIAL COVER
REMOVAL
(1) Wi th vehi cl e i n neutral , posi ti on vehi cl e on hoi st.
(2) Remove drai n pl ug.
(3) Remove cover bol ts.
(4) Remove cover and drai n l ubri cant.
INSTALLATION
(1) Appl y a 6.35mm (1/4 i n.) bead of Mopar Si l i -
cone Rubber Seal ant or equi val ent to the housi ng
cover (Fi g. 39).
CAUTION: If housing cover is not installed within 3
to 5 minutes, the cover must be cleaned and new
RTV applied. Failure to heed caution may result in
damage.
(2) I nstal l cover and i denti fi cati on tag. Ti ghten
cover bol ts i n a cri ss-cross pattern to 41 N·m (30 ft.
l bs.).
(3) Fi l l di fferenti al to speci fi cati ons.
(4) I nstal l fi l l pl ug and ti ghten to 34 N·m (25 ft.
l bs.).
DIFFERENTIAL
REMOVAL
(1) Remove di fferenti al fi l l pl ug.
(2) Remove di fferenti al cover and drai n fl ui d.
(3) Remove axl e shafts.
(4) Note reference l etters stamped on the beari ng
caps and housi ng machi ned seal i ng surface (Fi g. 40).
(5) Loosen di fferenti al beari ng cap bol ts.
(6) Posi ti on Spreader W-129-B wi th Adapter Ki t
6987B on di fferenti al l ocati ng hol es (Fi g. 41). I nstal l
hol d-down cl amps and ti ghten the turnbuckl e fi nger-
ti ght.
Fig. 39 HOUSING COVER - TYPICAL
1 - SEALANT SURFACE
2 - SEALANT
3 - SEALANT THICKESS
Fig. 40 BEARING CAP REFERENCE
1 - REFERENCE LETTERS
2 - REFERENCE LETTERS
Fig. 41 SPREADER LOCATION
1 - DIFFERENTIAL HOUSING
2 - DOWEL
3 - SAFETY HOLD DOWN
4 - SPREADER
5 - TURNBUCKLE
TJ REAR AXLE - 194RBI 3 - 105
(7) I nstal l a Pi l ot Stud C-3288-B at the l eft si de of
the di fferenti al housi ng. Attach Di al I ndi cator C-3339 to
pi l ot stud. Load i ndi cator pl unger agai nst the opposi te
si de of the housi ng (Fi g. 42) and zero the i ndi cator.
CAUTION: Never spread the housing over 0.38 mm
(0.015 in). Failure to heed caution may result in
damage.
(8) Spread housi ng whi l e measuri ng the di stance
wi th the di al i ndi cator (Fi g. 43).
(9) Remove di al i ndi cator.
(10) Whi l e hol di ng di fferenti al case i n posi ti on,
remove di fferenti al beari ng caps.
(11) Remove di fferenti al from housi ng and tag di f-
ferenti al beari ng cups to i ndi cate l ocati on (Fi g. 44).
(12) Remove spreader from housi ng.
(13) Cl ean the housi ng cavi ty wi th fl ushi ng oi l ,
l i ght engi ne oi l or l i nt free cl oth.
NOTE: Do not use water, steam, kerosene or gaso-
line for cleaning.
DISASSEMBLY
(1) Remove pi ni on shaft.
(2) Rotate di fferenti al si de gears and remove di f-
ferenti al pi ni ons and thrust washers (Fi g. 45).
(3) Remove di fferenti al si de gears and thrust
washers.
ASSEMBLY
(1) Lubri cate al l di fferenti al components wi th
hypoi d gear l ubri cant.
(2) I nstal l di fferenti al si de gears and thrust wash-
ers.
(3) I nstal l di fferenti al pi ni on gears and thrust
washers.
(4) I nstal l the pi ni on mate shaft.
(5) Al i gn hol e i n the pi ni on mate shaft wi th the
hol e i n the di fferenti al case and i nstal l pi ni on mate
shaft l ock screw fi nger ti ght.
Fig. 42 DIAL INDICATOR LOCATION
1 - CLAMP
2 - DIAL INDICATOR
3 - LEVER ADAPTER
4 - SPREADER
5 - PILOT STUD
Fig. 43 SPREAD DIFFERENTIAL HOUSING
1 - DIAL INDICATOR
2 - SPREADER
Fig. 44 DIFFERENTIAL CASE REMOVAL
1 - DIFFERENTIAL HOUSING
2 - DIFFERENTIAL CASE
3 - BEARING CUPS
3 - 106 REAR AXLE - 194RBI TJ
DIFFERENTIAL (Continued)
INSTALLATION
NOTE: If replacement differential bearings or differ-
ential case are being installed, differential side
bearing shim requirements may change. Refer
Adjustments (Differential Bearing Preload and Gear
Backlash) to determine the proper shim selection.
(1) Posi ti on Spreader W-129-B and adapters from
Adapter set 6987, wi th the tool dowel pi ns seated i n
the l ocati ng hol es (Fi g. 46). I nstal l hol d-down cl amps
and ti ghten turnbuckl e fi nger-ti ght.
(2) I nstal l Pi l ot Stud C-3288-B at the l eft si de of
the di fferenti al housi ng. Attach Di al I ndi cator C-3339
to pi l ot stud. Load the i ndi cator pl unger agai nst the
opposi te si de of the housi ng and zero the i ndi cator.
CAUTION: Never spread over 0.38 mm (0.015 in).
Failure to heed caution may result in damage.
(3) Spread the housi ng enough to i nstal l the case
i n the housi ng. Measure the di stance wi th the di al
i ndi cator.
(4) Remove the di al i ndi cator.
(5) I nstal l di fferenti al case i n the housi ng. Ensure
that the di fferenti al beari ng cups remai n i n posi ti on
on the di fferenti al beari ngs. Tap the di fferenti al case
to ensure the beari ngs cups are seated i n the hous-
i ng.
(6) I nstal l beari ng caps i n thei r ori gi nal l ocati ons
(Fi g. 47).
(7) Loosel y i nstal l di fferenti al beari ng cap bol ts.
(8) Remove axl e housi ng spreader.
(9) Ti ghten beari ng cap bol ts to 77 N·m (57 ft.
l bs.).
(10) I nstal l axl e shafts.
(11) I nstal l cover and i denti fi cati on tag.
Fig. 45 DIFFERENTIAL GEARS
1 - THRUST WASHER
2 - SIDE GEAR
3 - DIFFERENTIAL PINION
Fig. 46 SPREADER LOCATION
1 - DIFFERENTIAL HOUSING
2 - DOWEL
3 - SAFETY HOLD DOWN
4 - SPREADER
5 - TURNBUCKLE
Fig. 47 BEARING CAP REFERENCE
1 - REFERENCE LETTERS
2 - REFERENCE LETTERS
TJ REAR AXLE - 194RBI 3 - 107
DIFFERENTIAL (Continued)
DIFFERENTIAL - TRAC-LOK
DESCRIPTION
The Trac-Lok௡ di fferenti al has a one-pi ece di fferen-
ti al case, and si mi l ar i nternal components as a stan-
dard di fferenti al , pl us two cl utch di sc packs.
Di fferenti al beari ng prel oad and ri ng gear backl ash
are adjusted wi th shi ms l ocated between the di ffer-
enti al case beari ng cups and housi ng. Pi ni on beari ng
prel oad i s set and mai ntai ned by the use of a col l aps-
i bl e spacer.
OPERATION
Thi s di fferenti al s cl utches are engaged by two con-
current forces. The fi rst bei ng the prel oad force
exerted through Bel l evi l l e spri ng washers wi thi n the
cl utch packs. The second i s the separati ng forces gen-
erated by the si de gears as torque i s appl i ed through
the ri ng gear (Fi g. 48).
Thi s desi gn provi des the di fferenti al acti on needed
for turni ng corners and for dri vi ng strai ght ahead
duri ng peri ods of unequal tracti on. When one wheel
l ooses tracti on, the cl utch packs transfer addi ti onal
torque to the wheel havi ng the most tracti on. Thi s
di fferenti al resi st wheel spi n on bumpy roads and
provi de more pul l i ng power when one wheel l ooses
tracti on. Pul l i ng power i s provi ded conti nuousl y unti l
both wheel s l oose tracti on. I f both wheel s sl i p due to
unequal tracti on, Trac-l ok௡ operati on i s normal . I n
extreme cases of di fferences of tracti on, the wheel
wi th the l east tracti on may spi n.
DIAGNOSIS AND TESTING
The most common probl em i s a chatter noi se when
turni ng corners. Before removi ng the uni t for repai r,
drai n, fl ush and refi l l the axl e wi th the speci fi ed
l ubri cant. A contai ner of Mopar Trac-l ok௡ Lubri cant
(fri cti on modi fi er) shoul d be added after repai r ser-
vi ce or duri ng a l ubri cant change.
After changi ng the l ubri cant, dri ve the vehi cl e and
make 10 to 12 sl ow, fi gure-ei ght turns. Thi s maneu-
ver wi l l pump l ubri cant through the cl utches. Thi s
wi l l correct the condi ti on i n most i nstances. I f chatter
persi sts, cl utch damage coul d have occurred.
DIFFERENTIAL TEST
The di fferenti al can be tested wi thout removi ng the
di fferenti al case by measuri ng rotati ng torque. Make
sure brakes are not draggi ng duri ng thi s measure-
ment.
(1) Pl ace bl ocks i n front and rear of both front
wheel s.
(2) Rai se one rear wheel unti l i t i s compl etel y off
the ground.
(3) Engi ne off, transmi ssi on i n neutral , and park-
i ng brake off.
(4) Remove wheel and bol t Speci al Tool 6790 or
equi val ent tool to studs.
Fig. 48 TRAC-LOK LIMITED SLIP DIFFERENTIAL
1 - CASE
2 - RING GEAR
3 - DRIVE PINION
4 - PINION GEAR
5 - MATE SHAFT
6 - CLUTCH PACK
7 - SIDE GEAR
8 - CLUTCH PACK
3 - 108 REAR AXLE - 194RBI TJ
(5) Use torque wrench on speci al tool to rotate
wheel and read rotati ng torque (Fi g. 49).
(6) I f rotati ng torque i s l ess than 41 N·m (30 ft.
l bs.) or more than 271 N·m (200 ft. l bs.) on ei ther
wheel the uni t shoul d be servi ced.
DISASSEMBLY
(1) Cl amp Hol di ng Fi xture 6965 i n vi se and set
di fferenti al case on fi xture (Fi g. 50).
(2) Remove pi ni on gear mate shaft l ock screw.
(3) Remove pi ni on gear mate shaft.
(4) Lubri cate and i nstal l di sc wi thout threaded
hol e from Trac-Lok௡ Tool Ki t 6960 i nto l ower si de
gear (Fi g. 51).
(5) I nstal l di sc wi th threaded hol e i n the upper
si de gear. Thread forci ng screw from Trac-Lok௡ Tool
Ki t 6960 through the upper di sc unti l i t comes i n
contact wi th l ower di sc.
Fig. 49 ROTATING TORQUE TEST
1 - SPECIAL TOOL WITH BOLT IN CENTER HOLE
2 - TORQUE WRENCH
Fig. 50 DIFFERENTIAL CASE FIXTURE
1 - FIXTURE
2 - VISE
3 - DIFFERENTIAL
Fig. 51 DISC PLATE
1 - LOWER SIDE GEAR
2 - DIFFERENTIAL CASE
3 - DISC
TJ REAR AXLE - 194RBI 3 - 109
DIFFERENTIAL - TRAC-LOK (Continued)
(6) I nsert a screw dri ver i n sl ot of upper di sc (Fi g.
52) to prevent di sc from turni ng.
(7) Ti ghten forci ng screw to 122 N·m (90 ft. l bs.)
maxi mum to compress Bel l evi l l e spri ngs i n cl utch
packs (Fi g. 53).
(8) Wi th a feel er gauge remove thrust washers
from behi nd the pi ni on gears (Fi g. 54).
(9) I nsert turni ng bar from tool ki t i nto the pi ni on
mate shaft hol e i n the case (Fi g. 55).
(10) Loosen forci ng screw i n smal l i ncrements
unti l cl utch pack tensi on i s rel i eved and the di fferen-
ti al case can be rotated wi th turni ng bar.
(11) Rotate di fferenti al case unti l pi ni on gears can
be removed.
(12) Remove pi ni on gears from di fferenti al case.
(13) Remove forci ng screw and di scs.
(14) Remove top si de gear, cl utch pack retai ners
and cl utch pack (Fi g. 56).
NOTE: Keep plates in order during removal.
(15) Remove di fferenti al case from the fi xture.
(16) Remove si de gear, cl utch pack retai ner and
cl utch pack.
NOTE: Keep plates in order during removal.
ASSEMBLY
NOTE: New 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.
Fig. 52 THREAD ADAPTER DISC
1 - SOCKET
2 - SLOT IN DISC
3 - SCREWDRIVER
4 - LOWER DISC
5 - FORCING SCREW
6 - UPPER DISC
Fig. 53 TIGHTEN FORCING SCREW
1 - TORQUE WRENCH
2 - FORCING SCREW
3 - DIFFERENTIAL CASE
Fig. 54 PINION GEAR THRUST WASHER
1 - THRUST WASHER
2 - FEELER GAUGE
3 - 110 REAR AXLE - 194RBI TJ
DIFFERENTIAL - TRAC-LOK (Continued)
(1) Assembl e cl utch di scs i nto packs and secure
di sc packs wi th retai ni ng cl i ps (Fi g. 57).
(2) I nstal l assembl ed cl utch di sc packs on si de
gear hubs.
(3) I nstal l cl utch pack and l ower si de gear i n di f-
ferenti al case (Fi g. 58).
NOTE: Verify clutch pack retaining clips are in posi-
tion and seated in case pockets.
Fig. 55 TURNING BAR
1 - PINION GEARS
2 - TURNING BAR
Fig. 56 SIDE GEAR & CLUTCH DISC
1 - DIFFERENTIAL CASE
2 - RETAINER
3 - SIDE GEAR AND CLUTCH DISC PACK
Fig. 57 CLUTCH DISC PACK
1 - CLUTCH PACK
2 - RETAINER
3 - SIDE GEAR
4 - RETAINER
Fig. 58 CLUTCH PACK AND LOWER SIDE GEAR
1 - DIFFERENTIAL CASE
2 - LOWER SIDE GEAR AND CLUTCH PACK
TJ REAR AXLE - 194RBI 3 - 111
DIFFERENTIAL - TRAC-LOK (Continued)
(4) Lubri cated and i nstal l di sc wi thout the hol e
from Trac-Lok௡ Tool Ki t 6960 i nto l ower si de gear.
(5) I nstal l upper si de gear and cl utch di sc pack
(Fi g. 59).
NOTE: Verify clutch pack retaining clips are in posi-
tion and seated in case pockets.
(6) Lubri cate and i nstal l di sc wi th threaded hol e
i nto top si de gear.
(7) Thread forci ng screw from tool ki t through the
top di sc and unti l screw sl i ghtl y compress cl utch di sc.
(8) Pl ace pi ni on gears i n posi ti on i n si de gears and
veri fy pi ni on mate shaft hol e i s al i gned.
(9) Rotate case wi th turni ng bar unti l pi ni on mate
shaft hol es i n pi ni on gears al i gn wi th hol es i n case.
NOTE: It may be necessary to slightly tighten the
forcing screw in order to install the pinion gears.
(10) Ti ghten forci ng screw to 122 N·m (90 ft. l bs.)
maxi mum to compress the Bel l evi l l e spri ngs.
(11) Lubri cate and i nstal l thrust washers behi nd
pi ni on gears and al i gn washers wi th a smal l screw
dri ver. I nsert mate shaft i nto each pi ni on gear to ver-
i fy al i gnment.
(12) Remove forci ng screw and di scs.
(13) I nstal l pi ni on gear mate shaft and al i gn hol es
i n shaft and case.
(14) I nstal l pi ni on mate shaft l ock screw fi nger
ti ght to hol d shaft duri ng di fferenti al i nstal l ati on.
(15) Lubri cate al l di fferenti al components wi th
hypoi d gear l ubri cant.
DIFFERENTIAL CASE
BEARINGS
REMOVAL
(1) Remove di fferenti al from housi ng.
(2) Remove beari ngs from di fferenti al case wi th
Pul l er/Press C-293-PA , Adapters C-293-39 and Pl ug
SP-3289 (Fi g. 60).
Fig. 59 CLUTCH PACK AND UPPER SIDE GEAR
1 - SIDE GEAR AND CLUTCH PACK
2 - DIFFERENTIAL CASE
3 - LOWER DISC
Fig. 60 BEARING REMOVAL
1 - ADAPTERS
2 - BEARING
3 - DIFFERENTIAL
4 - PLUG
5 - PULLER
3 - 112 REAR AXLE - 194RBI TJ
DIFFERENTIAL - TRAC-LOK (Continued)
INSTALLATION
(1) I nstal l di fferenti al si de beari ngs wi th I nstal l er
C-3716-A wi th Handl e C-4171 (Fi g. 61).
(2) I nstal l di fferenti al i n the housi ng.
PINION GEAR/RING GEAR
REMOVAL
NOTE: The ring and pinion gears are serviced in a
matched set. Never replace one gear without replac-
ing the other gear.
(1) Remove di fferenti al from housi ng.
(2) Pl ace di fferenti al case i n a vi se wi th soft metal
jaw.
(3) Remove ri ng gear bol ts from the di fferenti al
case.
(4) Dri ve ri ng gear off the di fferenti al case wi th a
dead-bl ow hammer (Fi g. 62).
(5) Hol d pi ni on yoke wi th Wrench 6958 and
remove pi ni on yoke nut and washer.
(6) Remove pi ni on yoke from pi ni on shaft wi th
Remover C-452 and Wrench C-3281 (Fi g. 63).
Fig. 61 DIFFERENTIAL CASE BEARINGS
1 - HANDLE
2 - DIFFERENTIAL
3 - BEARING
4 - INSTALLER
Fig. 62 RING GEAR
1 - CASE
2 - RING GEAR
3 - DEAD-BLOW HAMMER
Fig. 63 PINION YOKE REMOVER
1 - WRENCH
2 - YOKE
3 - PULLER
TJ REAR AXLE - 194RBI 3 - 113
DIFFERENTIAL CASE BEARINGS (Continued)
(7) Remove pi ni on gear from housi ng wi th a dead-
bl ow hammer (Fi g. 64).
(8) Remove pi ni on shaft seal wi th a pry tool or a
sl i de hammer mounted screw.
(9) Remove oi l sl i nger, i f equi pped, and front pi n-
i on beari ng.
(10) Remove front pi ni on beari ng cup wi th
Remover C-4345 and Handl e C-4171 (Fi g. 65).
(11) Remove rear beari ng cup from housi ng (Fi g.
66) wi th Remover D-149 and Handl e C-4171.
(12) Remove col l apsi bl e prel oad spacer (Fi g. 67).
Fig. 64 REMOVE PINION GEAR
1 - DEAD-BLOW HAMMER
Fig. 65 FRONT PINION BEARING CUP
1 - REMOVER
2 - HANDLE
Fig. 66 REAR PINION BEARING CUP
1 - DRIVER
2 - HANDLE
Fig. 67 COLLAPSIBLE SPACER
1 - COLLAPSIBLE SPACER
2 - SHOULDER
3 - PINION GEAR
4 - SHIM
5 - REAR BEARING
3 - 114 REAR AXLE - 194RBI TJ
PINION GEAR/RING GEAR (Continued)
(13) Remove rear beari ng from the pi ni on shaft
wi th Pul l er/Press C-293-PA and Adapters C-293-40
(Fi g. 68).
(14) Remove depth shi ms from the pi ni on shaft
and record the shi ms thi ckness.
INSTALLATION
NOTE: A pinion depth shim/oil slinger is placed
between the rear pinion bearing cone and the pin-
ion head to achieve proper ring gear and pinion
mesh. If ring gear and pinion are reused, the pinion
depth shim/oil slinger should not require replace-
ment. Refer to Adjustment (Pinion Gear Depth) to
select the proper thickness shim/oil slinger if ring
and pinion gears are replaced.
(1) Appl y Mopar Door Ease or equi val ent l ubri cant
to outsi de surface of beari ng cups.
(2) I nstal l pi ni on rear beari ng cup wi th I nstal l er
D-146 and Dri ver Handl e C-4171 (Fi g. 69) and veri fy
cup i s seated.
(3) I nstal l pi ni on front beari ng cup wi th I nstal l er
D-130 and Handl e C-4171 (Fi g. 70) and veri fy cup i s
seated.
(4) I nstal l pi ni on front beari ng and shi m.
Fig. 68 REAR PINION BEARING
1 - PULLER
2 - VISE
3 - ADAPTERS
4 - DRIVE PINION GEAR SHAFT
Fig. 69 REAR PINION BEARING CUP
1 - INSTALLER
2 - HANDLE
Fig. 70 FRONT PINION BEARING CUP
1 - INSTALLER
2 - HANDLE
TJ REAR AXLE - 194RBI 3 - 115
PINION GEAR/RING GEAR (Continued)
(5) Appl y a l i ght coati ng of gear l ubri cant on the
l i p of pi ni on seal and i nstal l seal wi th an appropri ate
i nstal l er (Fi g. 71).
(6) I nstal l depth shi m on the pi ni on gear.
(7) I nstal l rear beari ng and shi m on the pi ni on
gear wi th I nstal l er W-262 and a press (Fi g. 72).
(8) I nstal l a new col l apsi bl e prel oad spacer on pi n-
i on shaft and i nstal l pi ni on gear i n the housi ng (Fi g.
73).
(9) I nstal l yoke wi th I nstal l er Screw 8112, Cup
8109 and Wrench 6958 (Fi g. 74).
Fig. 71 PINION SEAL INSTALLER
1 - HANDLE
2 - INSTALLER
Fig. 72 REAR PINION BEARING
1 - PRESS
2 - INSTALLER
3 - DRIVE PINION GEAR
4 - REAR PINION BEARING
Fig. 73 COLLAPSIBLE SPACER
1 - COLLAPSIBLE SPACER
2 - SHOULDER
3 - PINION GEAR
4 - SHIM
5 - REAR BEARING
Fig. 74 PINION YOKE INSTALLER
1 - INSTALLER
2 - PINION YOKE
3 - SPANNER WRENCH
3 - 116 REAR AXLE - 194RBI TJ
PINION GEAR/RING GEAR (Continued)
(10) I nstal l yoke washer and a new nut on the
pi ni on gear and ti ghten the pi ni on nut unti l there i s
zero beari ng end-pl ay.
(11) Ti ghten the nut to 271 N·m (200 ft. l bs.).
CAUTION: Never loosen pinion gear nut to decrease
pinion gear bearing rotating torque and never
exceed specified preload torque. Failure to heed
caution may result in damage.
(12) Usi ng Spanner Wrench 6958 and a torque
wrench set at 475 N·m (350 ft. l bs.), (Fi g. 75) sl owl y
ti ghten the nut i n 6.8 N·m (5 ft. l bs.) i ncrements
unti l the rotati ng torque i s achi eved. Measure the
rotati ng torque frequentl y to avoi d over crushi ng the
col l apsi bl e spacer (Fi g. 76).
CAUTION: If more than 475 N·m (350 ft. lbs.) torque
is required to crush the collapsible spacer, the
spacer is defective and must be replaced. Failure to
heed caution may result in damage.
(13) Check beari ng rotati ng torque wi th a i nch
pound torque wrench (Fi g. 76). The pi ni on gear rotat-
i ng torque shoul d be:
• Ori gi nal Beari ngs: 1 to 2 N·m (10 to 20 i n. l bs.).
• New Beari ngs: 2 to 4 N·m (20 to 35 i n. l bs.).
(14) I nvert the di fferenti al case and start two ri ng
gear bol ts. Thi s wi l l provi de case-to-ri ng gear bol t
hol e al i gnment.
(15) I nvert the di fferenti al case i n the vi se.
(16) I nstal l new ri ng gear bol ts and al ternatel y
ti ghten to 136 N·m (100 ft. l bs.) (Fi g. 77).
CAUTION: Do not reuse ring gear bolts, the bolts
can fracture causing extensive damage. Failure to
heed caution may result in damage.
(17) I nstal l di fferenti al i n axl e housi ng and veri fy
gear mesh and contact pattern. Refer to Adjustments
(Gear Contact Pattern) for procedure.
Fig. 75 PINION YOKE WRENCH
1 - PINION YOKE
2 - SPANNER WRENCH
3 - PIPE
Fig. 76 PINION ROTATING TORQUE
1 - TORQUE WRENCH
2 - PINION YOKE
Fig. 77 RING GEAR BOLTS
1 - TORQUE WRENCH
2 - RING GEAR BOLT
3 - RING GEAR
4 - CASE
TJ REAR AXLE - 194RBI 3 - 117
PINION GEAR/RING GEAR (Continued)
REAR AXLE - 216RBI
TABLE OF CONTENTS
page page
REAR AXLE - 216RBI
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . 118
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 122
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . 123
SPECIFICATIONS
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . 131
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . 131
AXLE SHAFTS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 134
AXLE BEARINGS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 136
PINION SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 137
DIFFERENTIAL COVER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 138
DIFFERENTIAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 140
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 141
DIFFERENTIAL -TRAC-LOK
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 141
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 141
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . 142
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 142
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
DIFFERENTIAL - TRU-LOK
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 146
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 146
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . 146
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 148
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 151
DIFFERENTIAL - TRU-LOK PUMP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 153
DIFFERENTIAL CASE BEARINGS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 154
PINION GEAR/RING GEAR/TONE RING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 157
REAR AXLE - 216RBI
DIAGNOSIS AND TESTING
GEAR NOISE
Axl e gear noi se can be caused by i nsuffi ci ent l ubri -
cant, i ncorrect backl ash, i ncorrect pi ni on depth, tooth
contact, worn/damaged gears, or the carri er housi ng
not havi ng the proper offset and squareness.
Gear noi se usual l y happens at a speci fi c speed
range. The noi se can al so occur duri ng a speci fi c type
of dri vi ng condi ti on. These condi ti ons are accel era-
ti on, decel erati on, coast, or constant l oad.
When road testi ng, fi rst warm-up the axl e fl ui d by
dri vi ng the vehi cl e at l east 5 mi l es and then accel er-
ate the vehi cl e to the speed range where the noi se i s
the greatest. Shi ft out-of-gear and coast through the
peak-noi se range. I f the noi se stops or changes
greatl y:
• Check for i nsuffi ci ent l ubri cant.
• I ncorrect ri ng gear backl ash.
• Gear damage.
Di fferenti al si de gears and pi ni ons can be checked
by turni ng the vehi cl e. They usual l y do not cause
noi se duri ng strai ght-ahead dri vi ng when the gears
are unl oaded. The si de gears are l oaded duri ng vehi -
cl e turns. A worn pi ni on shaft can al so cause a snap-
pi ng or a knocki ng noi se.
BEARING NOISE
The axl e shaft, di fferenti al and pi ni on beari ngs can
al l produce noi se when worn or damaged. Beari ng
noi se can be ei ther a whi ni ng, or a growl i ng sound.
Pi ni on beari ngs have a constant-pi tch noi se. Thi s
noi se changes onl y wi th vehi cl e speed. Pi ni on beari ng
noi se wi l l be hi gher pi tched because i t rotates at a
faster rate. Dri ve the vehi cl e and l oad the di fferen-
ti al . I f beari ng noi se occurs, the rear pi ni on beari ng
i s the source of the noi se. I f the beari ng noi se i s
heard duri ng a coast, the front pi ni on beari ng i s the
source.
Worn or damaged di fferenti al beari ngs usual l y pro-
duce a l ow pi tch noi se. Di fferenti al beari ng noi se i s
si mi l ar to pi ni on beari ng noi se. The pi tch of di fferen-
ti al beari ng noi se i s al so constant and vari es onl y
wi th vehi cl e speed.
3 - 118 REAR AXLE - 216RBI TJ
Axl e shaft beari ngs produce noi se and vi brati on
when worn or damaged. The noi se general l y changes
when the beari ngs are l oaded. Road test the vehi cl e.
Turn the vehi cl e sharpl y to the l eft and to the ri ght.
Thi s wi l l l oad the beari ngs and change the noi se
l evel . Where axl e beari ng damage i s sl i ght, the noi se
i s usual l y not noti ceabl e at speeds above 30 mph.
LOW SPEED KNOCK
Low speed knock i s general l y caused by a worn
U-joi nt or by worn si de-gear thrust washers. A worn
pi ni on shaft bore wi l l al so cause l ow speed knock.
VIBRATION
Vi brati on at the rear of the vehi cl e i s usual l y
caused by a:
• Damaged dri ve shaft.
• Mi ssi ng dri ve shaft bal ance wei ght(s).
• Worn or out-of-bal ance wheel s.
• Loose wheel l ug nuts.
• Worn U-joi nt(s).
• Loose/broken spri ngs.
• Damaged axl e shaft beari ng(s).
• Loose pi ni on gear nut.
• Excessi ve pi ni on yoke run out.
• Bent axl e shaft(s).
Check for l oose or damaged front-end components
or engi ne/transmi ssi on mounts. These components
can contri bute to what appears to be a rearend vi bra-
ti on. Do not overl ook engi ne accessori es, brackets
and dri ve bel ts.
NOTE: All driveline components should be exam-
ined before starting any repair.
DRIVELINE SNAP
A snap or cl unk noi se when the vehi cl e i s shi fted
i nto gear (or the cl utch engaged), can be caused by:
• Hi gh engi ne i dl e speed.
• Transmi ssi on shi ft operati on.
• Loose engi ne/transmi ssi on/transfer case mounts.
• Worn U-joi nts.
• Loose spri ng mounts.
• Loose pi ni on gear nut and yoke.
• Excessi ve ri ng gear backl ash.
• Excessi ve si de gear to case cl earance.
The source of a snap or a cl unk noi se can be deter-
mi ned wi th the assi stance of a hel per. Rai se the vehi -
cl e on a hoi st wi th the wheel s free to rotate. I nstruct
the hel per to shi ft the transmi ssi on i nto gear. Li sten
for the noi se, a mechani cs stethoscope i s hel pful i n
i sol ati ng the source of a noi se.
DIAGNOSTIC CHART
Condition Possible Causes Correction
Wheel Noise 1. Wheel loose. 1. Tighten loose nuts.
2. Faulty, brinelled wheel bearing. 2. Replace bearing.
Axle Shaft Noise 1. Misaligned axle tube. 1. Inspect axle tube alignment.
Correct as necessary.
2. Bent or sprung axle shaft. 2. Inspect and correct as necessary.
Axle Shaft Broke 1. Misaligned axle tube. 1. Replace the broken shaft after
correcting tube mis-alignment.
2 Vehicle overloaded. 2. Replace broken shaft and avoid
excessive weight on vehicle.
3. Erratic clutch operation. 3. Replace broken shaft and avoid
or correct erratic clutch operation.
4. Grabbing clutch. 4. Replace broken shaft and inspect
and repair clutch as necessary.
TJ REAR AXLE - 216RBI 3 - 119
REAR AXLE - 216RBI (Continued)
Condition Possible Causes Correction
Differential Cracked 1. Improper adjustment of the
differential bearings.
1. Replace case and inspect gears
and bearings for further damage.
Set differential bearing pre-load
properly.
2. Excessive ring gear backlash. 2. Replace case and inspect gears
and bearings for further damage.
Set ring gear backlash properly.
3. Vehicle overloaded. 3. Replace case and inspect gears
and bearings for further damage.
Avoid excessive vehicle weight.
4. Erratic clutch operation. 4. Replace case and inspect gears
and bearings for further damage.
Avoid erratic use of clutch.
Differential Gears Scored 1. Insufficient lubrication. 1. Replace scored gears. Fill
differential with the correct fluid type
and quantity.
2. Improper grade of lubricant. 2. Replace scored gears. Fill
differential with the correct fluid type
and quantity.
3. Excessive spinning of one
wheel/tire.
3. Replace scored gears. Inspect all
gears, pinion bores, and shaft for
damage. Service as necessary.
Loss Of Lubricant 1. Lubricant level too high. 1. Drain lubricant to the correct
level.
2. Worn axle shaft seals. 2. Replace seals.
3. Cracked differential housing. 3. Repair as necessary.
4. Worn pinion seal. 4. Replace seal.
5. Worn/scored yoke. 5. Replace yoke and seal.
6. Axle cover not properly sealed. 6. Remove, clean, and re-seal
cover.
Axle Overheating 1. Lubricant level low. 1. Fill differential to correct level.
2. Improper grade of lubricant. 2. Fill differential with the correct
fluid type and quantity.
3. Bearing pre-loads too high. 3. Re-adjust bearing pre-loads.
4. Insufficient ring gear backlash. 4. Re-adjust ring gear backlash.
3 - 120 REAR AXLE - 216RBI TJ
REAR AXLE - 216RBI (Continued)
Condition Possible Causes Correction
Gear Teeth Broke 1. Overloading. 1. Replace gears. Examine other
gears and bearings for possible
damage.
2. Erratic clutch operation. 2. Replace gears and examine the
remaining parts for damage. Avoid
erratic clutch operation.
3. Ice-spotted pavement. 3. Replace gears and examine
remaining parts for damage.
4. Improper adjustments. 4. Replace gears and examine
remaining parts for damage. Ensure
ring gear backlash is correct.
Axle Noise 1. Insufficient lubricant. 1. Fill differential with the correct
fluid type and quantity.
2. Improper ring gear and pinion
adjustment.
2. Check ring gear and pinion
contact pattern. Adjust backlash or
pinion depth.
3. Unmatched ring gear and pinion. 3. Replace gears with a matched
ring gear and pinion.
4. Worn teeth on ring gear and/or
pinion.
4. Replace ring gear and pinion.
5. Loose pinion bearings. 5. Adjust pinion bearing pre-load.
6. Loose differential bearings. 6. Adjust differential bearing
pre-load.
7. Mis-aligned or sprung ring gear. 7. Measure ring gear run-out.
Replace components as necessary.
8. Loose differential bearing cap
bolts.
8. Inspect differential components
and replace as necessary. Ensure
that the bearing caps are torqued
tot he proper specification.
9. Housing not machined properly. 9. Replace housing.
TJ REAR AXLE - 216RBI 3 - 121
REAR AXLE - 216RBI (Continued)
REMOVAL
(1) Wi th vehi cl e i n neutral , posi ti on vehi cl e on
hoi st.
(2) Posi ti on a sui tabl e l i fti ng devi ce under the
axl e.
(3) Secure axl e to devi ce.
(4) Remove brake components.
(5) Remove brake hose at the axl e juncti on bl ock.
(6) Remove vent hose from axl e tube.
(7) I f equi pped wi th Locker di fferenti al di sconnect
pressure hose from di fferenti al housi ng and l ocker
i ndi cator connector (Fi g. 1).
(8) Remove propel l er shaft.
(9) Remove stabi l i zer bar l i nks from axl e.
(10) Remove shock absorbers from axl e (Fi g. 2).
(11) Remove track bar from axl e (Fi g. 3).
(12) Remove upper and l ower suspensi on arms
from the axl e brackets.
(13) Separate the axl e from the vehi cl e.
INSTALLATION
CAUTION: The weight of the vehicle must be sup-
ported by the springs before suspension arms and
track bar fasteners can be tightened. Failure to
heed caution may result in damage.
(1) Rai se axl e wi th l i fti ng devi ce and al i gn coi l
spri ngs.
(2) Posi ti on upper and l ower suspensi on arms on
the axl e brackets. I nstal l nuts and bol ts, do not
ti ghten bol ts at thi s ti me.
(3) I nstal l track bar and attachment bol ts, do not
ti ghten bol ts at thi s ti me.
(4) I nstal l shock absorbers and ti ghten nuts to
torque speci fi cati on.
(5) I nstal l stabi l i zer bar l i nks and ti ghten nuts to
torque speci fi cati on.
(6) I nstal l the wheel speed sensors, i f necessary.
(7) I nstal l brake components.
(8) I nstal l brake hose to the axl e juncti on bl ock
and bl eed brakes.
(9) I nstal l axl e vent hose.
(10) I f equi pped wi th Locker di fferenti al connect
pressure hose and Locker i ndi cator swi th.
(11) I nstal l propel l er shaft.
(12) Remove l i fti ng devi ce from axl e and l ower the
vehi cl e.
(13) Ti ghten upper and l ower control arms nuts to
torque speci fi cati on (Fi g. 4).
(14) Ti ghten track bar bol ts to torque speci fi cati on.
Fig. 1 INDICATOR SWITCH CONNECTOR
1 - CONNECTOR
2 - DIFFERENTIAL COVER
Fig. 2 SHOCK ABSORBER
1 - AXLE BRACKET
2 - SHOCK
Fig. 3 REAR TRACK BAR
1 - TRACK BAR
2 - FRAME BRACKET
3 - REAR AXLE
3 - 122 REAR AXLE - 216RBI TJ
REAR AXLE - 216RBI (Continued)
ADJUSTMENTS
RING AND PINION GEAR
Ri ng and pi ni on gears are suppl i ed as matched
sets onl y. The i denti fyi ng numbers for the ri ng and
pi ni on gear are etched i nto the face of each gear (Fi g.
5). A pl us (+) number, mi nus (–) number or zero (0) i s
etched i nto the face of the pi ni on gear. Thi s number
i s the amount (i n thousandths of an i nch) the depth
vari es from the standard depth setti ng of a pi ni on
etched wi th a (0). The standard depth provi des the
best teeth contact pattern. Refer to Backl ash and
Contact Pattern Anal ysi s Paragraph i n thi s secti on
for addi ti onal i nformati on.
Compensati on for pi ni on depth vari ance i s
achi eved wi th sel ect shi ms. The shi ms are pl aced
under the i nner pi ni on beari ng on the pi ni on shaft.
I f a new gear set i s bei ng i nstal l ed, note the depth
vari ance etched i nto both the ori gi nal and repl ace-
ment pi ni on gear. Add or subtract the thi ckness of
the ori gi nal depth shi ms to compensate for the di ffer-
ence i n the depth vari ances. Refer to the Depth Vari -
ance charts.
Note where Ol d and New Pi ni on Marki ng col umns
i ntersect. The i ntersecti ng fi gure represents pl us or
mi nus the amount needed.
Note the etched number on the face of the dri ve
pi ni on gear (–1, –2, 0, +1, +2, etc.). The numbers rep-
resent thousands of an i nch devi ati on from the stan-
dard. I f the number i s negati ve, add that val ue to the
requi red thi ckness of the depth shi m(s). I f the num-
ber i s posi ti ve, subtract that val ue from the thi ckness
of the depth shi m(s). I f the number i s 0 no change i s
necessary. Refer to the Pi ni on Gear Depth Vari ance
Chart.
Fig. 4 UPPER AND LOWER SUSPENSION ARMS
1 - UPPER SUSPENSION ARM
2 - REAR AXLE
3 - LOWER SUSPENSION ARM
Fig. 5 PINION GEAR ID NUMBERS
1 - PRODUCTION NUMBERS
2 - DRIVE PINION GEAR DEPTH VARIANCE
3 - GEARS MATCHING NUMBER
TJ REAR AXLE - 216RBI 3 - 123
REAR AXLE - 216RBI (Continued)
PINION GEAR DEPTH VARIANCE
Original Pinion
Gear Depth
Variance
Replacement Pinion Gear Depth Variance
Ϫ4 Ϫ3 Ϫ2 Ϫ1 0 +1 +2 +3 +4
+4 +0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0
+3 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 Ϫ0.001
+2 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 Ϫ0.001 Ϫ0.002
+1 +0.005 +0.004 +0.003 +0.002 +0.001 0 Ϫ0.001 Ϫ0.002 Ϫ0.003
0 +0.004 +0.003 +0.002 +0.001 0 Ϫ0.001 Ϫ0.002 Ϫ0.003 Ϫ0.004
Ϫ1 +0.003 +0.002 +0.001 0 Ϫ0.001 Ϫ0.002 Ϫ0.003 Ϫ0.004 Ϫ0.005
Ϫ2 +0.002 +0.001 0 Ϫ0.001 Ϫ0.002 Ϫ0.003 Ϫ0.004 Ϫ0.005 Ϫ0.006
Ϫ3 +0.001 0 Ϫ0.001 Ϫ0.002 Ϫ0.003 Ϫ0.004 Ϫ0.005 Ϫ0.006 Ϫ0.007
Ϫ4 0 Ϫ0.001 Ϫ0.002 Ϫ0.003 Ϫ0.004 Ϫ0.005 Ϫ0.006 Ϫ0.007 Ϫ0.008
PINION DEPTH MEASUREMENT AND ADJUSTMENT
Measurements are taken wi th pi ni on cups and pi n-
i on beari ngs i nstal l ed i n housi ng. Take measure-
ments wi th Pi ni on Gauge Set 6730 and Di al
I ndi cator C-3339 (Fi g. 6).
(1) Assembl e Pi ni on Hei ght Bl ock 6739, Pi ni on
Bl ock 6734 and rear pi ni on beari ng onto Screw 6741
(Fi g. 6).
(2) I nsert assembl ed hei ght gauge components,
rear beari ng and screw i nto axl e housi ng through
pi ni on beari ng cups (Fi g. 7).
(3) I nstal l front pi ni on beari ng and Cone 6740
hand ti ght.
Fig. 6 PINION DEPTH GAUGE TOOLS
1 - DIAL INDICATOR
2 - ARBOR
3 - PINION HEIGHT BLOCK
4 - CONE
5 - SCREW
6 - PINION BLOCK
7 - SCOOTER BLOCK
8 - ARBOR DISC
Fig. 7 PINION HEIGHT BLOCK
1 - PINION BLOCK
2 - PINION HEIGHT BLOCK
3 - 124 REAR AXLE - 216RBI TJ
REAR AXLE - 216RBI (Continued)
(4) Pl ace Arbor Di sc 6732 on Arbor D-115-3 i n posi -
ti on i n the housi ng si de beari ng cradl es (Fi g. 8).
I nstal l di fferenti al beari ng caps on Arbor Di scs and
ti ghten cap bol ts to 41 N·m (30 ft. l bs.).
NOTE: Arbor Discs 6732 have different step diame-
ters to fit other axle sizes. Pick correct size step for
axle being serviced.
(5) Assembl e Di al I ndi cator C-3339 i nto Scooter
Bl ock D-115-2 and secure set screw.
(6) Pl ace Scooter Bl ock/Di al I ndi cator i n posi ti on
i n axl e housi ng so di al probe and scooter bl ock are
fl ush agai nst the rearward surface of the pi ni on
hei ght bl ock. Hol d scooter bl ock i n pl ace and zero the
di al i ndi cator face to the poi nter. Ti ghten di al i ndi ca-
tor face l ock screw.
(7) Sl owl y sl i de the Scooter Bl ock/Di al I ndi cator
across the pi ni on hei ght bl ock over to the arbor bar
(Fi g. 9). Move the Scooter Bl ock/Di al I ndi cator to the
crest of the arbor bar and record the hi ghest readi ng.
(8) Sel ect a shi m equal to the thi ckest di al i ndi ca-
tor readi ng pl us or mi nus the dri ve pi ni on gear depth
vari ance number etched i n the face of the pi ni on gear
(Fi g. 5).
(9) Remove the pi ni on depth gauge components
from the axl e housi ng.
PRELOAD SHIM SELECTION
Di fferenti al si de beari ng prel oad and gear backl ash
i s achi eved by sel ecti ve shi ms i nserted between the
beari ng cups and the housi ng. The proper shi m
thi ckness can be determi ned usi ng sl i p-fi t dummy
beari ngs D-345 i n pl ace of the di fferenti al si de bear-
i ngs and a di al i ndi cator C-3339. Before proceedi ng
wi th the di fferenti al beari ng prel oad and gear back-
l ash measurements, measure the pi ni on gear depth
and prepare the pi ni on gear for i nstal l ati on. Estab-
l i shi ng proper pi ni on gear depth i s essenti al to estab-
l i shi ng gear backl ash and tooth contact patterns.
After the overal l shi m thi ckness to take up di fferen-
ti al si de pl ay i s measured, the pi ni on gear i s
i nstal l ed, and the gear backl ash shi m thi ckness i s
measured. The overal l shi m thi ckness i s the total of
the di al i ndi cator readi ng and the prel oad speci fi ca-
ti on added together. The gear backl ash measurement
determi nes the thi ckness of the shi m used on the
ri ng gear si de of the di fferenti al case. Subtract the
gear backl ash shi m thi ckness from the total overal l
shi m thi ckness and sel ect that amount for the pi ni on
gear si de of the di fferenti al (Fi g. 10).
Fig. 8 GAUGE TOOLS IN HOUSING
1 - ARBOR DISC
2 - PINION BLOCK
3 - ARBOR
4 - PINION HEIGHT BLOCK
Fig. 9 PINION DEPTH MEASUREMENT
1 - ARBOR
2 - SCOOTER BLOCK
3 - DIAL INDICATOR
Fig. 10 ADJUSTMENT SHIM LOCATIONS
1 - PINION DEPTH SHIM
2 - DIFFERENTIAL BEARING PRELOAD SHIM
3 - RING GEAR
4 - DIFFERENTIAL BEARING PRELOAD SHIM
TJ REAR AXLE - 216RBI 3 - 125
REAR AXLE - 216RBI (Continued)
NOTE: It is difficult to salvage the differential side
bearings during the removal procedure. Install
replacement bearings if necessary.
(1) Remove di fferenti al si de beari ngs from di ffer-
enti al case.
(2) Remove factory i nstal l ed shi ms from di fferen-
ti al case.
(3) I nstal l ri ng gear on di fferenti al case and
ti ghten bol ts to speci fi cati on.
(4) I nstal l dummy si de beari ngs D-345 on di fferen-
ti al case.
(5) I nstal l di fferenti al case i n axl e housi ng (Fi g.
11).
(6) I nstal l the marked beari ng caps i n thei r correct
posi ti ons. I nstal l and snug the bol ts (Fi g. 12).
(7) Usi ng a dead-bl ow hammer seat the di fferen-
ti al dummy beari ngs to each si de of the housi ng (Fi g.
13) and (Fi g. 14).
Fig. 11 DIFFERENTIAL DUMMY BEARINGS
1 - DUMMY BEARINGS
2 - DIFFERENTIAL HOUSING
3 - DIFFERENTIAL CASE
Fig. 12 BEARING CAP BOLTS
1 - BEARING CAP
2 - DIFFERENTIAL HOUSING
3 - DIFFERENTIAL CASE
Fig. 13 SEAT DUMMY BEARING PINION SIDE
1 - MALLET
2 - DIFFERENTIAL HOUSING
3 - DIFFERENTIAL CASE
Fig. 14 SEAT DUMMY BEARING RING GEAR SIDE
1 - DIFFERENTIAL HOUSING
2 - MALLET
3 - DIFFERENTIAL CASE
3 - 126 REAR AXLE - 216RBI TJ
REAR AXLE - 216RBI (Continued)
(8) Thread Pi l ot Stud C-3288-B i nto rear cover bol t
hol e bel ow ri ng gear (Fi g. 15).
(9) Attach a di al i ndi cator C-3339 to Pi l ot Stud
C-3288-B. Posi ti on the di al i ndi cator pl unger on a
fl at surface between the ri ng gear bol t heads (Fi g.
15).
(10) Push and hol d di fferenti al case to pi ni on gear
si de of the housi ng and zero di al i ndi cator (Fi g. 16).
(11) Push and hol d di fferenti al case to ri ng gear
si de of the housi ng and record di al i ndi cator readi ng
(Fi g. 17).
(12) Add di al i ndi cator readi ng to the starti ng
poi nt shi m thi ckness. Thi s i s the total shi m thi ckness
to achi eve zero di fferenti al end pl ay.
(13) Add 0.254 mm (0.010 i n.) to the zero end pl ay
total . Thi s new total represents the thi ckness of
shi ms to compress, or prel oad the new beari ngs when
the di fferenti al i s i nstal l ed.
(14) Rotate di al i ndi cator out of the way on pi l ot
stud.
(15) Remove di fferenti al case and dummy beari ngs
from the housi ng.
(16) I nstal l pi ni on gear i n the housi ng. I nstal l the
pi ni on yoke and establ i sh the correct pi ni on rotati ng
torque.
(17) I nstal l di fferenti al case and dummy beari ngs
D-345 i n the housi ng (wi thout shi ms), i nstal l beari ng
caps and ti ghten bol ts snug.
(18) Seat ri ng gear si de dummy beari ng (Fi g. 14).
(19) Posi ti on the di al i ndi cator pl unger on a fl at
surface between the ri ng gear bol t heads. (Fi g. 15).
(20) Push and hol d di fferenti al case toward the
pi ni on gear and zero di al i ndi cator (Fi g. 18).
(21) Push and hol d di fferenti al case to ri ng gear
si de of the housi ng and record di al i ndi cator readi ng
(Fi g. 19).
(22) Subtract 0.05 mm (0.002 i n.) from the di al
i ndi cator readi ng to compensate for backl ash between
ri ng and pi ni on gears. Thi s total i s the thi ckness
shi m requi red to achi eve proper backl ash.
(23) Subtract the backl ash shi m thi ckness from
the total prel oad shi m thi ckness. The remai nder i s
the shi m thi ckness requi red on the pi ni on si de of the
housi ng.
Fig. 15 DIFFERENTIAL SIDE PLAY MEASUREMENT
1 - DIFFERENTIAL CASE
2 - DIFFERENTIAL HOUSING
3 - PILOT STUD
4 - DIAL INDICATOR
Fig. 16 ZERO DIAL INDICATOR
1 - DIAL INDICATOR
2 - FORCE DIFFERENTIAL CASE TO PINION GEAR SIDE
3 - PILOT STUD
4 - EXTENSION
Fig. 17 RECORD DIAL INDICATOR READING
1 - READ DIAL INDICATOR
2 - DIFFERENTIAL CASE TO RING GEAR SIDE
3 - DIFFERENTIAL HOUSING
TJ REAR AXLE - 216RBI 3 - 127
REAR AXLE - 216RBI (Continued)
(24) Rotate di al i ndi cator out of the way on pi l ot
stud.
(25) Remove di fferenti al case and dummy beari ngs
from the housi ng.
(26) I nstal l si de beari ng shi ms on di fferenti al case
hubs.
(27) I nstal l new si de beari ng cones and cups on
di fferenti al case.
(28) I nstal l spreader W-129-B on the housi ng and
spread axl e openi ng enough to recei ve di fferenti al
case.
(29) I nstal l di fferenti al case i n the housi ng.
(30) I nstal l di fferenti al beari ng caps l oosel y.
(31) Remove spreader from the housi ng.
(32) Ti ghten beari ng caps bol ts to 108 N·m (80 ft.
l bs.).
(33) Rotate the di fferenti al case several ti mes to
seat the si de beari ngs.
(34) Posi ti on the i ndi cator pl unger agai nst a ri ng
gear tooth (Fi g. 20).
(35) Push and hol d ri ng gear upward whi l e not
al l owi ng the pi ni on gear to rotate and zero di al i ndi -
cator.
(36) Push and hol d ri ng gear downward whi l e not
al l owi ng the pi ni on gear to rotate. Di al i ndi cator
readi ng shoul d be between 0.12 mm - 0.20 mm (0.005
i n. - 0.008 i n.). I f backl ash i s not wi thi n speci fi cati ons
transfer the necessary amount of shi m thi ckness
from one si de of the housi ng to the other (Fi g. 21).
(37) Veri fy di fferenti al case and ri ng gear runout
by measuri ng ri ng to pi ni on gear backl ash at ei ght
l ocati ons around the ri ng gear. Readi ngs shoul d not
vary more than 0.05 mm (0.002 i n.). I f readi ngs vary
more than speci fi ed, the ri ng gear or the di fferenti al
case i s defecti ve.
After the proper backl ash i s achi eved, perform
Gear Contact Pattern Anal ysi s procedure.
GEAR CONTACT PATTERN
The ri ng gear and pi ni on teeth contact patterns
wi l l show i f the pi ni on depth i s correct i n the hous-
i ng. I t wi l l al so show i f the ri ng gear backl ash has
been adjusted correctl y. The backl ash can be adjusted
wi thi n speci fi cati ons to achi eve desi red tooth contact
patterns.
The TOP LAND of the gear tooth i s the top surface
of the tooth. The PROFI LE of the gear tooth i s the
depth of the tooth. The TOE of the gear i s the por-
ti on of the tooth surface at the end towards the cen-
ter. The HEEL of the gear i s the porti on of the tooth
Fig. 18 ZERO DIAL INDICATOR
1 - DIAL INDICATOR FACE
2 - DIFFERENTIAL CASE TO PINION GEAR SIDE
3 - PINION GEAR
4 - DIFFERENTIAL HOUSING
5 - DIFFERENTIAL CASE
Fig. 19 RECORD DIAL INDICATOR READING
1 - DIAL INDICATOR
2 - DIFFERENTIAL CASE TO RING GEAR SIDE
3 - PINION GEAR
4 - DIFFERENTIAL HOUSING
5 - DIFFERENTIAL CASE
Fig. 20 RING GEAR BACKLASH MEASUREMENT
1 - DIAL INDICATOR
3 - 128 REAR AXLE - 216RBI TJ
REAR AXLE - 216RBI (Continued)
at the outer-end. The ROOT of the gear tooth i s the
l owest porti on of the tooth (Fi g. 22).
NOTE: If the PROFILE across the tooth is the same
it is a 3 Axis cut gear. If the PROFILE across the
tooth is tapered it is a 2 Axis cut gear.
(1) Appl y a thi n coat of hydrated ferri c oxi de or
equi val ent to the dri ve and coast si de of the ri ng gear
teeth.
(2) Wrap, twi st, and hol d a shop towel around the
pi ni on yoke to i ncrease the turni ng resi stance of the
pi ni on. Thi s wi l l provi de a more di sti nct contact pat-
tern.
(3) Usi ng a boxed end wrench on a ri ng gear bol t,
Rotate the di fferenti al case one compl ete revol uti on
i n both di recti ons whi l e a l oad i s bei ng appl i ed from
shop towel .
The areas on the ri ng gear teeth wi th the greatest
degree of contact agai nst the pi ni on teeth wi l l squee-
gee the compound to the areas wi th the l east amount
of contact. Note and compare patterns on the ri ng
gear teeth to Gear Tooth Contact Patterns chart (Fi g.
23) and (Fi g. 24) and adjust pi ni on depth and gear
backl ash as necessary.
DIFFERENTIAL BEARING PRELOAD CHECK
The fi nal check on the di fferenti al assembl y before
i nstal l i ng the axl es i s torque to rotate pi ni on and di f-
ferenti al combi ned. Thi s wi l l veri fy the correct di ffer-
enti al beari ng prel oad.
Torque to rotate the di fferenti al and pi ni on shoul d
be the torque to rotate the pi ni on pl us 0.79-1.24 N·m
(7-11 i n. l bs.).
Fig. 21 BACKLASH SHIM ADJUSTMENT
Fig. 22 GEAR DESCRIPTION
1 - TOP LAND
2 - PROFILE
3 - TOE
4 - HEEL
5 - ROOT
TJ REAR AXLE - 216RBI 3 - 129
REAR AXLE - 216RBI (Continued)
Fig. 23 PATTERN INTERPRETATION (GEAR CUT 2 AXIS)
Fig. 24 PATTERN INTERPRETATION (GEAR CUT 3 AXIS)
3 - 130 REAR AXLE - 216RBI TJ
REAR AXLE - 216RBI (Continued)
SPECIFICATIONS
REAR AXLE
AXLE SPECIFICATIONS
DESCRIPTION SPECIFICATION
Axle Ratio 3.07, 3.73, 4.10
Ring Gear Backlash 0.12-0.20 mm (0.005-0.008 in.)
Pinion Bearing Preload - Original Bearings 1-2 N·m (10-20 in. lbs.)
Pinion Bearing Preload - New Bearings 2-4.5 N·m (20-40 in. lbs.)
TORQUE SPECIFICATIONS
DESCRIPTION N·m Ft. Lbs. In. Lbs.
Fill Hole Plug 34 25 -
Differential Cover Bolts 41 30 -
Bearing Cap Bolts 108 80 -
Ring Gear Bolts 136 100 -
Pinion Nut 217-271 160-200 -
SPECIAL TOOLS
PULLER C-293-PA
ADAPTERS C-293-18
ADAPTERS C-293-39
PILOT STUDS C-3288-B
DIAL INDICATOR C-3339
TJ REAR AXLE - 216RBI 3 - 131
REAR AXLE - 216RBI (Continued)
HANDLE C-4171
TRAC-LOK TOOLS C-4487
PULLER C-452
INSTALLER D-144
INSTALLER D-145
REMOVER D-147
REMOVER D-148
INSTALLER D-156
DUMMY BEARINGS D-345
PLUG SP-3289
3 - 132 REAR AXLE - 216RBI TJ
REAR AXLE - 216RBI (Continued)
SPREADER W-129-B
INSTALLER W-162-D
INSTALLER W-262
SPLITTER 1130
PULLER 6444
JAWS 6447
PINION DEPTH SET 6730
PULLER 6790
SPANNER WRENCH 6958
FIXTURE 6963
TJ REAR AXLE - 216RBI 3 - 133
REAR AXLE - 216RBI (Continued)
AXLE SHAFTS
REMOVAL
(1) Wi th vehi cl e i n neutral , posi ti on vehi cl e on
hoi st.
(2) Remove brake cal i per and rotor.
(3) Remove axl e retai ner pl ate nuts through access
hol e i n axl e fl ange (Fi g. 25).
(4) Pul l axl e shaft from the axl e. I f axl e wi l l not
come out use Sl i de Hammer 7420 and Adapter 6790.
INSTALLATION
WARNING: NEVER REUSE AXLE RETAINING BOLTS
AND NUTS. USED TORQUE NUT CAN LOOSEN.
FAILURE TO FOLLOW THESE INSTRUCTIONS MAY
RESULT IN PERSONAL INJURY.
(1) I nstal l axl e i nto axl e tube wi th the fl at area of
the retai ner pl ate upward (Fi g. 26).
(2) I nstal l new axl e retai ni ng bol ts.
(3) I nstal l new retai ni ng nuts and ti ghten to 61
N·m (45 ft. l bs.).
(4) I nstal l brake rotor and cal i per.
ADAPTER KIT 6987B
SLIDE HAMMER 7420
INSTALLER 7913-A
CUP 8109
Fig. 25 AXLE SHAFT BOLTS
1 - ACCESS HOLE
2 - AXLE FLANGE
Fig. 26 AXLE SHAFT
1 - RETAINER RING
2 - AXLE BEARING
3 - AXLE SEAL
3 - 134 REAR AXLE - 216RBI TJ
REAR AXLE - 216RBI (Continued)
AXLE BEARINGS
REMOVAL
(1) Remove axl e shaft from vehi cl e.
NOTE: It is normal that the axle bearing race is
loose in the axle tube.
(2) Dri l l a shal l ow hol e i nto soft steel axl e beari ng
retai ni ng ri ng wi th a 3/8 i n. dri l l bi t (Fi g. 27). Use a
dri l l depth stop to avoi d marki ng the axl e.
(3) Wi th a col d chi sel cut the retai ni ng ri ng across
dri l l ed hol e. (Fi g. 28)
(4) Sl i de retai ni ng ri ng from axl e shaft.
(5) Remove axl e beari ng from the shaft wi th, a
press and Spl i tter 1130 pl aced between the seal and
beari ng (Fi g. 29).
(6) Remove seal from axl e.
(7) Remove retai ni ng pl ate from axl e shaft.
Fig. 27 DRILL RETAINING RING
1 - 3/8 in. DIA. DRILL BIT
2 - AXLE
3 - RETAINING PLATE
4 - SOFT METAL RETAINING RING
Fig. 28 CUT RETAINING RING
1 - COLD CHISEL
2 - VISE
3 - RETAINING RING
4 - AXLE
Fig. 29 AXLE BEARING AND SEAL
1 - AXLE
2 - UNIT BEARING
3 - PRESS PLATES
4 - BLOCKS
5 - SPLITTER
TJ REAR AXLE - 216RBI 3 - 135
INSTALLATION
(1) Veri fy axl e shaft retai ni ng pl ate i s fl at wi th a
strai ght edge.
NOTE: Replace the retaining plate if warped.
(2) I nstal l retai ni ng pl ate on axl e (Fi g. 30).
(3) Appl y a coat of mul ti -purpose grease on seal i ng
surface of axl e seal .
(4) I nstal l seal on axl e wi th cavi ty away from
retai ni ng pl ate (Fi g. 30).
(5) Lubri cate beari ng wi th Mopar Wheel Beari ng
Grease, or equi val ent. Wi pe excess grease from out-
si de of beari ng.
(6) I nstal l beari ng on the axl e shaft wi th I nstal l er
7913 and a press (Fi g. 31).
NOTE: Install bearing with groove on the outer sur-
face toward the seal.
(7) Press soft metal retai ni ng ri ng onto axl e shaft
wi th I nstal l er 7913 and a press (Fi g. 32).
(8) I nstal l axl e i n vehi cl e.
PINION SEAL
REMOVAL
(1) Wi th vehi cl e i n neutral , posi ti on vehi cl e on
hoi st.
(2) Remove brake drums/cal i pers.
(3) Remove propel l er shaft.
(4) Rotate pi ni on gear three or four ti mes and ver-
i fy that pi ni on rotates smoothl y.
Fig. 30 AXLE BEARING AND SEAL COMPONENTS
1 - RETAINING RING
2 - SEAL
3 - AXLE
4 - RETAINING PLATE
5 - BEARING
Fig. 31 PRESS BEARING ON AXLE
1 - PRESS RAM
2 - INSTALLER
3 - UNIT BEARING
4 - SEAL
5 - RETAINING PLATE
6 - AXLE
Fig. 32 PRESS RETAINING RING ON AXLE
1 - PRESS RAM
2 - UNIT BEARING
3 - INSTALLER
4 - METAL RETAINING RING
5 - AXLE
3 - 136 REAR AXLE - 216RBI TJ
AXLE BEARINGS (Continued)
(5) Usi ng Spanner Wrench 6958 to hol d the pi ni on
yoke, remove the pi ni on nut and washer.
(6) Remove pi ni on yoke wi th Remover C-452 and
Fl ange Wrench C-3281 (Fi g. 33).
(7) Remove pi ni on shaft seal wi th a pry tool or
sl i de hammer mounted screw.
INSTALLATION
(1) Appl y a l i ght coati ng of gear l ubri cant on the
l i p of pi ni on seal . I nstal l seal wi th I nstal l er 8681
(Fi g. 34).
(2) I nstal l yoke on pi ni on gear wi th I nstal l er
W-162–D, Cup 8109 and Spanner Wrench 6958 (Fi g.
35).
(3) I nstal l pi ni on washer and a new nut on the
pi ni on gear and ti ghten the nut unti l there i s zero
beari ng end-pl ay.
(4) Hol d pi ni on yoke wi th Spanner Wrench 6958
(Fi g. 36) and ti ghten pi ni on nut to 217 to 271N·m
(160 to 200 ft. l bs.).
(5) I nstal l propel l er shaft.
(6) I nstal l brake drums/cal i pers.
Fig. 33 PINION YOKE REMOVER
1 - FLANGE WRENCH
2 - PINION YOKE
3 - REMOVER
Fig. 34 PINION SEAL INSTALLER
1 - HANDLE
2 - INSTALLER
Fig. 35 YOKE SPANNER WRENCH
1 - INSTALLER
2 - PINION YOKE
3 - SPANNER WRENCH
Fig. 36 YOKE SPANNER WRENCH
1 - PINION YOKE
2 - SPANNER WRENCH
3 - PIPE
TJ REAR AXLE - 216RBI 3 - 137
PINION SEAL (Continued)
DIFFERENTIAL COVER
REMOVAL
(1) Wi th vehi cl e i n neutral , posi ti on vehi cl e on
hoi st.
(2) Remove drai n pl ug.
(3) I f equi pped wi th Tru-Lok, di sconnect i ndi cator
swi tch harness and remove connector from di fferen-
ti al cover (Fi g. 37).
(4) Remove cover bol ts.
(5) Remove cover and drai n l ubri cant.
INSTALLATION
(1) Appl y a 6.35mm (1/4 i n.) bead of Mopar Si l i -
cone Rubber Seal ant or equi val ent to the housi ng
cover (Fi g. 38).
CAUTION: If housing cover is not installed within 3
to 5 minutes, the cover must be cleaned and new
RTV applied. Failure to heed caution may result in
damage.
(2) I nstal l cover, i denti fi cati on tag and i ndi cator
swi tch connector i f equi pped wi th Tru-Lok (Fi g. 39).
Ti ghten cover bol ts i n a cri ss-cross pattern to 41 N·m
(30 ft. l bs.).
(3) Connect i ndi cator swi tch harness i f equi pped
wi th Tru-Lok.
(4) Fi l l di fferenti al to speci fi cati ons.
(5) I nstal l fi l l pl ug and ti ghten to 34 N·m (25 ft.
l bs.).
Fig. 37 INDICATOR SWITCH CONNECTOR
1 - CONNECTOR
2 - DIFFERENTIAL COVER
Fig. 38 HOUSING COVER - TYPICAL
1 - SEALANT SURFACE
2 - SEALANT
3 - SEALANT THICKESS
Fig. 39 INDICATOR SWITCH CONNECTOR
1 - CONNECTOR
2 - DIFFERENTIAL COVER
3 - 138 REAR AXLE - 216RBI TJ
DIFFERENTIAL
REMOVAL
(1) Remove di fferenti al housi ng cover and drai n
fl ui d.
(2) Remove axl e shafts.
(3) Note the reference l etters stamped on the bear-
i ng caps and housi ng machi ned seal i ng surface (Fi g.
40).
(4) Loosen the di fferenti al beari ng cap bol ts.
(5) Posi ti on Spreader W-129-B wi th Adapter Ki t
6987B on di fferenti al l ocati ng hol es (Fi g. 41). I nstal l
hol d-down cl amps and ti ghten the turnbuckl e fi nger-
ti ght.
(6) I nstal l a Pi l ot Stud C-3288-B at the l eft si de of
the di fferenti al housi ng. Attach Di al I ndi cator C-3339
to pi l ot stud. Load i ndi cator pl unger agai nst the
opposi te si de of the housi ng (Fi g. 42) and zero the
i ndi cator.
Fig. 40 BEARING CAP REFERENCE
1 - REFERENCE LETTERS
2 - REFERENCE LETTERS
Fig. 41 SPREADER LOCATION
1 - DIFFERENTIAL HOUSING
2 - DOWEL
3 - SAFETY HOLD DOWN
4 - SPREADER
5 - TURNBUCKLE
Fig. 42 DIAL INDICATOR LOCATION
1 - CLAMP
2 - DIAL INDICATOR
3 - LEVER ADAPTER
4 - SPREADER
5 - PILOT STUD
TJ REAR AXLE - 216RBI 3 - 139
(7) Spread housi ng whi l e measuri ng the di stance
wi th the di al i ndi cator (Fi g. 43).
CAUTION: Never spread the housing over 0.38 mm
(0.015 in). Failure to heed caution may result in
damage.
(8) Remove di al i ndi cator.
(9) Hol d di fferenti al case i n posi ti on and remove
di fferenti al beari ng caps.
(10) Remove di fferenti al from housi ng and tag di f-
ferenti al beari ng cups to i ndi cate l ocati on (Fi g. 44).
(11) Remove spreader from housi ng.
(12) Cl ean housi ng cavi ty wi th fl ushi ng oi l , l i ght
engi ne oi l or l i nt free cl oth.
NOTE: Do not use water, steam, kerosene or gaso-
line for cleaning.
DISASSEMBLY
(1) Remove pi ni on shaft l ock rol l pi n wi th a ham-
mer and punch.
(2) Remove pi ni on shaft.
(3) Rotate di fferenti al si de gears and remove di f-
ferenti al pi ni ons and thrust washers (Fi g. 45).
(4) Remove di fferenti al si de gears and thrust
washers.
ASSEMBLY
(1) I nstal l di fferenti al si de gears and thrust wash-
ers.
(2) I nstal l di fferenti al pi ni on gears and thrust
washers.
(3) I nstal l pi ni on mate shaft.
(4) Al i gn hol e i n the pi ni on mate shaft wi th the
hol e i n the di fferenti al case and i nstal l pi ni on mate
shaft rol l pi n. Stake (peen) metal of case over pi n i n
two pl aces 180 degrees apart.
(5) Lubri cate al l di fferenti al components wi th
hypoi d gear l ubri cant.
Fig. 43 SPREAD DIFFERENTIAL HOUSING
1 - DIAL INDICATOR
2 - SPREADER
Fig. 44 DIFFERENTIAL CASE REMOVAL
1 - DIFFERENTIAL HOUSING
2 - DIFFERENTIAL CASE
3 - BEARING CUPS
Fig. 45 DIFFERENTIAL GEARS
1 - THRUST WASHER
2 - SIDE GEAR
3 - DIFFERENTIAL PINION
3 - 140 REAR AXLE - 216RBI TJ
DIFFERENTIAL (Continued)
INSTALLATION
NOTE: If replacement differential bearings or differ-
ential case are being installed, differential side
bearing shim requirements may change. Refer
Adjustments (Differential Bearing Preload and Gear
Backlash) to determine the proper shim selection.
(1) Posi ti on Spreader W-129-B and adapters from
Adapter set 6987, wi th the tool dowel pi ns seated i n
the l ocati ng hol es (Fi g. 46). I nstal l hol d-down cl amps
and ti ghten turnbuckl e fi nger-ti ght.
(2) I nstal l Pi l ot Stud C-3288-B at the l eft si de of
the di fferenti al housi ng. Attach Di al I ndi cator C-3339
to pi l ot stud. Load i ndi cator pl unger agai nst the
opposi te si de of the housi ng and zero the i ndi cator.
(3) Spread housi ng whi l e measuri ng the di stance
wi th the di al i ndi cator.
CAUTION: Never spread over 0.38 mm (0.015 in).
Failure to heed caution may result in damage.
(4) Remove di al i ndi cator.
(5) I nstal l di fferenti al case i n the housi ng. Tap di f-
ferenti al case to seat beari ngs cups i n the housi ng.
(6) I nstal l beari ng caps i n thei r ori gi nal l ocati ons
(Fi g. 47).
(7) Loosel y i nstal l di fferenti al beari ng cap bol ts.
(8) Remove axl e housi ng spreader.
(9) Ti ghten beari ng cap bol ts to 108 N·m (80 ft.
l bs.).
(10) I nstal l axl e shafts.
(11) I nstal l cover and i denti fi cati on tag.
DIFFERENTIAL -TRAC-LOK
DESCRIPTION
The Trac-Lok௡ di fferenti al has a one-pi ece di fferen-
ti al case, and si mi l ar i nternal components as a stan-
dard di fferenti al , pl us two cl utch di sc packs.
Di fferenti al beari ng prel oad and ri ng gear backl ash
are adjusted wi th shi ms l ocated between the di ffer-
enti al case beari ng cups and housi ng. Pi ni on beari ng
prel oad i s set and mai ntai ned by the use of a col l aps-
i bl e spacer.
OPERATION
Thi s di fferenti al s cl utches are engaged by two con-
current forces. The fi rst bei ng the prel oad force
exerted through Bel l evi l l e spri ng washers wi thi n the
cl utch packs. The second i s the separati ng forces gen-
erated by the si de gears as torque i s appl i ed through
the ri ng gear (Fi g. 48).
Thi s desi gn provi des the di fferenti al acti on needed
for turni ng corners and for dri vi ng strai ght ahead
duri ng peri ods of unequal tracti on. When one wheel
l ooses tracti on, the cl utch packs transfer addi ti onal
torque to the wheel havi ng the most tracti on. Thi s
di fferenti al resi st wheel spi n on bumpy roads and
provi de more pul l i ng power when one wheel l ooses
tracti on. Pul l i ng power i s provi ded conti nuousl y unti l
both wheel s l oose tracti on. I f both wheel s sl i p due to
unequal tracti on, Trac-l ok௡ operati on i s normal . I n
extreme cases of di fferences of tracti on, the wheel
wi th the l east tracti on may spi n.
Fig. 46 SPREADER LOCATION
1 - DIFFERENTIAL HOUSING
2 - DOWEL
3 - SAFETY HOLD DOWN
4 - SPREADER
5 - TURNBUCKLE
Fig. 47 BEARING CAP REFERENCE
1 - REFERENCE LETTERS
2 - REFERENCE LETTERS
TJ REAR AXLE - 216RBI 3 - 141
DIFFERENTIAL (Continued)
DIAGNOSIS AND TESTING
The most common probl em i s a chatter noi se when
turni ng corners. Before removi ng the uni t for repai r,
drai n, fl ush and refi l l the axl e wi th the speci fi ed
l ubri cant. A contai ner of Mopar Trac-l ok௡ Lubri cant
(fri cti on modi fi er) shoul d be added after repai r ser-
vi ce or duri ng a l ubri cant change.
After changi ng the l ubri cant, dri ve the vehi cl e and
make 10 to 12 sl ow, fi gure-ei ght turns. Thi s maneu-
ver wi l l pump l ubri cant through the cl utches. Thi s
wi l l correct the condi ti on i n most i nstances. I f the
chatter persi sts, cl utch damage coul d have occurred.
DIFFERENTIAL TEST
The di fferenti al can be tested wi thout removi ng the
di fferenti al case by measuri ng rotati ng torque. Make
sure brakes are not draggi ng duri ng thi s measure-
ment.
(1) Pl ace bl ocks i n front and rear of both front
wheel s.
(2) Rai se one rear wheel unti l i t i s compl etel y off
the ground.
(3) Engi ne off, transmi ssi on i n neutral , and park-
i ng brake off.
(4) Remove wheel and bol t Speci al Tool 6790 or
equi val ent tool to studs.
(5) Use torque wrench on speci al tool to rotate
wheel and read rotati ng torque (Fi g. 49).
(6) I f rotati ng torque i s l ess than 41 N·m (56 ft.
l bs.) or more than 271 N·m (200 ft. l bs.) on ei ther
wheel the uni t shoul d be servi ced.
DISASSEMBLY
(1) Cl amp si de gear Fi xture 6965 i n a vi se and set
di fferenti al case on the fi xture (Fi g. 50).
NOTE: The Trac-lokா differential can be serviced
with the ring gear installed unless the gear hangs
over the pinion shaft, then it must be removed.
(2) Remove pi ni on gear mate shaft rol l pi n wi th a
hammer and punch.
(3) Remove pi ni on gear mate shaft wi th a dri ft and
hammer.
(4) Lubri cate and i nstal l di sc wi thout threaded
hol e from Trac-l ok௡ Tool C-4487 i nto l ower si de gear
(Fi g. 51).
(5) Lubri cate and i nstal l di sc wi th threaded hol e
from Trac-l ok௡ Tool C-4487 i nto upper si de gear.
Thread forci ng screw from tool i nto threaded di sc
unti l i t becomes centered i n l ower di sc.
(6) Posi ti on a smal l screw dri ver i n sl ot of the
threaded di sc (Fi g. 52) to prevent adapter from turn-
i ng.
(7) Ti ghten forci ng screw to 122 N·m (90 ft. l bs.)
maxi mum to compress Bel l evi l l e spri ngs i n cl utch
packs (Fi g. 53).
Fig. 48 TRAC-LOK LIMITED SLIP DIFFERENTIAL
1 - CASE
2 - RING GEAR
3 - DRIVE PINION
4 - PINION GEAR
5 - MATE SHAFT
6 - CLUTCH PACK
7 - SIDE GEAR
8 - CLUTCH PACK
Fig. 49 ROTATING TORQUE TEST
1 - SPECIAL TOOL WITH BOLT IN CENTER HOLE
2 - TORQUE WRENCH
3 - 142 REAR AXLE - 216RBI TJ
DIFFERENTIAL -TRAC-LOK (Continued)
Fig. 50 DIFFERENTIAL CASE FIXTURE
1 - HOLDING FIXTURE
2 - VISE
3 - DIFFERENTIAL
Fig. 51 TRAC-LOK DISC
1 - LOWER SIDE GEAR
2 - DIFFERENTIAL CASE
3 - DISC
Fig. 52 TRAC-LOK TOOLS ASSEMBLY
1 - SOCKET
2 - SLOT IN DISC
3 - SCREWDRIVER
4 - STEP PLATE
5 - THREADED ROD
6 - DISC
Fig. 53 COMPRESS BELLEVILLE SPRING
1 - TORQUE WRENCH
2 - FORCING SCREW
3 - DIFFERENTIAL CASE
TJ REAR AXLE - 216RBI 3 - 143
DIFFERENTIAL -TRAC-LOK (Continued)
(8) Wi th a feel er gauge remove thrust washers
from behi nd the pi ni on gears (Fi g. 54).
(9) I nsert turni ng bar from tool i nto the pi ni on
mate shaft hol e i n the case (Fi g. 55).
(10) Loosen forci ng screw i n smal l i ncrements
unti l cl utch pack tensi on i s rel i eved and the di fferen-
ti al case can be turned usi ng turni ng bar.
(11) Rotate di fferenti al case unti l the pi ni on gears
can be removed.
(12) Remove pi ni on gears from di fferenti al case.
(13) Remove Forci ng Screw, Step Pl ate and
Threaded Adapter.
(14) Remove top si de gear, cl utch pack retai ner
and cl utch pack. Keep pl ates i n order duri ng removal
(Fi g. 56).
(15) Remove di fferenti al case from the Hol di ng
Fi xture. Remove si de gear, cl utch pack retai ner and
cl utch pack. Keep pl ates i n order duri ng removal .
ASSEMBLY
NOTE: New 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.
(1) Lubri cate components wi th gear l ubri cant.
(2) Assembl e cl utch di scs i nto packs and secure
di sc packs wi th retai ni ng cl i ps (Fi g. 57).
NOTE: Dished plate is position with the convex side
against the side gear.
(3) Posi ti on assembl ed cl utch di sc packs on the
si de gear hubs.
(4) I nstal l cl utch pack and si de gear i n the ri ng
gear si de of the di fferenti al case, wi th retai ni ng cl i ps
seated i n the case pockets (Fi g. 58).
(5) Posi ti on the di fferenti al case on the Hol di ng
Fi xture 6965.
Fig. 54 PINION GEAR THRUST WASHER
1 - THRUST WASHER
2 - FEELER GAUGE
Fig. 55 PINION GEARS
1 - PINION GEARS
2 - TURNING BAR
Fig. 56 SIDE GEARS AND CLUTCH DISCS
1 - DIFFERENTIAL CASE
2 - RETAINER
3 - SIDE GEAR AND CLUTCH DISC PACK
3 - 144 REAR AXLE - 216RBI TJ
DIFFERENTIAL -TRAC-LOK (Continued)
(6) Lubri cated and i nstal l di sc wi thout threaded
hol e from Trac-Lok௡ Tool C-4487 i nto l ower si de gear.
(7) I nstal l upper si de gear and cl utch di sc pack
wi th retai ni ng cl i ps seated i n the case pockets (Fi g.
59).
(8) Hol d assembl y i n posi ti on and i nstal l threaded
di sc from Trac-Lok௡ Tool C-4487 i nto top si de gear.
(9) I nstal l forci ng screw and ti ghten screw to
sl i ghtl y compress cl utch di sc.
(10) Pl ace pi ni on gears i n posi ti on i n si de gears
and veri fy that the pi ni on mate shaft hol e i s al i gned.
(11) Rotate case wi th turni ng bar C-4487-2 unti l
pi ni on mate shaft hol es i n pi ni on gears al i gn wi th
hol es i n case. I t may be necessary to sl i ghtl y ti ghten
the forci ng screw i n order to i nstal l the pi ni on gears.
(12) Ti ghten forci ng screw to 122 N·m (90 ft. l bs.)
maxi mum to compress the Bel l evi l l e spri ngs.
(13) Lubri cate and i nstal l thrust washers behi nd
pi ni on gears and al i gn washers wi th a smal l screw
dri ver. I nsert mate shaft i nto each pi ni on gear to ver-
i fy al i gnment.
(14) Remove Forci ng Screw, Step Pl ate and
Threaded Adapter.
(15) I nstal l pi ni on gear mate shaft and al i gn hol es
i n shaft and case.
(16) I nstal l pi ni on mate shaft rol l pi n. Stake (peen)
case over pi n i n two pl aces 180 degrees apart.
(17) Lubri cate al l di fferenti al components wi th
hypoi d gear l ubri cant.
Fig. 57 CLUTCH PACK
1 - DISCS
2 - DISHED PLATE
3 - RETAINER
4 - SIDE GEAR
5 - RETAINER
6 - PLATES
Fig. 58 CLUTCH PACK AND LOWER SIDE GEAR
1 - DIFFERENTIAL CASE
2 - SIDE GEAR AND CLUTCH PACK
Fig. 59 CLUTCH PACK AND UPPER SIDE GEAR
1 - SIDE GEAR AND CLUTCH PACK
2 - DIFFERENTIAL CASE
3 - DISC
TJ REAR AXLE - 216RBI 3 - 145
DIFFERENTIAL -TRAC-LOK (Continued)
DIFFERENTIAL - TRU-LOK
DESCRIPTION
The di fferenti al i s a l ocki ng di fferenti al , that pro-
vi des a posi ti ve mechani cal connecti on between the
ri ght and l eft axl e when engauged. The di fferenti al
uses a dog cl utch to connecti on the ri ght and l eft
axl e.
OPERATION
The Tru-l ok di fferenti al i s acti vated by the axl e
l ock swi tch l ocated on the dash panel . When the
swi tch i s acti vated, an ai r pump wi th a bui l t-i n pres-
sure regul ator sends 5 PSI of ai r pressure to a accua-
tor di aphragm i n the di fferenti al housi ng. The
di aphragm then engages a dog cl utch and a posi ti on
swi tch. The dog cl utch has one gear attached to the
di fferenti al case and another gear attached to a di f-
ferenti al si de gear. When the dog cl utch i s engaged
the ri ght and l eft wheel s turn at the same speed. The
posi ti on swi tch l i ghts a l amp on the dash to i ndi cate
the system has been engaged. The di fferenti al works
as standard di fferenti al when not engaged.
NOTE: The differential is serviced as an assembly,
the diaphragm and indicator switch are serviced
separately. The differential case must be removed
to service the diaphragm actuator and indicator
switch.
DIAGNOSIS AND TESTING
UNLOCKED
(1) Bl ock ti res opposi te the axl e to be tested to pre-
vent the vehi cl e from rol l i ng.
(2) Pl ace transfer case i n 4WD Low and automan-
ti c transmi ssi on i n Park (1st gear i f manual trans-
mi ssi on).
(3) Rai se both wheel s of the axl e to be tested off
the ground.
(4) Turn i gni ti on to the ON posi ti on and dash
swi tch to the OFF posi ti on.
(5) Rotate one ti re by hand. The other ti re shoul d
spi n i n the opposi te di recti on.
NOTE: If wheel cannot be rotated the differential
must be repaired/replaced.
LOCKED
(1) Bl ock ti res opposi te the axl e to be tested to pre-
vent the vehi cl e from rol l i ng.
(2) Pl ace transfer case i n 4WD Low and automan-
ti c transmi ssi on i n Park (1st gear i f manual trans-
mi ssi on).
(3) Rai se both wheel s of the axl e to be tested off
the ground.
(4) Turn i gni ti on to the ON posi ti on and dash
swi tch to the ON posi ti on.
(5) Try to rotate one ti re by hand. You shoul d not
be abl e to rotate the ti re.
NOTE: If wheel does rotated verify locker pump
operation. If the pump is fuctional the differential
must be repaired/replaced.
TRU-LOK INDICATOR SWITCH
(1) Turn i gni ti on swi tch off.
(2) Di sconnect i ndi cator swi tch harness (Fi g. 60)
from the di fferenti al housi ng.
(3) Measure el ectri cal conti nui ty across the swi tch
termi nal s. Ci rcui t shoul d be cl osed (zero resi stance).
NOTE: If circuit is not closed replace indicator
switch.
Fig. 60 INDICATOR SWITCH CONNECTOR
1 - CONNECTOR
2 - DIFFERENTIAL COVER
3 - 146 REAR AXLE - 216RBI TJ
TRU-LOK PUMPS
(1) Connect a pressure gauge to the rear pump.
(2) Pl ace transfer case i n 4WD Low and automati c
transmi ssi on i n Park (1st gear i f manual transmi s-
si on).
(3) Turn i gni ti on to the ON posi ti on and push the
dash swi tch to acti vate the rear pump.
NOTE: If pump is not running, verify pump has (Fig.
61) 12 volts and ground.
(4) Wi th the pump runni ng the pressure gauge
shoul d show 5 psi ..
NOTE: If pump does not produce 5 psi. replace the
pump.
REMOVAL
(1) Remove drai n pl ug from the di fferenti al hous-
i ng.
(2) Di sconnect i ndi cator swi tch harness and
remove connector from di fferenti al cover (Fi g. 62).
(3) Remove di fferenti al housi ng cover.
(4) Remove axl e shafts.
(5) Remove pressure hose from actuator assembl y
(Fi g. 63).
Fig. 61 PUMP CONNECTORS
1 - REAR PUMP CONNECTOR
2 - FRONT PUMP CONNECTOR
3 - AXLE HARNESS
Fig. 62 INDICATOR SWITCH CONNECTOR
1 - CONNECTOR
2 - DIFFERENTIAL COVER
Fig. 63 PRESSURE HOSE
1 - PRESSURE HOSE
2 - BEARING CAP
3 - PRESSURE HOSE CLAMP
TJ REAR AXLE - 216RBI 3 - 147
DIFFERENTIAL - TRU-LOK (Continued)
(6) Note the reference l etters stamped on the beari ng
caps and housi ng machi ned seal i ng surface (Fi g. 64).
(7) Loosen di fferenti al beari ng cap bol ts.
(8) Posi ti on Spreader W-129-B wi th Adapter Ki t
6987B on di fferenti al l ocati ng hol es (Fi g. 65). I nstal l
hol d-down cl amps and ti ghten the turnbuckl e fi nger-
ti ght.
(9) I nstal l a Pi l ot Stud C-3288-B at the l eft si de of
the di fferenti al housi ng. Attach Di al I ndi cator C-3339
to pi l ot stud (Fi g. 66). Load i ndi cator pl unger agai nst
the opposi te si de of the housi ng and zero the i ndi ca-
tor.
CAUTION: Never spread the housing over 0.38 mm
(0.015 in). Failure to heed caution may result in
damage.
(10) Spread housi ng whi l e measuri ng the di stance
wi th the di al i ndi cator (Fi g. 67).
(11) Remove di al i ndi cator.
(12) Remove di fferenti al beari ng cap bol ts and ri ng
gear si de beari ng cap.
(13) Remove di fferenti al from housi ng wi th pi ni on
gear si de beari ng cap (Fi g. 68) and tag di fferenti al
beari ng cups and prel oad shi ms to i ndi cate l ocati on.
CAUTION: Do not bend actuator mounting tabs,
during differential removal. Failure to heed caution
may result in damage.
(14) Remove spreader from housi ng.
(15) Remove i ndi cator swi tch (Fi g. 69) from di ffer-
enti al housi ng.
(16) Cl ean the housi ng cavi ty wi th fl ushi ng oi l ,
l i ght engi ne oi l or l i nt free cl oth.
NOTE: Do not use water, steam, kerosene or gaso-
line for cleaning.
DISASSEMBLY
(1) I nstal l Pl ug C-293-3 i nto the di fferenti al axl e
shaft hol e.
Fig. 64 LOCATION MARKS
1 - REFERENCE MARKS
2 - REFERENCE MARKS
Fig. 65 SPREADER LOCATION
1 - DIFFERENTIAL CASE
2 - ADAPTER
3 - HOLD DOWN
4 - SPREADER
5 - TURNBUCKLE
Fig. 66 DIAL INDICATOR LOCATION
1 - DIAL INDICATOR
2 - PILOT STUD
3 - 148 REAR AXLE - 216RBI TJ
DIFFERENTIAL - TRU-LOK (Continued)
(2) Remove di fferenti al case beari ngs wi th Pul l er
6444, Pul l er Rods 6444-3 and Pul l er Fl ange 6444-1.
Posi ti on pul l er (Fi g. 70) on the di fferenti al .
Fig. 67 SPREAD DIFFERENTIAL CASE
1 - DIAL INDICATOR
2 - SPREADER
Fig. 68 DIFFERENTIAL
1 - DIFFERENTIAL
2 - BEARING CAP
Fig. 69 INDICATOR SWITCH
1 - DIFFERENTIAL CASE
2 - SWITCH
Fig. 70 PULLER AND FLANGE
1 - PULLER
2 - ROD
3 - PLUG
4 - FLANGE
TJ REAR AXLE - 216RBI 3 - 149
DIFFERENTIAL - TRU-LOK (Continued)
(3) Posi ti on Pul l er Jaws 6444-7 (Fi g. 71) around
the case beari ng and pul l er fl ange.
(4) Posi ti on Pul l er Col l ar 6444-8 (Fi g. 72) around
the pul l er jaws.
(5) Ti ghten the pul l er nut and remove di fferenti al
case beari ng.
(6) Remove l ocki ng actuator (Fi g. 73).
Fig. 71 PULLER AND JAWS
1 - PULLER
2 - ROD
3 - PLUG
4 - JAW
Fig. 72 PULLER AND COLLAR
1 - PULLER
2 - ROD
3 - PLUG
4 - COLLAR
Fig. 73 ACTUATOR
1 - ACTUATOR
2 - PRESSURE PLATE
3 - 150 REAR AXLE - 216RBI TJ
DIFFERENTIAL - TRU-LOK (Continued)
ASSEMBLY
(1) Veri fy pressure pl ate tabs are seated (Fi g. 74)
i n the dog cl utch sl ots.
(2) Pl ace actuator on the pressure pl ate and case
beari ng on the case (Fi g. 75).
(3) I nstal l di fferenti al case beari ngs wi th I nstal l er
D-156 and Handl e C-4171.
INSTALLATION
NOTE: If replacement differential bearings or differ-
ential case are being installed, differential side
bearing shim requirements may change. Refer
Adjustments (Differential Bearing Preload and Gear
Backlash) to determine the proper shim selection.
(1) I nstal l i ndi cator swi tch i nto the housi ng.
(2) Posi ti on Spreader W-129-B and adapters from
Adapter set 6987, wi th the tool dowel pi ns seated i n
the l ocati ng hol es (Fi g. 76). I nstal l hol d-down cl amps
and ti ghten the tool turnbuckl e fi nger-ti ght.
(3) I nstal l Pi l ot Stud C-3288-B at the l eft si de of
the di fferenti al housi ng. Attach Di al I ndi cator C-3339
to pi l ot stud. Load i ndi cator pl unger agai nst the
opposi te si de of the housi ng and zero i ndi cator.
(4) Spread housi ng whi l e measuri ng the di stance
wi th the di al i ndi cator.
CAUTION: Never spread over 0.38 mm (0.015 in).
Failure to heed caution may result in damage.
Fig. 74 PRESSURE PLATE
1 - PLATE
2 - PLATE TABS
Fig. 75 ACTUATOR AND CASE BEARING
1 - CASE BEARING
2 - ACTUATOR
Fig. 76 SPREADER LOCATION
1 - DIFFERENTIAL CASE
2 - ADAPTER
3 - HOLD DOWN
4 - SPREADER
5 - TURNBUCKLE
TJ REAR AXLE - 216RBI 3 - 151
DIFFERENTIAL - TRU-LOK (Continued)
(5) Remove di al i ndi cator.
(6) I nstal l di fferenti al case wi th pi ni on gear si de
beari ng cap and di fferenti al prel oad shi ms i n the
housi ng. Tap di fferenti al case to seat beari ngs cups
i n the housi ng.
CAUTION: Ensure indicator switch plunger head is
positioned under the actuator. Failure to heed cau-
tion may result in damage.
(7) I nstal l ri ng gear si de beari ng cap wi th refer-
ence marks al i gned (Fi g. 77).
(8) Loosel y i nstal l di fferenti al beari ng cap bol ts.
(9) Remove axl e housi ng spreader.
(10) Ti ghten beari ng cap bol ts to 108 N·m (80 ft.
l bs.).
(11) Wi th a 1/4 i nch dri l l bi t check the cl earance
between the actuator and actuator pressure pl ate at
the top and the bottom.
CAUTION: If clearance is not correct, indicator
switch plunger may be on top of the actuator or
actuator mounting tabs may be bent. Failure to
heed caution may result in damage.
(12) I nstal l pressure hose on the actuator assem-
bl y.
(13) I nstal l axl e shafts.
(14) I nstal l di fferenti al cover, i denti fi cati on tag
and i ndi cator swi tch connector (Fi g. 78).
DIFFERENTIAL - TRU-LOK
PUMP
REMOVAL
(1) Di sconnect pumps and axl e harness connectors
(Fi g. 79).
Fig. 77 BEARING CAP REFERENCE MARKS
1 - REFERENCE MARKS
2 - REFERENCE MARKS
Fig. 78 INDICATOR SWITCH CONNECTOR
1 - CONNECTOR
2 - DIFFERENTIAL COVER
Fig. 79 PUMP CONNECTORS
1 - REAR PUMP CONNECTOR
2 - FRONT PUMP CONNECTOR
3 - AXLE HARNESS
3 - 152 REAR AXLE - 216RBI TJ
DIFFERENTIAL - TRU-LOK (Continued)
(2) Remove pressure hoses from the front and rear
pumps.
(3) Remove pump mounti ng bracket bol ts (Fi g. 80).
(4) Remove pumps and bracket assembl y from the
vehi cl e.
(5) Remove pump connectors from the mounti ng
bracket.
(6) Remove pump mounti ng screws (Fi g. 81) from
the bracket and remove pump/pumps.
INSTALLATION
(1) Al i gn pump wi th screw hol es i n pump bracket.
(2) I nstal l and ti ghten pump mounti ng screws
(Fi g. 82).
(3) I nstal l pump bracket assembl y on the cross-
member/ski d pl ate and i nstal l pump bracket mount-
i ng bol ts (Fi g. 83).
Fig. 80 PUMP BRACKET
1 - PUMP BRACKET
2 - CROSSMEMBER/SKID PLATE
Fig. 81 PUMP SCREWS
1 - REAR PUMP SCREWS
2 - FRONT PUMP SCREWS
Fig. 82 PUMP SCREWS
1 - REAR PUMP SCREWS
2 - FRONT PUMP SCREWS
Fig. 83 PUMP BRACKET
1 - PUMP BRACKET
2 - CROSSMEMBER/SKID PLATE
TJ REAR AXLE - 216RBI 3 - 153
DIFFERENTIAL - TRU-LOK PUMP (Continued)
(4) Ti ghten pump bracket bol ts to 14 N·m (125 i n.
l bs.).
(5) Connector pump and axl e harness connectors
(Fi g. 84).
(6) I nstal l pressure hoses on the pumps.
(7) Veri fy pump operati on.
DIFFERENTIAL CASE
BEARINGS
REMOVAL
(1) Remove di fferenti al case from axl e housi ng.
(2) Remove beari ngs from the di fferenti al case
wi th Pul l er/Press C-293-PA, Adapters C-293-18 and
Pl ug SP-3289 (Fi g. 85).
INSTALLATION
NOTE: If replacement differential side bearings or
differential case are being installed, differential side
bearing shim requirements may change. Refer to
Adjustments for (Differential Bearing Preload and
Gear Backlash) procedures.
(1) I nstal l di fferenti al si de beari ngs wi th I nstal l er
D-156 and Handl e C-4171 (Fi g. 86).
(2) I nstal l di fferenti al i nto the housi ng.
Fig. 84 PUMP CONNECTORS
1 - REAR PUMP CONNECTOR
2 - FRONT PUMP CONNECTOR
3 - AXLE HARNESS
Fig. 85 DIFFERENTIAL CASE BEARING
1 - ADAPTERS
2 - BEARING
3 - DIFFERENTIAL
4 - PLUG
5 - PULLER
Fig. 86 DIFFERENTIAL SIDE BEARING
1 - INSTALLER
2 - HANDLE
3 - 154 REAR AXLE - 216RBI TJ
DIFFERENTIAL - TRU-LOK PUMP (Continued)
PINION GEAR/RING GEAR/
TONE RING
REMOVAL
NOTE: The ring gear and pinion are serviced as a
matched set. Never replace one gear without replac-
ing the other matched gear.
(1) Wi th vehi cl e i n neutral , posi ti on vehi cl e on
hoi st.
(2) Remove di fferenti al assembl y from axl e hous-
i ng.
(3) Pl ace di fferenti al case i n a vi se wi th soft metal
jaw.
(4) Remove bol ts hol di ng ri ng gear to di fferenti al
case.
(5) Dri ver ri ng gear off the di fferenti al case wi th a
dead-bl ow hammer (Fi g. 87).
(6) Usi ng Spanner Wrench 6958 to hol d yoke,
remove the pi ni on nut and washer (Fi g. 88).
(7) Remove pi ni on yoke from pi ni on shaft wi th
Remover C-452 and Fl ange Wrench C-3281 (Fi g. 89).
Fig. 87 RING GEAR
1 - CASE
2 - RING GEAR
3 - DEAD-BLOW HAMMER
Fig. 88 YOKE SPANNER WRENCH
1 - PINION YOKE
2 - SPANNER WRENCH
3 - PIPE
Fig. 89 PINION YOKE REMOVER
1 - REMOVER
2 - PINION YOKE
3 - FLANGE WRENCH
TJ REAR AXLE - 216RBI 3 - 155
(8) Remove pi ni on gear from the housi ng (Fi g. 90).
(9) Remove front pi ni on beari ng cup, beari ng and
pi ni on seal wi th Remover D-147 and Handl e C-4171
(Fi g. 91).
(10) Remove rear pi ni on beari ng cup from axl e
housi ng wi th remover D-148 and Handl e C-4171 (Fi g.
92).
(11) Remove rear pi ni on beari ng from the pi ni on
wi th Pul l er/Press C-293-PA and Adapters C-293-39
(Fi g. 93).
Fig. 90 PINION GEAR
1 - DEAD-BLOW HAMMER
Fig. 91 FRONT BEARING CUP
1 - REMOVER
2 - HANDLE
Fig. 92 REAR BEARING CUP
1 - DRIVER
2 - HANDLE
Fig. 93 REAR PINION BEARING
1 - PULLER
2 - VISE
3 - ADAPTERS
4 - PINION GEAR SHAFT
3 - 156 REAR AXLE - 216RBI TJ
PINION GEAR/RING GEAR/TONE RING (Continued)
(12) Remove and record pi ni on depth shi ms from
the pi ni on gear shaft.
INSTALLATION
NOTE: Pinion depth shims are placed between the
rear pinion bearing and pinion gear head to achieve
proper ring and pinion gear mesh. If the ring and
pinion gears are reused, the original pinion depth
shim can be used. Refer to Adjustments (Pinion
Gear Depth) to select the proper shim thickness.
(1) I nstal l pi ni on depth shi m i n rear pi ni on bear-
i ng cup bore.
(2) Appl y Mopar Door Ease or equi val ent l ubri cant
to the outsi de surface of pi ni on beari ng cups. I nstal l
rear beari ng cup wi th I nstal l er D-145 and Handl e
C-4171 (Fi g. 94) and veri fy cup i s seated.
(3) I nstal l front beari ng cup wi th I nstal l er D-144
and Handl e C-4171 (Fi g. 95) and veri fy cup i s seated.
(4) I nstal l front pi ni on beari ng and oi l sl i nger, i f
equi pped.
(5) Appl y a l i ght coati ng of gear l ubri cant on the
l i p of pi ni on seal . I nstal l seal wi th I nstal l er 8681
(Fi g. 96).
Fig. 94 REAR BEARING CUP
1 - INSTALLER
2 - HANDLE
Fig. 95 FRONT BEARING CUP
1 - INSTALLER
2 - HANDLE
Fig. 96 PINION SEAL INSTALLER
1 - HANDLE
2 - INSTALLER
TJ REAR AXLE - 216RBI 3 - 157
PINION GEAR/RING GEAR/TONE RING (Continued)
(6) I nstal l pi ni on depth shi m on the pi ni on shaft.
I nstal l rear pi ni on beari ng on the pi ni on gear wi th
I nstal l er W-262 and a press (Fi g. 97).
(7) I nstal l pi ni on gear i nto the housi ng.
(8) I nstal l yoke wi th I nstal l er W-162-B, Cup 8109
and Spanner Wrench 6958 (Fi g. 98).
(9) I nstal l pi ni on washer and a new nut hol d pi n-
i on yoke Spanner Wrench 6958 (Fi g. 99) and ti ghten
nut to 217-271 N·m (160-200 ft. l bs.).
Fig. 97 REAR PINION BEARING
1 - INSTALLER
2 - SHIM
3 - DRIVE PINION GEAR
4 - REAR PINION BEARING
5 - PRESS
Fig. 98 PINION YOKE INSTALLER
1 - INSTALLER
2 - PINION YOKE
3 - SPANNER WRENCH
Fig. 99 YOKE SPANNER WRENCH
1 - PINION YOKE
2 - SPANNER WRENCH
3 - PIPE
3 - 158 REAR AXLE - 216RBI TJ
PINION GEAR/RING GEAR/TONE RING (Continued)
(10) Check beari ng prel oad torque wi th an i nch
pound torque wrench (Fi g. 100). The torque neces-
sary to rotate the pi ni on gear shoul d be:
• Ori gi nal Beari ngs: 1 to 2.26 N·m (10 to 20 i n.
l bs.).
• New Beari ngs: 2.26 to 4.52 N·m (20 to 40 i n.
l bs.).
(11) I f rotati ng torque i s above the desi red
amount, remove the pi ni on yoke and i ncrease the
prel oad shi m pack thi ckness. I ncreasi ng the shi m
pack thi ckness 0.025 mm (0.001 i n.) wi l l decrease the
rotati ng torque approxi matel y 0.9 N·m (8 i n. l bs.).
(12) I f the maxi mum ti ghteni ng torque i s reached
pri or to achi evi ng the desi red rotati ng torque, remove
the pi ni on yoke and decrease the thi ckness of the
prel oad shi m pack. Decreasi ng the shi m pack thi ck-
ness 0.025 mm (0.001 i n.) wi l l i ncrease the rotati ng
torque approxi matel y 0.9 N·m (8 i n. l bs.).
(13) I nvert di fferenti al case and start two ri ng
gear bol ts. Thi s wi l l provi de case-to-ri ng gear bol t
hol e al i gnment.
CAUTION: Never reuse ring gear bolts, the bolts
can fracture causing extensive damage. Failure to
heed caution may result in damage.
(14) I nvert di fferenti al case i n the vi se.
(15) I nstal l new ri ng gear bol ts and al ternatel y
ti ghten to 108 N·m (100 ft. l bs.) (Fi g. 101).
(16) I nstal l di fferenti al i n axl e housi ng and veri fy
gear mesh and contact pattern. Refer to Adjustment
(Gear Contact Pattern).
Fig. 100 PINION ROTATING TORQUE
1 - TORQUE WRENCH
2 - PINION YOKE
Fig. 101 RING GEAR
1 - TORQUE WRENCH
2 - RING GEAR BOLT
3 - RING GEAR
4 - CASE
TJ REAR AXLE - 216RBI 3 - 159
PINION GEAR/RING GEAR/TONE RING (Continued)
BRAKES
TABLE OF CONTENTS
page page
BRAKES - BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 BRAKES - ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
BRAKES - BASE
TABLE OF CONTENTS
page page
BRAKES - BASE
DESCRIPTION
DESCRIPTION - BRAKE SYSTEM . . . . . . . . . . 2
DESCRIPTION - SERVICE WARNINGS &
CAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DIAGNOSIS AND TESTING - BASE BRAKE
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
STANDARD PROCEDURE
STANDARD PROCEDURE - MANUAL
BLEEDING. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
STANDARD PROCEDURE - PRESSURE
BLEEDING. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SPECIFICATIONS
BRAKE COMPONENTS . . . . . . . . . . . . . . . . . . 6
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . 7
SPECIAL TOOLS
BASE BRAKES . . . . . . . . . . . . . . . . . . . . . . . . 8
BRAKE LINES
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
DIAGNOSIS AND TESTING - BRAKE LINE
AND HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . 8
STANDARD PROCEDURE
STANDARD PROCEDURE - BRAKE TUBE
FLARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
STANDARD PROCEDURE - DOUBLE
INVERTED FLARING . . . . . . . . . . . . . . . . . . . . 8
STANDARD PROCEDURE - ISO FLARING . . . 9
DISC BRAKE CALIPERS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 10
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
REMOVAL
REMOVAL - FRONT . . . . . . . . . . . . . . . . . . . . 10
REMOVAL - REAR . . . . . . . . . . . . . . . . . . . . . 11
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 12
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 13
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
INSTALLATION
INSTALLATION - FRONT . . . . . . . . . . . . . . . . 15
INSTALLATION - REAR . . . . . . . . . . . . . . . . . 16
BRAKE PADS/SHOES
REMOVAL
REMOVAL - FRONT PADS . . . . . . . . . . . . . . . 16
REMOVAL - DRUM BRAKE SHOES . . . . . . . . 17
REMOVAL - REAR DISC BRAKE PADS . . . . . 17
INSTALLATION
INSTALLATION - FRONT PADS . . . . . . . . . . . 17
INSTALLATION - DRUM BRAKE SHOES . . . . 17
INSTALLATION - REAR DISC BRAKE PADS . 19
DRUM
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 19
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
DIAGNOSIS AND TESTING - BRAKE DRUM
RUNOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
STANDARD PROCEDURE - BRAKE DRUM
MACHINING . . . . . . . . . . . . . . . . . . . . . . . . . . 19
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 19
ADJUSTMENTS - REAR DRUM BRAKE . . . . . . 20
FLUID
DIAGNOSIS AND TESTING - BRAKE FLUID
CONTAMINATION . . . . . . . . . . . . . . . . . . . . . 21
STANDARD PROCEDURE - BRAKE FLUID
LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
SPECIFICATIONS
BRAKE FLUID . . . . . . . . . . . . . . . . . . . . . . . . 21
FLUID RESERVOIR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 23
MASTER CYLINDER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 23
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
TJ BRAKES 5 - 1
DIAGNOSIS AND TESTING - MASTER
CYLINDER/POWER BOOSTER . . . . . . . . . . . 23
STANDARD PROCEDURE - MASTER
CYLINDER BLEEDING . . . . . . . . . . . . . . . . . . 24
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 25
PEDAL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 25
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 25
POWER BRAKE BOOSTER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 26
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 27
COMBINATION VALVE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 27
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
DIAGNOSIS AND TESTING - COMBINATION
VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 28
ROTORS
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - DISC BRAKE
ROTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
DIAGNOSIS AND TESTING - BRAKE DRUM
IN HAT ROTOR . . . . . . . . . . . . . . . . . . . . . . . 29
STANDARD PROCEDURE
STANDARD PROCEDURE - DISC ROTOR
MACHINING. . . . . . . . . . . . . . . . . . . . . . . . . . 29
STANDARD PROCEDURE - BRAKE DRUM
IN HAT ROTOR MACHINING . . . . . . . . . . . . . 30
REMOVAL
REMOVAL - FRONT . . . . . . . . . . . . . . . . . . . . 30
REMOVAL - REAR . . . . . . . . . . . . . . . . . . . . . 30
INSTALLATION
INSTALLATION - FRONT . . . . . . . . . . . . . . . . 31
INSTALLATION - REAR . . . . . . . . . . . . . . . . . 31
WHEEL CYLINDERS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 31
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 31
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 32
SUPPORT PLATE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 32
PARKING BRAKE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 33
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
DIAGNOSIS AND TESTING - PARKING BRAKE . 33
SHOES
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 34
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
CLEANING - REAR DRUM IN HAT BRAKE . . . . 34
INSPECTION - REAR DRUM IN HAT BRAKE . . 34
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 35
ADJUSTMENTS
ADJUSTMENT - REAR DRUM IN HAT PARK
BRAKE (ROTOR REMOVED) . . . . . . . . . . . . . 35
ADJUSTMENT - WITH ADJUSTING TOOL . . . 37
CABLES
REMOVAL
REMOVAL - DRUM BRAKES . . . . . . . . . . . . . 37
REMOVAL - DISC BRAKES . . . . . . . . . . . . . . 38
INSTALLATION
INSTALLATION - DRUM BRAKES . . . . . . . . . 38
INSTALLATION - DISC BRAKES . . . . . . . . . . 38
BRAKES - BASE
DESCRIPTION
DESCRIPTION - BRAKE SYSTEM
Power assi st front di sc and rear drum brakes are
standard equi pment. Di sc brake components consi st
of si ngl e pi ston cal i pers and venti l ated rotors. Rear
drum brakes are dual shoe uni ts wi th cast brake
drums.
The parki ng brake mechani sm i s l ever and cabl e
operated. The cabl es are attached to l evers on the
rear drum brake secondary shoes. The parki ng
brakes are operated by a hand l ever.
A dual di aphragm vacuum power brake booster i s
used for al l appl i cati ons. Al l model s have an al umi -
num master cyl i nder wi th pl asti c reservoi r.
Al l model s are equi pped wi th a combi nati on val ve.
The val ve contai ns a pressure di fferenti al val ve and
swi tch and a fi xed rate rear proporti oni ng val ve.
Factory brake l i ni ng on al l model s consi sts of an
organi c base materi al combi ned wi th metal l i c parti -
cl es. The ori gi nal equi pment l i ni ngs do not contai n
asbestos.
5 - 2 BRAKES - BASE TJ
DESCRIPTION - SERVICE WARNINGS &
CAUTIONS
WARNING: DUST AND DIRT ACCUMULATING ON
BRAKE PARTS DURING NORMAL USE MAY CON-
TAIN ASBESTOS FIBERS FROM PRODUCTION OR
AFTERMARKET LININGS. BREATHING EXCESSIVE
CONCENTRATIONS OF ASBESTOS FIBERS CAN
CAUSE SERIOUS BODILY HARM. EXERCISE CARE
WHEN SERVICING BRAKE PARTS. DO NOT CLEAN
BRAKE PARTS WITH COMPRESSED AIR OR BY
DRY BRUSHING. USE A VACUUM CLEANER SPE-
CIFICALLY DESIGNED FOR THE REMOVAL OF
ASBESTOS FIBERS FROM BRAKE COMPONENTS.
IF A SUITABLE VACUUM CLEANER IS NOT AVAIL-
ABLE, CLEANING SHOULD BE DONE WITH A
WATER DAMPENED CLOTH. DO NOT SAND, OR
GRIND BRAKE LINING UNLESS EQUIPMENT USED
IS DESIGNED TO CONTAIN THE DUST RESIDUE.
DISPOSE OF ALL RESIDUE CONTAINING ASBES-
TOS FIBERS IN SEALED BAGS OR CONTAINERS
TO MINIMIZE EXPOSURE TO YOURSELF AND OTH-
ERS. FOLLOW PRACTICES PRESCRIBED BY THE
OCCUPATIONAL SAFETY AND HEALTH ADMINIS-
TRATION AND THE ENVIRONMENTAL PROTECTION
AGENCY FOR THE HANDLING, PROCESSING, AND
DISPOSITION OF DUST OR DEBRIS THAT MAY
CONTAIN ASBESTOS FIBERS.
CAUTION: Never use gasoline, kerosene, alcohol,
motor oil, transmission fluid, or any fluid containing
mineral oil to clean the system components. These
fluids damage rubber cups and seals. Use only
fresh brake fluid or Mopar brake cleaner to clean or
flush brake system components. These are the only
cleaning materials recommended. If system contam-
ination is suspected, check the fluid for dirt, discol-
oration, or separation into distinct layers. Also
check the reservoir cap seal for distortion. Drain
and flush the system with new brake fluid if con-
tamination is suspected.
CAUTION: Use Mopar brake fluid, or an equivalent
quality fluid meeting SAE/DOT standards J1703 and
DOT 3. Brake fluid must be clean and free of con-
taminants. Use fresh fluid from sealed containers
only to ensure proper antilock component opera-
tion.
CAUTION: Use Mopar multi-mileage or high temper-
ature grease to lubricate caliper slide surfaces,
drum brake pivot pins, and shoe contact points on
the backing plates. Use multi-mileage grease or GE
661 or Dow 111 silicone grease on caliper slide pins
to ensure proper operation.
DIAGNOSIS AND TESTING - BASE BRAKE
SYSTEM
Base brake components consi st of the brake shoes,
cal i pers, wheel cyl i nders, brake drums, rotors, brake
l i nes, master cyl i nder, booster, and parki ng brake
components.
Brake di agnosi s i nvol ves determi ni ng i f the prob-
l em i s rel ated to a mechani cal , hydraul i c, or vacuum
operated component.
The fi rst di agnosi s step i s the prel i mi nary check.
PRELIMINARY BRAKE CHECK
(1) Check condi ti on of ti res and wheel s. Damaged
wheel s and worn, damaged, or underi nfl ated ti res
can cause pul l , shudder, vi brati on, and a condi ti on
si mi l ar to grab.
(2) I f compl ai nt was based on noi se when braki ng,
check suspensi on components. Jounce front and rear
of vehi cl e and l i sten for noi se that mi ght be caused
by l oose, worn or damaged suspensi on or steeri ng
components.
(3) I nspect brake fl ui d l evel and condi ti on. Note
that the front di sc brake reservoi r fl ui d l evel wi l l
decrease i n proporti on to normal l i ni ng wear. Also
note that brake fluid tends to darken over time.
This is normal and should not be mistaken for
contamination.
(a) I f fl ui d l evel i s abnormal l y l ow, l ook for evi -
dence of l eaks at cal i pers, wheel cyl i nders, brake
l i nes, and master cyl i nder.
(b) I f fl ui d appears contami nated, drai n out a
sampl e. System wi l l have to be fl ushed i f fl ui d i s
separated i nto l ayers, or contai ns a substance
other than brake fl ui d. The system seal s and cups
wi l l al so have to be repl aced after fl ushi ng. Use
cl ean brake fl ui d to fl ush the system.
(4) Check parki ng brake operati on. Veri fy free
movement and ful l rel ease of cabl es and pedal . Al so
note i f vehi cl e was bei ng operated wi th parki ng
brake parti al l y appl i ed.
(5) Check brake pedal operati on. Veri fy that pedal
does not bi nd and has adequate free pl ay. I f pedal
l acks free pl ay, check pedal and power booster for
bei ng l oose or for bi nd condi ti on. Do not road test
unti l condi ti on i s corrected.
(6) I f components checked appear OK, road test
the vehi cl e.
ROAD TESTING
(1) I f compl ai nt i nvol ved l ow brake pedal , pump
pedal and note i f i t comes back up to normal hei ght.
TJ BRAKES - BASE 5 - 3
BRAKES - BASE (Continued)
(2) Check brake pedal response wi th transmi ssi on
i n Neutral and engi ne runni ng. Pedal shoul d remai n
fi rm under constant foot pressure.
(3) Duri ng road test, make normal and fi rm brake
stops i n 25-40 mph range. Note faul ty brake opera-
ti on such as l ow pedal , hard pedal , fade, pedal pul sa-
ti on, pul l , grab, drag, noi se, etc.
PEDAL FALLS AWAY
A brake pedal that fal l s away under steady foot
pressure i s general l y the resul t of a system l eak. The
l eak poi nt coul d be at a brake l i ne, fi tti ng, hose, or
cal i per/wheel cyl i nder. I nternal l eakage i n the master
cyl i nder caused by worn or damaged pi ston cups,
may al so be the probl em cause.
I f l eakage i s severe, fl ui d wi l l be evi dent at or
around the l eaki ng component. However, i nternal
l eakage i n the master cyl i nder may not be physi cal l y
evi dent.
LOW PEDAL
I f a l ow pedal i s experi enced, pump the pedal sev-
eral ti mes. I f the pedal comes back up, worn l i ni ng,
rotors, or drums are the most l i kel y causes.
SPONGY PEDAL
A spongy pedal i s most often caused by ai r i n the
system. However, thi n brake drums or substandard
brake l i nes and hoses can al so cause a spongy pedal .
The proper course of acti on i s to bl eed the system, or
repl ace thi n drums and suspect qual i ty brake l i nes
and hoses.
HARD PEDAL OR HIGH PEDAL EFFORT
A hard pedal or hi gh pedal effort may be due to
l i ni ng that i s water soaked, contami nated, gl azed, or
badl y worn. The power booster or check val ve coul d
al so be faul ty.
PEDAL PULSATION
Pedal pul sati on i s caused by components that are
l oose, or beyond tol erance l i mi ts.
The pri mary cause of pul sati on are di sc brake
rotors wi th excessi ve l ateral runout or thi ckness vari -
ati on, or out of round brake drums. Other causes are
l oose wheel beari ngs or cal i pers and worn, damaged
ti res.
NOTE: Some pedal pulsation may be felt during
ABS activation.
BRAKE DRAG
Brake drag occurs when the l i ni ng i s i n constant
contact wi th the rotor or drum. Drag can occur at one
wheel , al l wheel s, fronts onl y, or rears onl y.
Drag i s a product of i ncompl ete brake shoe rel ease.
Drag can be mi nor or severe enough to overheat the
l i ni ngs, rotors and drums.
Mi nor drag wi l l usual l y cause sl i ght surface char-
ri ng of the l i ni ng. I t can al so generate hard spots i n
rotors and drums from the overheat-cool down pro-
cess. I n most cases, the rotors, drums, wheel s and
ti res are qui te warm to the touch after the vehi cl e i s
stopped.
Severe drag can char the brake l i ni ng al l the way
through. I t can al so di stort and score rotors and
drums to the poi nt of repl acement. The wheel s, ti res
and brake components wi l l be extremel y hot. I n
severe cases, the l i ni ng may generate smoke as i t
chars from overheati ng.
Possi bl e causes for brake drag condi ti on are:
• Sei zed or i mproperl y adjusted parki ng brake
cabl es.
• Loose/worn wheel beari ng.
• Sei zed cal i per or wheel cyl i nder pi ston.
• Cal i per bi ndi ng on corroded bushi ngs or rusted
sl i de surfaces.
• Loose cal i per mounti ng bracket.
• Drum brake shoes bi ndi ng on worn/damaged
support pl ates.
• Mi s-assembl ed components.
I f brake drag occurs at al l wheel s, the probl em
may be rel ated to a bl ocked master cyl i nder return
port, or faul ty power booster (bi nds-does not rel ease).
BRAKE FADE
Brake fade i s usual l y a product of overheati ng
caused by brake drag. However, brake overheati ng
and resul ti ng fade can al so be caused by ri di ng the
brake pedal , maki ng repeated hi gh decel erati on stops
i n a short ti me span, or constant braki ng on steep
mountai n roads. Refer to the Brake Drag i nformati on
i n thi s secti on for causes.
BRAKE PULL
Possi bl e causes for front brake pul l condi ti on are:
• Contami nated l i ni ng i n one cal i per.
• Sei zed cal i per pi ston.
• Bi ndi ng cal i per.
• Loose cal i per.
• Rusty adapter/cal i per sl i de surfaces.
• I mproper brake shoes.
• Damaged rotor.
A worn, damaged wheel beari ng or suspensi on
component are further causes of pul l . A damaged
front ti re (brui sed, pl y separati on) can al so cause
pul l .
A common and frequentl y mi sdi agnosed pul l condi -
ti on i s where di recti on of pul l changes after a few
stops. The cause i s a combi nati on of brake drag fol -
l owed by fade at one of the brake uni ts.
5 - 4 BRAKES - BASE TJ
BRAKES - BASE (Continued)
As the draggi ng brake overheats, effi ci ency i s so
reduced that fade occurs. Si nce the opposi te brake
uni t i s sti l l functi oni ng normal l y, i ts braki ng effect i s
magni fi ed. Thi s causes pul l to swi tch di recti on i n
favor of the normal l y functi oni ng brake uni t.
An addi ti onal poi nt when di agnosi ng a change i n
pul l condi ti on concerns brake cool down. Remember
that pul l wi l l return to the ori gi nal di recti on, i f the
draggi ng brake uni t i s al l owed to cool down (and i s
not seri ousl y damaged).
REAR BRAKE GRAB OR PULL
Rear grab or pul l i s usual l y caused by i mproperl y
adjusted or sei zed parki ng brake cabl es, contami -
nated l i ni ng, bent or bi ndi ng shoes and support
pl ates, or i mproperl y assembl ed components. Thi s i s
parti cul arl y true when onl y one rear wheel i s
i nvol ved. However, when both rear wheel s are
affected, the master cyl i nder or proporti oni ng val ve
coul d be at faul t.
BRAKES DO NOT HOLD AFTER DRIVING THROUGH DEEP
WATER PUDDLES
Thi s condi ti on i s general l y caused by water soaked
l i ni ng. I f the l i ni ng i s onl y wet, i t can be dri ed by
dri vi ng wi th the brakes very l i ghtl y appl i ed for a
mi l e or two. However, i f the l i ni ng i s both soaked and
di rt contami nated, cl eani ng and/or repl acement wi l l
be necessary.
BRAKE SQUEAK/SQUEAL
Brake squeak or squeal may be due to l i ni ngs that
are wet or contami nated wi th brake fl ui d, grease, or
oi l . Gl azed l i ni ngs and rotors wi th hard spots can
al so contri bute to squeak. Di rt and forei gn materi al
embedded i n the brake l i ni ng wi l l al so cause squeak/
squeal .
A very l oud squeak or squeal i s frequentl y a si gn of
severel y worn brake l i ni ng. I f the l i ni ng has worn
through to the brake shoes i n spots, metal -to-metal
contact occurs. I f the condi ti on i s al l owed to conti nue,
rotors and drums can become so scored that repl ace-
ment i s necessary.
BRAKE CHATTER
Brake chatter i s usual l y caused by l oose or worn
components, or gl azed/burnt l i ni ng. Rotors wi th hard
spots can al so contri bute to chatter. Addi ti onal causes
of chatter are out-of-tol erance rotors, brake l i ni ng not
securel y attached to the shoes, l oose wheel beari ngs
and contami nated brake l i ni ng.
THUMP/CLUNK NOISE
Thumpi ng or cl unk noi ses duri ng braki ng are fre-
quentl y not caused by brake components. I n many
cases, such noi ses are caused by l oose or damaged
steeri ng, suspensi on, or engi ne components. However,
cal i pers that bi nd on the sl i de surfaces can generate
a thump or cl unk noi se. I n addi ti on, worn out,
i mproperl y adjusted, or i mproperl y assembl ed rear
brake shoes can al so produce a thump noi se.
BRAKE LINING CONTAMINATION
Brake l i ni ng contami nati on i s mostl y a product of
l eaki ng cal i pers or wheel cyl i nders, worn seal s, dri v-
i ng through deep water puddl es, or l i ni ng that has
become covered wi th grease and gri t duri ng repai r.
Contami nated l i ni ng shoul d be repl aced to avoi d fur-
ther brake probl ems.
WHEEL AND TIRE PROBLEMS
Some condi ti ons attri buted to brake components
may actual l y be caused by a wheel or ti re probl em.
A damaged wheel can cause shudder, vi brati on and
pul l . A worn or damaged ti re can al so cause pul l .
Severel y worn ti res wi th very l i ttl e tread l eft can
produce a grab-l i ke condi ti on as the ti re l oses and
recovers tracti on. Fl at-spotted ti res can cause vi bra-
ti on and generate shudder duri ng brake operati on. A
ti re wi th i nternal damage such as a severe brui se,
cut, or pl y separati on can cause pul l and vi brati on.
STANDARD PROCEDURE
STANDARD PROCEDURE - MANUAL BLEEDING
Use Mopar brake fl ui d, or an equi val ent qual i ty
fl ui d meeti ng SAE J1703-F and DOT 3 standards
onl y. Use fresh, cl ean fl ui d from a seal ed contai ner at
al l ti mes.
(1) Remove reservoi r fi l l er caps and fi l l reservoi r.
(2) I f cal i pers, or wheel cyl i nders were overhaul ed,
open al l cal i per and wheel cyl i nder bl eed screws.
Then cl ose each bl eed screw as fl ui d starts to dri p
from i t. Top off master cyl i nder reservoi r once more
before proceedi ng.
(3) Attach one end of bl eed hose to bl eed screw
and i nsert opposi te end i n gl ass contai ner parti al l y
fi l l ed wi th brake fl ui d (Fi g. 1). Be sure end of bl eed
hose i s i mmersed i n fl ui d.
(4) Open up bl eeder, then have a hel per press
down the brake pedal . Once the pedal i s down cl ose
the bl eeder. Repeat bl eedi ng unti l fl ui d stream i s
cl ear and free of bubbl es. Then move to the next
wheel .
STANDARD PROCEDURE - PRESSURE
BLEEDING
Use Mopar brake fl ui d, or an equi val ent qual i ty
fl ui d meeti ng SAE J1703-F and DOT 3 standards
onl y. Use fresh, cl ean fl ui d from a seal ed contai ner at
al l ti mes.
TJ BRAKES - BASE 5 - 5
BRAKES - BASE (Continued)
Fol l ow the manufacturers i nstructi ons careful l y
when usi ng pressure equi pment. Do not exceed the
tank manufacturers pressure recommendati ons. Gen-
eral l y, a tank pressure of 15-20 psi i s suffi ci ent for
bl eedi ng.
Fi l l the bl eeder tank wi th recommended fl ui d and
purge ai r from the tank l i nes before bl eedi ng.
Do not pressure bl eed wi thout a proper master cyl -
i nder adapter. The wrong adapter can l ead to l eak-
age, or drawi ng ai r back i nto the system. Use
adapter provi ded wi th the equi pment or Adapter
6921.
SPECIFICATIONS
BRAKE COMPONENTS
SPECIFICATIONS
DESCRIPTION SPECIFICATION
Disc Brake Caliper
Type
Sliding
Disc Brake Rotor
Type
Front
Ventilated
Disc Brake Rotor
Type
Rear
Solid
Disc Brake Rotor
Diameter
Front
279.4 x 23.876 mm (11 x
0.94 in.)
Disc Brake Rotor
Diameter
Rear
285 x 12 mm (11 x 0.472
in.)
Disc Brake Rotor
Ventilated
Front
Max. Runout
0.12 mm (0.005 in.)
Disc Brake Rotor
Solid
Rear
Max. Runout
0.102 mm (0.004 in)
Disc Brake Rotor
Ventilated
Front
Max. Thickness Variation
0.013 mm (0.0005 in.)
Disc Brake Rotor
Solid
Rear
Max Thickness Variation
0.018 mm (0.0007 in)
Disc Brake Rotor
Ventilated
Front
Min. Thickness
22.7 mm (0.8937 in.)
Disc Brake Rotor
Solid
Rear
Min. Thickness
11.00 mm (0.433 in.)
Brake Drum
Diameter
228.6 x 63.5 mm (9 x 2.5
in.)
Brake Booster
Type
Tandem Diaphragm
Fig. 1 Bleed Hose Setup
1 - BLEED HOSE
2 - FLUID CONTAINER PARTIALLY FILLED WITH FLUID
5 - 6 BRAKES - BASE TJ
BRAKES - BASE (Continued)
TORQUE CHART
TORQUE SPECIFICATIONS
DESCRIPTION N·m Ft. Lbs. In. Lbs.
Brake Pedal
Support Bolt
28 21 —
Brake Booster
Mounting Nuts
39 29 —
Master Cylinder
Mounting Nuts
17 13 —
Master Cylinder
Brake Lines
19 14 —
Combination Valve
Mounting Nuts
20 15 —
Combination Valve
Brake Lines
19 14 —
Caliper
Mounting Bolts
Front
15 11 —
Caliper
Mounting Bolts
Rear
25 — 220
Caliper
Brake Hose Banjo Bolt
Front
31 23 —
Caliper
Brake Hose Banjo Bolt
Rear
31 23 —
Wheel Cylinder
Mounting Bolts
10 7 —
Wheel Cylinder
Brake Line
16 12 —
Parking Brake
Lever Bolts
12 9 —
Parking Brake
Lever Bracket Bolts
12 9 —
Parking Brake
Cable Retainer Nut
1.5 — 14
TJ BRAKES - BASE 5 - 7
BRAKES - BASE (Continued)
SPECIAL TOOLS
BASE BRAKES
BRAKE LINES
DESCRIPTION
Fl exi bl e rubber hose i s used at both front brakes
and at the rear axl e juncti on bl ock. Doubl e wal l ed
steel tubi ng i s used to connect the master cyl i nder to
the major hydraul i c braki ng components and then to
the fl exi bl e rubber hoses. Doubl e i nverted styl e and
I SO styl e fl ares are used on the brake l i nes.
OPERATION
The hoses and l i nes transmi t the brake fl ui d
hydraul i c pressure to the cal i pers and or wheel cyl -
i nders.
DIAGNOSIS AND TESTING - BRAKE LINE AND
HOSES
Fl exi bl e rubber hose i s used at both front brakes
and at the rear axl e juncti on bl ock. I nspect the hoses
whenever the brake system i s servi ced, at every
engi ne oi l change, or whenever the vehi cl e i s i n for
servi ce.
I nspect the hoses for surface cracki ng, scuffi ng, or
worn spots. Repl ace any brake hose i mmedi atel y i f
the fabri c casi ng of the hose i s exposed due to cracks
or abrasi ons.
Al so check brake hose i nstal l ati on. Faul ty i nstal l a-
ti on can resul t i n ki nked, twi sted hoses, or contact
wi th the wheel s and ti res or other chassi s compo-
nents. Al l of these condi ti ons can l ead to scuffi ng,
cracki ng and eventual fai l ure.
The steel brake l i nes shoul d be i nspected peri odi -
cal l y for evi dence of corrosi on, twi sts, ki nks, l eaks, or
other damage. Heavi l y corroded l i nes wi l l eventual l y
rust through causi ng l eaks. I n any case, corroded or
damaged brake l i nes shoul d be repl aced.
Factory repl acement brake l i nes and hoses are rec-
ommended to ensure qual i ty, correct l ength and supe-
ri or fati gue l i fe. Care shoul d be taken to make sure
that brake l i ne and hose mati ng surfaces are cl ean
and free from ni cks and burrs. Al so remember that
ri ght and l eft brake hoses are not i nterchangeabl e.
Use new copper seal washers at al l cal i per connec-
ti ons. Be sure brake l i ne connecti ons are properl y
made (not cross threaded) and ti ghtened to recom-
mended torque.
STANDARD PROCEDURE
STANDARD PROCEDURE - BRAKE TUBE
FLARING
A preformed metal brake tube i s recommended and
preferred for al l repai rs. However, doubl e-wal l steel
tube can be used for emergency repai r when factory
repl acement parts are not readi l y avai l abl e.
Speci al bendi ng tool s are needed to avoi d ki nki ng
or twi sti ng of metal brake tubes. Speci al fl ari ng tool s
are needed to make a doubl e i nverted fl are or I SO
fl are (Fi g. 2).
STANDARD PROCEDURE - DOUBLE INVERTED
FLARING
A preformed metal brake tube i s recommended and
preferred for al l repai rs. However, doubl e-wal l steel
tube can be used for emergency repai r when factory
repl acement parts are not readi l y avai l abl e.
(1) Cut off damaged tube wi th Tubi ng Cutter.
(2) Ream cut edges of tubi ng to ensure proper
fl are.
Installer Caliper Dust Boot C-4842
Handle C-4171
Adaptor Cap Pressure Bleeder 6921
5 - 8 BRAKES - BASE TJ
BRAKES - BASE (Continued)
(3) I nstal l repl acement tube nut on the tube.
(4) I nsert tube i n fl ari ng tool .
(5) Pl ace gauge form over the end of the tube.
(6) Push tubi ng through fl ari ng tool jaws unti l
tube contacts recessed notch i n gauge that matches
tube di ameter.
(7) Ti ghten the tool bar on the tube
(8) I nsert pl ug on gauge i n the tube. Then swi ng
compressi on di sc over gauge and center tapered fl ar-
i ng screw i n recess of compressi on di sc (Fi g. 3).
(9) Ti ghten tool handl e unti l pl ug gauge i s
squarel y seated on jaws of fl ari ng tool . Thi s wi l l start
the i nverted fl are.
(10) Remove the pl ug gauge and compl ete the
i nverted fl are.
STANDARD PROCEDURE - ISO FLARING
A preformed metal brake tube i s recommended and
preferred for al l repai rs. However, doubl e-wal l steel
tube can be used for emergency repai r when factory
repl acement parts are not readi l y avai l abl e.
To make a I SO fl are use a Fl ari ng Tool ki t.
(1) Cut off damaged tube wi th Tubi ng Cutter.
(2) Remove any burrs from the i nsi de of the tube.
(3) I nstal l tube nut on the tube.
(4) Posi ti on the tube i n the fl ari ng tool fl ush wi th
the top of the tool bar (Fi g. 4). Then ti ghten the tool
bar on the tube.
(5) I nstal l the correct si ze adaptor on the fl ari ng
tool yoke screw.
(6) Lubri cate the adaptor.
(7) Al i gn the adaptor and yoke screw over the tube
(Fi g. 4).
(8) Turn the yoke screw i n unti l the adaptor i s
squarel y seated on the tool bar.
Fig. 2 Inverted Flare And ISO Flare
1 - ISO-STYLE FLARE
2 - DOUBLE INVERTED-STYLE FLARE
Fig. 3 Inverted Flare Tools
Fig. 4 ISO Flaring
1 - ADAPTER
2 - LUBRICATE HERE
3 - PILOT
4 - FLUSH WITH BAR
5 - TUBING
6 - BAR ASSEMBLY
TJ BRAKES - BASE 5 - 9
BRAKE LINES (Continued)
DISC BRAKE CALIPERS
DESCRIPTION
The cal i pers are a si ngl e pi ston type. The cal i pers
are free to sl i de l ateral l y, thi s al l ows conti nuous com-
pensati on for l i ni ng wear.
OPERATION
When the brakes are appl i ed fl ui d pressure i s
exerted agai nst the cal i per pi ston. The fl ui d pressure
i s exerted equal l y and i n al l di recti ons. Thi s means
pressure exerted agai nst the cal i per pi ston and
wi thi n the cal i per bore wi l l be equal (Fi g. 5).
Fl ui d pressure appl i ed to the pi ston i s transmi tted
di rectl y to the i nboard brake shoe. Thi s forces the
shoe l i ni ng agai nst the i nner surface of the di sc
brake rotor. At the same ti me, fl ui d pressure wi thi n
the pi ston bore forces the cal i per to sl i de i nward on
the mounti ng bol ts. Thi s acti on bri ngs the outboard
brake shoe l i ni ng i nto contact wi th the outer surface
of the di sc brake rotor.
I n summary, fl ui d pressure acti ng si mul taneousl y
on both pi ston and cal i per, produces a strong cl amp-
i ng acti on. When suffi ci ent force i s appl i ed, fri cti on
wi l l attempt to stop the rotors from turni ng and
bri ng the vehi cl e to a stop.
Appl i cati on and rel ease of the brake pedal gener-
ates onl y a very sl i ght movement of the cal i per and
pi ston. Upon rel ease of the pedal , the cal i per and pi s-
ton return to a rest posi ti on. The brake shoes do not
retract an appreci abl e di stance from the rotor. I n
fact, cl earance i s usual l y at, or cl ose to zero. The rea-
sons for thi s are to keep road debri s from getti ng
between the rotor and l i ni ng and i n wi pi ng the rotor
surface cl ear each revol uti on.
The cal i per pi ston seal control s the amount of pi s-
ton extensi on needed to compensate for normal l i ni ng
wear.
Duri ng brake appl i cati on, the seal i s defl ected out-
ward by fl ui d pressure and pi ston movement (Fi g. 6).
When the brakes (and fl ui d pressure) are rel eased,
the seal rel axes and retracts the pi ston.
The amount of pi ston retracti on i s determi ned by
the amount of seal defl ecti on. General l y the amount
i s just enough to mai ntai n contact between the pi s-
ton and i nboard brake shoe.
REMOVAL
REMOVAL - FRONT
(1) Rai se and support vehi cl e.
(2) Remove front wheel and ti re assembl y.
(3) Drai n smal l amount of fl ui d from master cyl i n-
der brake reservoi r wi th sucti on gun.
(4) Bottom cal i per pi ston i n bore wi th C-cl amp.
Posi ti on cl amp screw on outboard brake shoe and
cl amp frame on rear of cal i per (Fi g. 7). Do not allow
clamp screw to bear directly on outboard shoe
retainer spring. Use wood or metal spacer
between shoe and clamp screw.
Fig. 5 Brake Caliper Operation
1 - CALIPER
2 - PISTON
3 - PISTON BORE
4 - SEAL
5 - INBOARD SHOE
6 - OUTBOARD SHOE
Fig. 6 Lining Wear Compensation By Piston Seal
1 - PISTON
2 - CYLINDER BORE
3 - PISTON SEAL BRAKE PRESSURE OFF
4 - CALIPER HOUSING
5 - DUST BOOT
6 - PISTON SEAL BRAKE PRESSURE ON
5 - 10 BRAKES - BASE TJ
(5) Remove brake hose mounti ng bol t and di scard
washers (Fi g. 8).
(6) Remove cal i per mounti ng bol ts (Fi g. 9).
(7) Ti l t top of cal i per outward wi th pry tool i f nec-
essary (Fi g. 10) and remove cal i per.
(8) Remove cal i per from vehi cl e.
REMOVAL - REAR
(1) I nstal l prop rod on the brake pedal to keep
pressure on the brake system.
(2) Rai se and support vehi cl e.
(3) Remove the wheel and ti re assembl y.
(4) Remove the brake hose banjo bol t i f repl aci ng
cal i per.
(5) Remove the cal i per mounti ng sl i de pi n bol ts
(Fi g. 11).
(6) Remove the cal i per from vehi cl e.
Fig. 7 Bottoming Caliper Piston With C-Clamp
1 - CALIPER BOSS
2 - OUTBOARD BRAKESHOE
3 - C-CLAMP
Fig. 8 Brake Hose And Bolt
1 - FITTING WASHERS
2 - CALIPERS
Fig. 9 Caliper Mounting Bolts
1 - CALIPER MOUNTING BOLT (2)
2 - CALIPER
Fig. 10 Caliper Removal
1 - TILT CALIPER OUTBOARD TO REMOVE
TJ BRAKES - BASE 5 - 11
DISC BRAKE CALIPERS (Continued)
DISASSEMBLY
(1) Remove brake shoes from cal i per.
(2) Drai n brake fl ui d out of cal i per.
(3) Take a pi ece of wood and pad i t wi th one-i nch
thi ckness of shop towel s. Pl ace thi s pi ece i n the out-
board shoe si de of the cal i per i n front of the pi ston.
Thi s wi l l cushi on and protect cal i per pi ston duri ng
removal (Fi g. 12).
(4) Remove cal i per pi ston wi th short bursts of
l ow pressure compressed ai r. Di rect ai r through fl ui d
i nl et port and ease pi ston out of bore (Fi g. 13).
CAUTION: Do not blow the piston out of the bore
with sustained air pressure. This could result in a
cracked piston. Use only enough air pressure to
ease the piston out.
WARNING: NEVER ATTEMPT TO CATCH THE PIS-
TON AS IT LEAVES THE BORE. THIS MAY RESULT
IN PERSONAL INJURY.
(5) Remove cal i per pi ston dust boot wi th sui tabl e
pry tool (Fi g. 14).
(6) Remove cal i per pi ston seal wi th wood or pl asti c
tool (Fi g. 15). Do not use metal tool s as they wi l l
scratch pi ston bore.
Fig. 11 CALIPER MOUNTING
1 - BRAKE HOSE
2 - CALIPER MOUNTING BOLTS
3 - BANJO BOLT
Fig. 12 Padding Caliper Interior
1 - SHOP TOWELS OR CLOTHS
2 - CALIPER
Fig. 13 Caliper Piston Removal
1 - AIR GUN
2 - CALIPER PISTON
3 - PADDING MATERIAL
Fig. 14 Caliper
1 - COLLAPSE BOOT WITH PUNCH OR SCREWDRIVER
2 - PISTON DUST BOOT
5 - 12 BRAKES - BASE TJ
DISC BRAKE CALIPERS (Continued)
(7) Remove cal i per mounti ng bol t bushi ngs and
boots (Fi g. 16).
CLEANING
Cl ean the cal i per components wi th cl ean brake
fl ui d or brake cl ean onl y. Wi pe the cal i per and pi ston
dry wi th l i nt free towel s or use l ow pressure com-
pressed ai r.
CAUTION: Do not use gasoline, kerosene, paint
thinner, or similar solvents. These products may
leave a residue that could damage the piston and
seal.
INSPECTION
The pi ston i s made from a phenol i c resi n (pl asti c
materi al ) and shoul d be smooth and cl ean.
The pi ston must be repl aced i f cracked or scored.
Do not attempt to restore a scored pi ston surface by
sandi ng or pol i shi ng.
CAUTION: If the caliper piston is replaced, install
the same type of piston in the caliper. Never inter-
change phenolic resin and steel caliper pistons.
The pistons, seals, seal grooves, caliper bore and
piston tolerances are different.
The bore can be lightly pol i shed wi th a brake
hone to remove very mi nor surface i mperfecti ons
(Fi g. 17). The cal i per shoul d be repl aced i f the bore i s
severel y corroded, rusted, scored, or i f pol i shi ng
woul d i ncrease bore di ameter more than 0.025 mm
(0.001 i nch).
ASSEMBLY
CAUTION: Dirt, oil, and solvents can damage cali-
per seals. Insure assembly area is clean and dry.
(1) Lubri cate cal i per pi ston bore, new pi ston seal
and pi ston wi th cl ean brake fl ui d.
(2) Lubri cate cal i per bushi ngs and i nteri or of
bushi ng boots wi th si l i cone grease.
Fig. 15 Piston Seal Removal
1 - REMOVE SEAL WITH WOOD PENCIL OR SIMILAR TOOL
2 - PISTON SEAL
Fig. 16 Mounting Bolt Bushing And Boot
1 - CALIPER SLIDE BUSHING
2 - BOOT
Fig. 17 Polishing Piston Bore
1 - SPECIAL HONE
2 - CALIPER
3 - PISTON BORE
TJ BRAKES - BASE 5 - 13
DISC BRAKE CALIPERS (Continued)
(3) I nstal l bushi ng boots i n cal i per, then i nsert
bushi ng i nto boot and push bushi ng i nto pl ace (Fi g.
18).
(4) I nstal l new pi ston seal i nto seal groove wi th
fi nger (Fi g. 19).
(5) I nstal l new dust boot on cal i per pi ston and seat
boot i n pi ston groove (Fi g. 20).
(6) Press pi ston i nto cal i per bore by hand, use a
turn and push moti on to work pi ston i nto seal (Fi g.
21).
(7) Press cal i per pi ston to bottom of bore.
(8) Seat dust boot i n cal i per wi th I nstal l er Tool
C-4842 and Tool Handl e C-4171 (Fi g. 22).
(9) Repl ace cal i per bl eed screw i f removed.
Fig. 18 Bushings And Boots Installation
1 - BUSHING
2 - BOOT
Fig. 19 Piston Seal Installation
1 - SEAL GROOVE
2 - PISTON SEAL
Fig. 20 Dust Boot On Piston
1 - PISTON
2 - DUST BOOT
Fig. 21 Caliper Piston Installation
1 - PISTON
2 - BOOT
5 - 14 BRAKES - BASE TJ
DISC BRAKE CALIPERS (Continued)
INSTALLATION
INSTALLATION - FRONT
(1) Cl ean brake shoe mounti ng l edges wi th wi re
brush and appl y l i ght coat of Mopar mul ti -mi l eage
grease to surfaces (Fi g. 23).
(2) I nstal l cal i per by posi ti on notches at l ower end
of brake shoes on bottom mounti ng l edge. Then
rotate cal i per over rotor and seat notches at upper
end of shoes on top mounti ng l edge (Fi g. 24).
(3) Coat cal i per mounti ng bol ts wi th si l i cone
grease. Then i nstal l and ti ghten bol ts to 15 N·m (11
ft. l bs.).
CAUTION: If new caliper bolts are being installed,
or if the original reason for repair was a drag/pull
condition, check caliper bolt length before proceed-
ing. Bolts must not have a shank length greater
than 67.6 mm (2.66 in.) (Fig. 25).
Fig. 22 Piston Dust Boot Installation
1 - HANDLE C-4171
2 - INSTALLER C-4842
3 - DUST BOOT
Fig. 23 Caliper Lubrication Points
1 - BUSHINGS
2 - CALIPER MOUNTING BOLTS
3 - MOUNTING LEDGES
Fig. 24 Caliper Installation
1 - TOP LEDGE
2 - BRAKESHOE TAB ON LEDGE OUTER SURFACE
3 - LEDGE SEATED IN BRAKESHOE NOTCH
4 - BOTTOM LEDGE
Fig. 25 Mounting Bolt Dimensions
1 - 67 mm (± 0.6 mm) 2.637 in. (± 0.0236 in.)
2 - 22 mm (0.866 in.) THREAD LENGTH
3 - CALIPER BOLT
TJ BRAKES - BASE 5 - 15
DISC BRAKE CALIPERS (Continued)
(4) I nstal l brake hose to cal i per wi th new seal
washers and ti ghten fi tti ng bol t to 31 N·m (23 ft.
l bs.).
CAUTION: Verify brake hose is not twisted or
kinked before tightening fitting bolt.
(5) Bl eed base brake system. (Refer to 5 - BRAKES
- STANDARD PROCEDURE).
(6) I nstal l wheel and ti re assembl i es. (Refer to 22 -
TI RES/WHEELS/WHEELS - STANDARD PROCE-
DURE).
(7) Remove supports and l ower vehi cl e.
(8) Veri fy fi rm pedal before movi ng vehi cl e.
INSTALLATION - REAR
(1) I nstal l the brake pads i f removed.
(2) Lubri cate ant-rattl e cl i ps for the di sc brake
pads (Fi g. 26).
(3) I nstal l cal i per to the cal i per adapter.
(4) Coat the cal i per mounti ng sl i de pi n bol ts wi th
si l i cone grease. Then i nstal l and ti ghten the bol ts to
15 N·m (11 ft. l bs.).
(5) I nstal l the brake hose banjo bol t i f removed
(Fi g. 27).
(6) I nstal l the brake hose to the cal i per wi th new
seal washers and ti ghten fi tti ng bol t to 31 N·m (23
ft. l bs.).
CAUTION: Verify brake hose is not twisted or
kinked before tightening fitting bolt.
(7) Remove the prop rod from the vehi cl e.
(8) Bl eed the base brake system, (Refer to 5 -
BRAKES - STANDARD PROCEDURE) OR (Refer to
5 - BRAKES - STANDARD PROCEDURE).
(9) I nstal l the wheel and ti re assembl i es (Refer to
22 - TI RES/WHEELS/WHEELS - STANDARD PRO-
CEDURE).
(10) Remove the supports and l ower the vehi cl e.
(11) Veri fy a fi rm pedal before movi ng the vehi cl e.
BRAKE PADS/SHOES
REMOVAL
REMOVAL - FRONT PADS
(1) Rai se and support vehi cl e.
(2) Remove wheel and ti re assembl y.
(3) Remove cal i per. (Refer to 5 - BRAKES/HY-
DRAULI C/MECHANI CAL/DI SC BRAKE CALI PERS
- REMOVAL).
(4) Pressi ng one end of outboard shoe i nward to
di sengage shoe l ug. Then rotate shoe upward unti l
retai ner spri ng cl ears cal i per. Press opposi te end of
shoe i nward to di sengage shoe l ug and rotate shoe up
and out of cal i per (Fi g. 28).
(5) Grasp ends of i nboard shoe and ti l t shoe out-
ward to rel ease spri ngs from cal i per pi ston (Fi g. 29)
and remove shoe from cal i per.
NOTE: If original brake shoes will be used, keep
them in sets left and right. They are not inter-
changeable.
(6) Secure cal i per to nearby suspensi on part wi th
wi re. Do not allow brake hose to support caliper
weight.
(7) Wi pe cal i per off wi th shop rags or towel s.
Fig. 26 ANTI-RATTLE CLIPS
1 - ROTOR
2 - ANTI-RATTLE CLIPS
Fig. 27 CALIPER INSTALLED
1 - CALIPER MOUNTING BOLTS
2 - CALIPER SLIDES
5 - 16 BRAKES - BASE TJ
DISC BRAKE CALIPERS (Continued)
CAUTION: Do not use compressed air, this can
unseat dust boot and force dirt into piston bore.
REMOVAL - DRUM BRAKE SHOES
(1) Rai se vehi cl e and remove rear wheel s.
(2) Remove and di scard spri ng nuts securi ng
drums to wheel studs.
(3) Remove brake drums.
NOTE: If drums are difficult to remove, back off
adjuster through support plate access hole with
brake tool and screwdriver.
(4) Remove U-cl i p and washer securi ng adjuster
cabl e to parki ng brake l ever (Fi g. 30).
(5) Remove pri mary and secondary return spri ngs
from anchor pi n wi th brake spri ng pl i ers.
(6) Remove hol d-down spri ngs, retai ners and pi ns
wi th standard retai ni ng spri ng tool .
(7) I nstal l spri ng cl amps on wheel cyl i nders to
hol d pi stons i n pl ace.
(8) Remove adjuster l ever, adjuster screw and
spri ng.
(9) Remove adjuster cabl e and cabl e gui de.
(10) Remove brake shoes and parki ng brake strut.
(11) Di sconnect cabl e from parki ng brake l ever and
remove l ever.
REMOVAL - REAR DISC BRAKE PADS
(1) Rai se and support vehi cl e.
(2) Remove the wheel and ti re assembl i es.
(3) Compress the cal i per.
(4) Remove the cal i per, (Refer to 5 - BRAKES/HY-
DRAULI C/MECHANI CAL/DI SC BRAKE CALI PERS
- REMOVAL).
(5) Remove the cal i per by ti l ti ng the top up and off
the cal i per adapter.
NOTE: Do not allow brake hose to support caliper
assembly.
(6) Support and hang the cal i per.
(7) Remove the i nboard brake pad from the cal i per
adapter.
(8) Remove the outboard brake pad from the cal i -
per adapter.
INSTALLATION
INSTALLATION - FRONT PADS
(1) I nstal l i nboard shoe i n cal i per and veri fy shoe
retai ni ng i s ful l y seated i nto the pi ston.
(2) Starti ng one end of outboard shoe i n cal i per
and rotati ng shoe downward i nto pl ace. Veri fy shoe
l ocati ng l ugs and shoe spri ng are seated.
(3) I nstal l cal i per. (Refer to 5 - BRAKES/HY-
DRAULI C/MECHANI CAL/DI SC BRAKE CALI PERS
- I NSTALLATI ON).
(4) I nstal l wheel and ti re assembl y. (Refer to 22 -
TI RES/WHEELS/WHEELS - STANDARD PROCE-
DURE).
(5) Remove support and l ower vehi cl e.
(6) Pump brake pedal unti l cal i per pi stons and
brake shoes are seated.
(7) Top off brake fl ui d l evel i f necessary.
INSTALLATION - DRUM BRAKE SHOES
(1) Cl ean support pl ate wi th brake cl eaner.
Fig. 28 Outboard Brake Shoe Removal
1 - OUTBOARD BRAKESHOE
2 - SHOE SPRING
3 - LOCATING LUG
4 - CALIPER
5 - LOCATING LUG
Fig. 29 Inboard Brake
1 - CALIPER PISTON
2 - SHOE SPRINGS
3 - INBOARD BRAKESHOE
TJ BRAKES - BASE 5 - 17
BRAKE PADS/SHOES (Continued)
(2) I f new drums are bei ng i nstal l ed, remove pro-
tecti ve coati ng wi th carburetor cl eaner or brake
cl eaner.
(3) Appl y mul ti -purpose grease to brake shoe con-
tact surfaces of support pl ate (Fi g. 31).
(4) Lubri cate adjuster screw threads and pi vot
wi th spray l ube.
(5) Attach parki ng brake l ever to secondary brake
shoe. Use new washer and U-cl i p to secure l ever.
(6) Remove wheel cyl i nder cl amps.
(7) Attach parki ng brake cabl e to l ever.
(8) I nstal l brake shoes on support pl ate. Secure
shoes wi th new hol d-down spri ngs, pi ns and retai n-
ers.
(9) I nstal l parki ng brake strut and spri ng.
(10) I nstal l gui de pl ate and adjuster cabl e on
anchor pi n.
(11) I nstal l pri mary and secondary return spri ngs.
(12) I nstal l adjuster cabl e gui de on secondary
shoe.
(13) Lubri cate and assembl e adjuster screw.
(14) I nstal l adjuster screw, spri ng and l ever and
connect to adjuster cabl e.
(15) Adjust shoes to drum. (Refer to 5 - BRAKES/
HYDRAULI C/MECHANI CAL/DRUM - ADJUST-
MENTS).
Fig. 30 Drum Brake Components—Typical
1 - ADJUSTER LEVER
2 - ADJUSTER CABLE
3 - HOLDDOWN SPRING AND RETAINERS
4 - ADJUSTER LEVER SPRING
5 - TRAILING SHOE
6 - CYLINDER-TO-SUPPORT SEAL
7 - HOLDDOWN PINS
8 - ACCESS PLUGS
9 - SUPPORT PLATE
10 - CABLE HOLE PLUG
11 - PARK BRAKE STRUT AND SPRING
12 - ADJUSTER SCREW ASSEMBLY
13 - HOLDDOWN SPRING AND RETAINERS
14 - LEADING SHOE
15 - CABLE GUIDE
16 - SHOE RETURN SPRINGS
17 - SHOE GUIDE PLATE
18 - PIN
19 - SHOE SPRING
20 - PARK BRAKE LEVER
Fig. 31 Shoe Contact Surfaces
1 - ANCHOR PIN
2 - SUPPORT PLATE
3 - SHOE CONTACT SURFACES
5 - 18 BRAKES - BASE TJ
BRAKE PADS/SHOES (Continued)
(16) I nstal l wheel /ti re assembl i es and l ower vehi -
cl e. (Refer to 22 - TI RES/WHEELS/WHEELS -
STANDARD PROCEDURE).
(17) Veri fy fi rm brake pedal before movi ng vehi cl e.
INSTALLATION - REAR DISC BRAKE PADS
(1) Bottom pi stons i n cal i per bore wi th C-cl amp.
Pl ace an ol d brake shoe between a C-cl amp and cal -
i per pi ston.
(2) Cl ean cal i per mounti ng adapter and anti -rattl e
spri ngs.
(3) Lubri cate anti -rattl e spri ngs wi th Mopar brake
grease.
(4) I nstal l anti -rattl e spri ngs.
NOTE: Anti-rattle springs are not interchangeable.
(5) I nstal l i nboard brake pad i n adapter.
(6) I nstal l outboard brake pad i n adapter.
(7) Ti l t the top of the cal i per over rotor and under
adapter. Then push the bottom of the cal i per down
onto the adapter.
(8) I nstal l cal i per, (Refer to 5 - BRAKES/HY-
DRAULI C/MECHANI CAL/DI SC BRAKE CALI PERS
- I NSTALLATI ON).
(9) I nstal l wheel and ti re assembl i es and l ower
vehi cl e, (Refer to 22 - TI RES/WHEELS/WHEELS -
STANDARD PROCEDURE).
(10) Appl y brakes several ti mes to seat cal i per pi s-
tons and brake shoes and obtai n fi rm pedal .
(11) Top off master cyl i nder fl ui d l evel .
DRUM
DESCRIPTION
The brake systems use a l eadi ng shoe (pri mary)
and trai l i ng shoe (secondary). The mounti ng hard-
ware i s si mi l ar but not i nterchangeabl e (Fi g. 30).
OPERATION
When the brake pedal i s depressed hydraul i c pres-
sure pushes the rear brake wheel cyl i nder pi stons
outward. The wheel cyl i nder push rods then push the
brake shoes outward agai nst the brake drum. When
the brake pedal i s rel eased return spri ngs attached
to the brake shoes pul l the shoes back to there ori g-
i nal posi ti on. (Fi g. 30)
DIAGNOSIS AND TESTING - BRAKE DRUM
RUNOUT
The maxi mum al l owabl e di ameter of the drum
braki ng surface i s i ndi cated on the drum outer edge.
General l y, a drum can be machi ned to a maxi mum of
1.52 mm (0.060 i n.) oversi ze. Al ways repl ace the
drum i f machi ni ng woul d cause drum di ameter to
exceed the si ze l i mi t i ndi cated on the drum.
BRAKE DRUM RUNOUT
Measure drum di ameter and runout wi th an accu-
rate gauge. The most accurate method of measure-
ment i nvol ves mounti ng the drum i n a brake l athe
and checki ng vari ati on and runout wi th a di al i ndi -
cator.
Vari ati ons i n drum di ameter shoul d not exceed
0.069 mm (0.0028 i n.). Drum runout shoul d not
exceed 0.18 mm (0.007 i n.) out of round. Machi ne the
drum i f runout or vari ati on exceed these val ues.
Repl ace the drum i f machi ni ng causes the drum to
exceed the maxi mum al l owabl e di ameter.
STANDARD PROCEDURE - BRAKE DRUM
MACHINING
The brake drums can be machi ned on a drum l athe
when necessary. I ni ti al machi ni ng cuts shoul d be l i m-
i ted to 0.12 - 0.20 mm (0.005 - 0.008 i n.) at a ti me as
heavi er feed rates can produce taper and surface
vari ati on. Fi nal fi ni sh cuts of 0.025 to 0.038 mm
(0.001 to 0.0015 i n.) are recommended and wi l l gen-
eral l y provi de the best surface fi ni sh.
Be sure the drum i s securel y mounted i n the l athe
before machi ni ng operati ons. A damper strap shoul d
al ways be used around the drum to reduce vi brati on
and avoi d chatter marks.
The maxi mum al l owabl e di ameter of the drum
braki ng surface i s stamped or cast i nto the drum
outer edge.
CAUTION: Replace the drum if machining will cause
the drum to exceed the maximum allowable diame-
ter.
CLEANING
Cl ean the i ndi vi dual brake components, i ncl udi ng
the support pl ate and wheel cyl i nder exteri or, wi th a
water dampened cl oth or wi th brake cl eaner. Do not
use any other cl eani ng agents. Remove l i ght rust and
scal e from the brake shoe contact pads on the sup-
port pl ate wi th fi ne sandpaper.
INSPECTION
As a general rul e, ri veted brake shoes shoul d be
repl aced when worn to wi thi n 0.78 mm (1/32 i n.) of
the ri vet heads. Bonded l i ni ng shoul d be repl aced
when worn to a thi ckness of 1.6 mm (1/16 i n.).
Exami ne the l i ni ng contact pattern to determi ne i f
the shoes are bent or the drum i s tapered. The l i ni ng
shoul d exhi bi t contact across i ts enti re wi dth. Shoes
exhi bi ti ng contact onl y on one si de shoul d be
repl aced and the drum checked for runout or taper.
TJ BRAKES - BASE 5 - 19
BRAKE PADS/SHOES (Continued)
I nspect the adjuster screw assembl y. Repl ace the
assembl y i f the star wheel or threads are damaged,
or the components are severel y rusted or corroded.
Di scard the brake spri ngs and retai ner components
i f worn, di storted or col l apsed. Al so repl ace the
spri ngs i f a brake drag condi ti on had occurred. Over-
heati ng wi l l di stort and weaken the spri ngs.
I nspect the brake shoe contact pads on the support
pl ate, repl ace the support pl ate i f any of the pads are
worn or rusted through. Al so repl ace the pl ate i f i t i s
bent or di storted (Fi g. 32).
ADJUSTMENTS - REAR DRUM BRAKE
The rear drum brakes are equi pped wi th a sel f-ad-
justi ng mechani sm. Under normal ci rcumstances, the
onl y ti me adjustment i s requi red i s when the shoes
are repl aced, removed for access to other parts, or
when one or both drums are repl aced.
Adjustment can be made wi th a standard brake
gauge or wi th adjusti ng tool . Adjustment i s per-
formed wi th the compl ete brake assembl y i nstal l ed
on the backi ng pl ate.
ADJUSTMENT WITH BRAKE GAUGE
(1) Be sure parki ng brakes are ful l y rel eased.
(2) Rai se rear of vehi cl e and remove wheel s and
brake drums.
(3) Veri fy that l eft and ri ght automati c adjuster
l evers and cabl es are properl y connected.
(4) I nsert brake gauge i n drum. Expand gauge
unti l gauge i nner l egs contact drum braki ng surface.
Then l ock gauge i n posi ti on (Fi g. 33).
(5) Reverse gauge and i nstal l i t on brake shoes.
Posi ti on gauge l egs at shoe centers as shown (Fi g.
34). I f gauge does not fi t (too l oose/too ti ght), adjust
shoes.
(6) Pul l shoe adjuster l ever away from adjuster
screw star wheel .
(7) Turn adjuster screw star wheel (by hand) to
expand or retract brake shoes. Conti nue adjustment
unti l gauge outsi de l egs are l i ght drag-fi t on shoes.
(8) I nstal l brake drums and wheel s and l ower
vehi cl e.
(9) Dri ve vehi cl e and make one forward stop fol -
l owed by one reverse stop. Repeat procedure 8-10
ti mes to operate automati c adjusters and equal i ze
adjustment.
NOTE: Bring vehicle to complete standstill at each
stop. Incomplete, rolling stops will not activate
automatic adjusters.
Fig. 32 Shoe Contact Surfaces
1 - ANCHOR PIN
2 - SUPPORT PLATE
3 - SHOE CONTACT SURFACES
Fig. 33 Adjusting Gauge On Drum
1 - BRAKE GAUGE
2 - BRAKE DRUM
Fig. 34 Adjusting Gauge On Brake Shoes
1 - BRAKE GAUGE
2 - BRAKE SHOES
5 - 20 BRAKES - BASE TJ
DRUM (Continued)
ADJUSTMENT WITH ADJUSTING TOOL
(1) Be sure parki ng brake l ever i s ful l y rel eased.
(2) Rai se vehi cl e so rear wheel s can be rotated
freel y.
(3) Remove pl ug from each access hol e i n brake
support pl ates.
(4) Loosen parki ng brake cabl e adjustment nut
unti l there i s sl ack i n front cabl e.
(5) I nsert adjusti ng tool through support pl ate
access hol e and engage tool i n teeth of adjusti ng
screw star wheel (Fi g. 35).
(6) Rotate adjuster screw star wheel (move tool
handl e upward) unti l sl i ght drag can be fel t when
wheel i s rotated.
(7) Push and hol d adjuster l ever away from star
wheel wi th thi n screwdri ver.
(8) Back off adjuster screw star wheel unti l brake
drag i s el i mi nated.
(9) Repeat adjustment at opposi te wheel . Be sure
adjustment i s equal at both wheel s.
(10) I nstal l support pl ate access hol e pl ugs.
(11) Adjust parki ng brake cabl e and l ower vehi cl e.
(12) Dri ve vehi cl e and make one forward stop fol -
l owed by one reverse stop. Repeat procedure 8-10
ti mes to operate automati c adjusters and equal i ze
adjustment.
NOTE: Bring vehicle to complete standstill at each
stop. Incomplete, rolling stops will not activate
automatic adjusters.
FLUID
DIAGNOSIS AND TESTING - BRAKE FLUID
CONTAMINATION
I ndi cati ons of fl ui d contami nati on are swol l en or
deteri orated rubber parts.
Swol l en rubber parts i ndi cate the presence of
petrol eum i n the brake fl ui d.
To test for contami nati on, put a smal l amount of
drai ned brake fl ui d i n cl ear gl ass jar. I f fl ui d sepa-
rates i nto l ayers, there i s mi neral oi l or other fl ui d
contami nati on of the brake fl ui d.
I f brake fl ui d i s contami nated, drai n and thor-
oughl y fl ush system. Repl ace master cyl i nder, propor-
ti oni ng val ve, cal i per seal s, wheel cyl i nder seal s,
Anti l ock Brakes hydraul i c uni t and al l hydraul i c
fl ui d hoses.
STANDARD PROCEDURE - BRAKE FLUID
LEVEL
Al ways cl ean the master cyl i nder reservoi r and
caps before checki ng fl ui d l evel . I f not cl eaned, di rt
coul d enter the fl ui d.
The fl ui d fi l l l evel i s i ndi cated on the si de of the
master cyl i nder reservoi r (Fi g. 36).
The correct fl ui d l evel i s to the FULL i ndi cator on
the si de of the reservoi r. I f necessary, add fl ui d to the
proper l evel .
SPECIFICATIONS
BRAKE FLUID
The brake fl ui d used i n thi s vehi cl e must conform
to DOT 3 speci fi cati ons and SAE J1703 standards.
No other type of brake fl ui d i s recommended or
approved for usage i n the vehi cl e brake system. Use
Fig. 35 Brake Adjustment
1 - STAR WHEEL
2 - LEVER
3 - BRAKE SHOE WEB
4 - SCREWDRIVER
5 - ADJUSTING TOOL
6 - ADJUSTER SPRING
Fig. 36 Master Cylinder Fluid
1 - INDICATOR
2 - RESERVOIR
TJ BRAKES - BASE 5 - 21
DRUM (Continued)
onl y Mopar brake fl ui d or an equi val ent from a
ti ghtl y seal ed contai ner.
CAUTION: Never use reclaimed brake fluid or fluid
from an container which has been left open. An
open container of brake fluid will absorb moisture
from the air and contaminate the fluid.
CAUTION: Never use any type of a petroleum-based
fluid in the brake hydraulic system. Use of such
type fluids will result in seal damage of the vehicle
brake hydraulic system causing a failure of the
vehicle brake system. Petroleum based fluids would
be items such as engine oil, transmission fluid,
power steering fluid, etc.
FLUID RESERVOIR
REMOVAL
(1) Remove reservoi r cap and empty fl ui d i nto
drai n contai ner.
(2) Remove pi ns that retai n reservoi r to master
cyl i nder. Use hammer and pi n punch to remove pi ns
(Fi g. 37).
(3) Cl amp cyl i nder body i n vi se wi th brass protec-
ti ve jaws.
(4) Loosen reservoi r from grommets wi th pry tool
(Fi g. 38).
(5) Remove reservoi r by rocki ng i t to one si de and
pul l i ng free of grommets (Fi g. 39).
(6) Remove ol d grommets from cyl i nder body (Fi g.
40).
Fig. 37 Reservoir Retaining Pins
1 - PIN PUNCH
2 - RESERVOIR
3 - BODY
4 - ROLL PINS
Fig. 38 Loosening Reservoir
1 - PRY TOOL
2 - RESERVOIR
3 - GROMMET
4 - MASTER CYLINDER BODY
Fig. 39 Reservoir Removal
1 - RESERVOIR
2 - GROMMETS
Fig. 40 Grommet Removal
1 - MASTER CYLINDER BODY
2 - GROMMETS
5 - 22 BRAKES - BASE TJ
FLUID (Continued)
INSTALLATION
CAUTION: Do not use any type of tool to install the
grommets. Tools may cut, or tear the grommets cre-
ating a leak problem after installation. Install the
grommets using finger pressure only.
(1) Lubri cate new grommets wi th cl ean brake fl ui d
and I nstal l new grommets i n cyl i nder body (Fi g. 41).
Use fi nger pressure to i nstal l and seat grommets.
(2) Start reservoi r i n grommets. Then rock reser-
voi r back and forth whi l e pressi ng downward to seat
i t i n grommets.
(3) I nstal l pi ns that retai n reservoi r to cyl i nder
body.
(4) Fi l l and bl eed master cyl i nder on bench before
i nstal l ati on i n vehi cl e.
MASTER CYLINDER
DESCRIPTION
The master cyl i nder has a removabl e nyl on reser-
voi r. The cyl i nder body i s made of al umi num and
contai ns a pri mary and secondary pi ston assembl y.
The cyl i nder body i ncl udi ng the pi ston assembl i es
are not servi ceabl e. I f di agnosi s i ndi cates an i nternal
probl em wi th the cyl i nder body, i t must be repl aced
as an assembl y. The reservoi r and grommets are the
onl y repl aceabl e parts on the master cyl i nder.
OPERATION
The master cyl i nder bore contai ns a pri mary and
secondary pi ston. The pri mary pi ston suppl i es
hydraul i c pressure to the front brakes. The secondary
pi ston suppl i es hydraul i c pressure to the rear brakes.
The master cyl i nder reservoi r stores reserve brake
fl ui d for the hydraul i c brake ci rcui ts.
DIAGNOSIS AND TESTING - MASTER
CYLINDER/POWER BOOSTER
(1) Start engi ne and check booster vacuum hose
connecti ons. A hi ssi ng noi se i ndi cates vacuum l eak.
Correct any vacuum l eak before proceedi ng.
(2) Stop engi ne and shi ft transmi ssi on i nto Neu-
tral .
(3) Pump brake pedal unti l al l vacuum reserve i n
booster i s depl eted.
(4) Press and hol d brake pedal under l i ght foot
pressure. The pedal shoul d hol d fi rm, i f the pedal
fal l s away master cyl i nder i s faul ty (i nternal l eak-
age).
(5) Start engi ne and note pedal acti on. I t shoul d
fal l away sl i ghtl y under l i ght foot pressure then hol d
fi rm. I f no pedal acti on i s di scerni bl e, power booster,
vacuum suppl y, or vacuum check val ve i s faul ty. Pro-
ceed to the POWER BOOSTER VACUUM TEST.
(6) I f the POWER BOOSTER VACUUM TEST
passes, rebui l d booster vacuum reserve as fol l ows:
Rel ease brake pedal . I ncrease engi ne speed to 1500
rpm, cl ose the throttl e and i mmedi atel y turn off i gni -
ti on to stop engi ne.
(7) Wai t a mi ni mum of 90 seconds and try brake
acti on agai n. Booster shoul d provi de two or more vac-
uum assi sted pedal appl i cati ons. I f vacuum assi st i s
not provi ded, booster i s faul ty.
POWER BOOSTER VACUUM TEST
(1) Connect vacuum gauge to booster check val ve
wi th short l ength of hose and T-fi tti ng (Fi g. 42).
(2) Start and run engi ne at curb i dl e speed for one
mi nute.
(3) Observe the vacuum suppl y. I f vacuum suppl y
i s not adequate, repai r vacuum suppl y.
(4) Cl amp hose shut between vacuum source and
check val ve.
(5) Stop engi ne and observe vacuum gauge.
(6) I f vacuum drops more than one i nch HG (33
mi l l i bars) wi thi n 15 seconds, booster di aphragm or
check val ve i s faul ty.
POWER BOOSTER CHECK VALVE TEST
(1) Di sconnect vacuum hose from check val ve.
(2) Remove check val ve and val ve seal from
booster.
(3) Use a hand operated vacuum pump for test.
(4) Appl y 15-20 i nches vacuum at l arge end of
check val ve (Fi g. 43).
(5) Vacuum shoul d hol d steady. I f gauge on pump
i ndi cates vacuum l oss, check val ve i s faul ty and
shoul d be repl aced.
Fig. 41 Grommet Installation
1 - WORK NEW GROMMETS INTO PLACE USING FINGER
PRESSURE ONLY
TJ BRAKES - BASE 5 - 23
FLUID RESERVOIR (Continued)
STANDARD PROCEDURE - MASTER CYLINDER
BLEEDING
A new master cyl i nder shoul d be bl ed before i nstal -
l ati on on the vehi cl e. Requi red bl eedi ng tool s i ncl ude
bl eed tubes and a wood dowel to stroke the pi stons.
Bl eed tubes can be fabri cated from brake l i ne.
(1) Mount master cyl i nder i n vi se.
(2) Attach bl eed tubes to cyl i nder outl et ports.
Then posi ti on each tube end i nto the reservoi r (Fi g.
44).
(3) Fi l l reservoi r wi th fresh brake fl ui d.
(4) Press cyl i nder pi stons i nward wi th wood dowel .
Then rel ease pi stons and al l ow them to return under
spri ng pressure. Conti nue bl eedi ng operati ons unti l
ai r bubbl es are no l onger vi si bl e i n fl ui d.
REMOVAL
(1) Remove evaporati ve cani ster.
(2) Di sconnect brake l i nes to master cyl i nder and
combi nati on val ve (Fi g. 45).
(3) Remove combi nati on val ve bracket mounti ng
nuts and remove val ve.
(4) Remove master cyl i nder mounti ng nuts and
remove master cyl i nder.
(5) Remove cyl i nder cover and drai n fl ui d.
Fig. 42 Typical Booster Vacuum Test Connections
1 - TEE FITTING
2 - SHORT CONNECTING HOSE
3 - CHECK VALVE
4 - CHECK VALVE HOSE
5 - CLAMP TOOL
6 - INTAKE MANIFOLD
7 - VACUUM GAUGE
Fig. 43 Vacuum Check Valve And Seal
1 - BOOSTER CHECK VALVE
2 - APPLY TEST VACUUM HERE
3 - VALVE SEAL
Fig. 44 Master Cylinder Bleeding
1 - BLEEDING TUBES
2 - RESERVOIR
Fig. 45 Master
1 - COMBINATION VALVE
2 - MASTER CYLINDER
5 - 24 BRAKES - BASE TJ
MASTER CYLINDER (Continued)
INSTALLATION
NOTE: If master cylinder is replaced, bleed cylinder
before installation.
(1) Remove protecti ve sl eeve from pri mary pi ston
shank on new master cyl i nder.
(2) Check condi ti on of seal at rear of cyl i nder body.
Reposi ti on seal i f di sl odged. Repl ace seal i f cut, or
torn.
(3) I nstal l master cyl i nder onto brake booster
studs and ti ghten mounti ng nuts to 17 N·m (13 ft.
l bs.).
NOTE: Use only original or factory replacement
nuts.
(4) I nstal l combi nati on val ve onto brake booster
studs and ti ghten mounti ng nuts to 20 N·m (15 ft.
l bs.).
(5) I nstal l brake l i nes to master cyl i nder and com-
bi nati on val ve by hand to avoi d cross threadi ng.
(6) Ti ghten master cyl i nder brake l i nes to 19 N·m
(14 ft. l bs.).
(7) Ti ghten combi nati on val ve brake l i nes to 19
N·m (14 ft. l bs.).
(8) I nstal l evaporati ve cani ster.
(9) Bl eed base brake system. (Refer to 5 - BRAKES
- STANDARD PROCEDURE).
PEDAL
DESCRIPTION
A suspended-type brake pedal i s used, the pedal
pi vots on a shaft mounted i n the pedal support
bracket. The bracket i s attached to the dash panel .
The brake pedal assembl y and pedal pad are the
onl y servi ceabl e component.
OPERATION
The brake pedal i s attached to the booster push
rod. When the pedal i s depressed, the pri mary
booster push rod i s depressed whi ch moves the
booster secondary rod. The booster secondary rod
depresses the master cyl i nder pi ston.
REMOVAL
(1) Remove negati ve battery cabl e.
(2) Remove brake l amp swi tch.
(3) Remove ABS control l er i f equi pped.
(4) Remove retai ner cl i p securi ng booster push rod
to pedal (Fi g. 46) and cl utch rod retai ner cl i p i f
equi pped.
(5) Remove bol ts from brake pedal support and
booster mounti ng nuts. Remove mounti ng stud pl ate
nuts or cl utch cyl i nder mounti ng nuts i f equi pped.
(6) Sl i d brake booster/master cyl i nder assembl y
forward.
(7) Remove mounti ng stud pl ate or sl i d cl utch cyl -
i nder forward i f equi pped.
(8) Ti l t the pedal support down to gai n shaft cl ear-
ance.
(9) Remove pedal shaft C–cl i p from passenger si de
of the shaft.
(10) Sl i de the pedal shaft toward the dri vers si de
and remove the remai ni ng C-cl i p.
(11) Sl i d the shaft out of the pedal bracket and
remove the pedal .
(12) Remove pedal bushi ngs i f they are to be
repl aced.
INSTALLATION
(1) I nstal l new bushi ngs i n pedal . Lubri cate bush-
i ngs and shaft wi th mul ti -purpose grease.
(2) Posi ti on pedal i n bracket and i nstal l shaft.
(3) I nstal l new pi vot pi n C-cl i p.
(4) Posi ti on pedal support and i nstal l support bol ts
and ti ghten to 28 N·m (21 ft. l bs.).
(5) Sl i d the booster/master cyl i nder assembl y i nto
pl ace, i nstal l mounti ng nuts and ti ghten to 39 N·m
(29 ft. l bs.).
(6) I nstal l stud pl ate or cl utch cyl i nder i f equi pped
and ti ghten mounti ng nut to 28 N·m (21 ft. l bs.).
I nstal l retai ner cl i p securi ng booster push rod to
pedal (Fi g. 46) and cl utch rod retai ner cl i p i f
equi pped.
(7) I nstal l ABS control l er i f equi pped.
(8) I nstal l and connect brake l amp swi tch.
(9) I nstal l negati ve battery cabl e.
Fig. 46 Push Rod Attachment
1 - BRAKE PEDAL
2 - BOOSTER ROD
TJ BRAKES - BASE 5 - 25
MASTER CYLINDER (Continued)
POWER BRAKE BOOSTER
DESCRIPTION
The booster assembl y consi sts of a housi ng di vi ded
i nto separate chambers by two i nternal di aphragms.
The outer edge of each di aphragm i s attached to the
booster housi ng.
Two push rods are used i n the booster. The pri -
mary push rod connects the booster to the brake
pedal . The secondary push rod connects the booster
to the master cyl i nder to stroke the cyl i nder pi stons.
OPERATION
The atmospheri c i nl et val ve i s opened and cl osed
by the pri mary push rod. Booster vacuum suppl y i s
through a hose attached to an i ntake mani fol d fi tti ng
at one end and to the booster check val ve at the
other. The vacuum check val ve i n the booster housi ng
i s a one-way devi ce that prevents vacuum l eak back.
Power assi st i s generated by uti l i zi ng the pressure
di fferenti al between normal atmospheri c pressure
and a vacuum. The vacuum needed for booster oper-
ati on i s taken di rectl y from the engi ne i ntake mani -
fol d. The entry poi nt for atmospheri c pressure i s
through a fi l ter and i nl et val ve at the rear of the
housi ng (Fi g. 47).
Fig. 47 Power Brake Booster–Typical
1 - VACUUM CHECK VALVE
2 - FRONT DIAPHRAGM
3 - REAR DIAPHRAGM
4 - HOUSING
5 - SEAL
6 - AIR FILTER
7 - PRIMARY PUSH ROD (TO BRAKE PEDAL)
8 - ATMOSPHERIC INLET VALVE ASSEMBLY
9 - BOOSTER MOUNTING STUDS (4)
10 - SECONDARY PUSH ROD (TO MASTER CYLINDER)
11 - MASTER CYLINDER MOUNTING STUD (2)
12 - SPRING
5 - 26 BRAKES - BASE TJ
The chamber areas forward of the booster di a-
phragms are exposed to vacuum from the i ntake
mani fol d. The chamber areas to the rear of the di a-
phragms, are exposed to normal atmospheri c pres-
sure of 101.3 ki l opascal s (14.7 pounds/square i n.).
Brake pedal appl i cati on causes the pri mary push
rod to open the atmospheri c i nl et val ve. Thi s exposes
the area behi nd the di aphragms to atmospheri c pres-
sure. The resul ti ng pressure di fferenti al provi des the
extra appl y force for power assi st.
The booster check val ve, check val ve grommet and
booster seal s are servi ceabl e.
REMOVAL
(1) Remove combi nati on val ve and master cyl i nder.
(2) Di sconnect vacuum hose from booster check
val ve.
(3) Remove retai ni ng cl i p that secures booster
push rod to brake pedal (Fi g. 48) and sl i de the rod off
the pi n.
(4) Remove four nuts attachi ng booster to front
cowl panel (Fi g. 49).
(5) I n engi ne compartment, sl i de booster studs out
of cowl panel , and remove the booster from engi ne
compartment.
(6) Remove dash seal from booster.
INSTALLATION
(1) Cl ean the booster mounti ng surface.
(2) I nstal l dash seal on booster.
(3) Al i gn and posi ti on booster on the front cowl
panel .
(4) I n passenger compartment, i nstal l nuts that
attach booster to dash panel . Ti ghten nuts just
enough to hol d booster i n pl ace.
(5) Lubri cate the pedal pi n and bushi ng wi th
Mopar mul ti -mi l eage grease. Then sl i d the booster
push rod onto brake pedal pi n and secure wi th
retai ni ng cl i p.
(6) Ti ghten booster mounti ng nuts to 39 N·m (29
ft. l bs.).
(7) Connect vacuum hose to booster check val ve.
(8) I nstal l master cyl i nder and combi nati on val ve.
(9) Top off master cyl i nder fl ui d l evel and bl eed
base brakes.
COMBINATION VALVE
DESCRIPTION
The combi nati on val ve contai ns a pressure di ffer-
enti al val ve and swi tch and a rear brake proporti on-
i ng val ve. The val ve i s not repai rabl e and must be
repl aced as an assembl y i f di agnosi s i ndi cates thi s i s
necessary.
OPERATION
PRESSURE DIFFERENTIAL VALVE
The pressure di fferenti al swi tch i s connected to the
brake warni ng l i ght. The swi tch i s actuated by move-
ment of the swi tch val ve. The swi tch moni tors fl ui d
pressure i n the separate front/rear brake hydraul i c
ci rcui ts.
A decrease or l oss of fl ui d pressure i n ei ther
hydraul i c ci rcui t wi l l cause the swi tch val ve to shut-
tl e to the l ow pressure si de. Movement of the val ve
pushes the swi tch pl unger upward. Thi s acti on cl oses
the swi tch i nternal contacts compl eti ng the el ectri cal
ci rcui t to the red warni ng l i ght. The swi tch val ve wi l l
remai n i n an actuated posi ti on unti l repai rs to the
brake system are made.
Fig. 48 Push Rod & Clip
1 - BRAKE PEDAL
2 - BOOSTER ROD
Fig. 49 Booster Mounting Nuts
1 - BOOSTER
2 - BRAKE PEDAL
TJ BRAKES - BASE 5 - 27
POWER BRAKE BOOSTER (Continued)
PROPORTIONING VALVE
The proporti oni ng val ve i s used to bal ance front-
rear brake acti on at hi gh decel erati ons. The val ve
al l ows normal fl ui d fl ow duri ng moderate braki ng.
The val ve onl y control s fl ui d fl ow duri ng hi gh decel -
erati ons brake stops.
DIAGNOSIS AND TESTING - COMBINATION
VALVE
Pressure Differential Switch
(1) Have hel per si t i n dri vers seat to appl y brake
pedal and observe red brake warni ng l i ght.
(2) Rai se vehi cl e on hoi st.
(3) Connect bl eed hose to a rear wheel cyl i nder
and i mmerse hose end i n contai ner parti al l y fi l l ed
wi th brake fl ui d.
(4) Have hel per press and hol d brake pedal to fl oor
and observe warni ng l i ght.
(a) I f warni ng l i ght i l l umi nates, swi tch i s operat-
i ng correctl y.
(b) I f l i ght fai l s to i l l umi nate, check ci rcui t fuse,
bul b, and wi ri ng. The parki ng brake swi tch can be
used to ai d i n i denti fyi ng whether or not the brake
l i ght bul b and fuse i s functi onal . Repai r or repl ace
parts as necessary and test di fferenti al pressure
swi tch operati on agai n.
(5) I f warni ng l i ght sti l l does not i l l umi nate,
swi tch i s faul ty. Repl ace combi nati on val ve assembl y,
bl eed brake system and veri fy proper swi tch and
val ve operati on.
REMOVAL
(1) Remove brake l i nes that connect master cyl i n-
der to combi nati on val ve (Fi g. 50).
(2) Di sconnect brake l i nes that connect combi na-
ti on val ve to front and rear brakes.
(3) Di sconnect wi re from combi nati on val ve swi tch
termi nal . Be careful when separati ng wi re connector
as l ock tabs are easi l y damaged i f not ful l y di sen-
gaged.
(4) Remove nuts attachi ng combi nati on val ve
bracket to booster studs and remove val ve bracket off
booster studs (Fi g. 51).
INSTALLATION
(1) Posi ti on val ve bracket on booster studs and
ti ghten bracket attachi ng nuts to 20 N·m (15 ft. l bs.).
(2) Al i gn and start brake l i ne fi tti ngs i n combi na-
ti on val ve and master cyl i nder by hand to avoi d cross
threadi ng.
(3) Ti ghten brake l i ne fi tti ngs at combi nati on val ve
to 19 N·m (14 ft. l bs.).
(4) Ti ghten brake l i ne fi tti ngs at master cyl i nder
to 19 N·m (14 ft. l bs.).
(5) Connect wi re to di fferenti al pressure swi tch i n
combi nati on val ve.
(6) Bl eed base brake system. (Refer to 5 - BRAKES
- STANDARD PROCEDURE).
ROTORS
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - DISC BRAKE
ROTOR
The rotor braki ng surfaces shoul d not be refi ni shed
unl ess necessary.
Li ght surface rust and scal e can be removed wi th a
l athe equi pped wi th dual sandi ng di scs. The rotor
Fig. 50 Combination Valve/Master Cylinder
1 - COMBINATION VALVE
2 - MASTER CYLINDER
Fig. 51 Combination Valve Bracket
1 - MASTER CYLINDER
2 - COMBINATION VALVE BRACKET
5 - 28 BRAKES - BASE TJ
COMBINATION VALVE (Continued)
surfaces can be restored by machi ni ng i n a di sc brake
l athe i f surface scori ng and wear are l i ght.
Repl ace the rotor under the fol l owi ng condi ti ons:
• Severel y Scored
• Tapered
• Hard Spots
• Cracked
• Bel ow Mi ni mum Thi ckness
ROTOR MINIMUM THICKNESS
Measure rotor thi ckness at the center of the brake
shoe contact surface. Repl ace the rotor i f worn bel ow
mi ni mum thi ckness, or i f machi ni ng woul d reduce
thi ckness bel ow the al l owabl e mi ni mum.
Rotor mi ni mum thi ckness i s usual l y speci fi ed on
the rotor hub. The speci fi cati on i s ei ther stamped or
cast i nto the hub surface.
ROTOR RUNOUT
Check rotor l ateral runout wi th di al i ndi cator
C-3339 (Fi g. 52). Excessi ve l ateral runout wi l l cause
brake pedal pul sati on and rapi d, uneven wear of the
brake shoes. Posi ti on the di al i ndi cator pl unger
approxi matel y 25.4 mm (1 i n.) i nward from the rotor
edge.
NOTE: Be sure wheel bearing has zero end play
before checking rotor runout.
Maxi mum al l owabl e rotor runout i s 0.102 mm
(0.004 i n.).
ROTOR THICKNESS VARIATION
Vari ati ons i n rotor thi ckness wi l l cause pedal pul -
sati on, noi se and shudder.
Measure rotor thi ckness at 6-to-12 poi nts around
the rotor face (Fi g. 53).
Posi ti on the mi crometer approxi matel y 25.4 mm ( 1
i n.) from the rotor outer ci rcumference for each mea-
surement.
Thi ckness shoul d not vary by more than 0.013 mm
(0.0005 i n.) from poi nt-to-poi nt on the rotor. Machi ne
or repl ace the rotor i f necessary.
DIAGNOSIS AND TESTING - BRAKE DRUM IN
HAT ROTOR
The maxi mum al l owabl e di ameter of the drum
braki ng surface i s i ndi cated on the drum outer edge.
Al ways repl ace the drum i f machi ni ng woul d cause
drum di ameter to exceed the si ze l i mi t i ndi cated on
the drum i n hat.
BRAKE DRUM RUNOUT
Measure drum di ameter and runout wi th an accu-
rate gauge. The most accurate method of measure-
ment i nvol ves mounti ng the drum i n a brake l athe
and checki ng vari ati on and runout wi th a di al i ndi -
cator.
Machi ne the drum i f runout or vari ati on exceed
val ues. Repl ace the drum i n hat rotor i f machi ni ng
causes the drum i n hat rotor to exceed the maxi mum
al l owabl e di ameter.
STANDARD PROCEDURE
STANDARD PROCEDURE - DISC ROTOR
MACHINING
The di sc brake rotor can be machi ned i f scored or
worn. The l athe must machi ne both si des of the rotor
Fig. 52 Checking Rotor Runout And Thickness
Variation
1 - DIAL INDICATOR
Fig. 53 Measuring Rotor Thickness
1 - MICROMETER
2 - ROTOR
TJ BRAKES - BASE 5 - 29
ROTORS (Continued)
si mul taneousl y wi th dual cutter heads. The rotor
mounti ng surface must be cl ean before pl aci ng on the
l athe. Equi pment capabl e of machi ni ng onl y one si de
at a ti me may produce a tapered rotor.
NOTE: A hub mounted on-vehicle lathe is recom-
mended. This type of lathe trues the rotor to the
vehicles hub/bearing.
CAUTION: Brake rotors that do not meet minimum
thickness specifications before or after machining
must be replaced.
STANDARD PROCEDURE - BRAKE DRUM IN
HAT ROTOR MACHINING
The brake drum i n hat rotor can be machi ned on a
drum l athe when necessary. I ni ti al machi ni ng cuts
shoul d be l i mi ted to 0.12 - 0.20 mm (0.005 - 0.008 i n.)
at a ti me as heavi er feed rates can produce taper and
surface vari ati on. Fi nal fi ni sh cuts of 0.025 to 0.038
mm (0.001 to 0.0015 i n.) are recommended and wi l l
general l y provi de the best surface fi ni sh.
Be sure the drum i n hat rotor i s securel y mounted
i n the l athe before machi ni ng operati ons. A damper
strap shoul d al ways be used around the drum to
reduce vi brati on and avoi d chatter marks.
The maxi mum al l owabl e di ameter of the drum
braki ng surface i s stamped or cast i nto the drum i n
hat rotor.
CAUTION: Replace the drum in hat rotor if machin-
ing will cause the drum to exceed the maximum
allowable diameter.
REMOVAL
REMOVAL - FRONT
(1) Remove wheel and ti re assembl e.
(2) Remove cal i per. (Refer to 5 - BRAKES/HY-
DRAULI C/MECHANI CAL/DI SC BRAKE CALI PERS
- REMOVAL).
(3) Remove retai ners securi ng rotor to hub studs
(Fi g. 54).
(4) Remove rotor from hub.
(5) I f rotor shi el d requi res servi ce, remove front
hub and beari ng assembl y.
REMOVAL - REAR
(1) Rai se and support the vehi cl e
(2) Remove the ti re and wheel assembl y (Fi g. 55).
(3) Remove the di sc brake cal i per and pads, (Refer
to 5 - BRAKES/HYDRAULI C/MECHANI CAL/DI SC
BRAKE CALI PERS - REMOVAL) (Fi g. 56).
(4) Remove the reti ani ng cl i ps and rotor assembl y.
Fig. 54 Rotor & Hub
1 - ROTOR
2 - RETAINER
3 - BEARING NUT
4 - NUT LOCK
5 - COTTER PIN
6 - WASHER
Fig. 55 ROTOR/CALIPER
1 - CALIPER
2 - ROTOR
3 - OUTBOARD DISC BRAKE PAD
5 - 30 BRAKES - BASE TJ
ROTORS (Continued)
INSTALLATION
INSTALLATION - FRONT
(1) I f new rotor i s bei ng i nstal l ed, remove protec-
ti ve coati ng from rotor surfaces wi th carburetor
cl eaner.
(2) I nstal l rotor on hub.
(3) I nstal l cal i per. (Refer to 5 - BRAKES/HY-
DRAULI C/MECHANI CAL/DI SC BRAKE CALI PERS
- I NSTALLATI ON).
(4) I nstal l wheel and ti re assembl y. (Refer to 22 -
TI RES/WHEELS/WHEELS - STANDARD PROCE-
DURE).
INSTALLATION - REAR
(1) I nstal l the rotor to the axl eshaft.
(2) I nstal l the di sc brake cal i per and pads (Fi g.
56), (Refer to 5 - BRAKES/HYDRAULI C/MECHANI -
CAL/DI SC BRAKE CALI PERS - I NSTALLATI ON).
(3) I nstal l the ti re and wheel assembl y (Refer to 22
- TI RES/WHEELS/WHEELS - STANDARD PROCE-
DURE).
(4) Lower the vehi cl e.
WHEEL CYLINDERS
REMOVAL
(1) Remove wheel and ti re assembl y.
(2) Remove brake drum.
(3) Remove wheel cyl i nder brake l i ne.
(4) Remove brake shoe return spri ngs and move
shoes out of engagement wi th cyl i nder push rods.
(5) Remove cyl i nder attachi ng bol ts and remove
cyl i nder from support pl ate.
DISASSEMBLY
(1) Remove push rods and boots (Fi g. 57).
(2) Press pi stons, cups and spri ng and expander
out of cyl i nder bore.
(3) Remove bl eed screw.
CLEANING
Cl ean the cyl i nder and pi stons wi th cl ean brake
fl ui d or brake cl eaner onl y. Do not use any other
cl eani ng agents.
Dry the cyl i nder and pi stons wi th compressed ai r.
Do not use rags or shop towel s to dry the cyl i nder
components. Li nt from cl oth materi al wi l l adhere to
the cyl i nder bores and pi stons.
INSPECTION
I nspect the cyl i nder bore. Li ght di scol orati on and
dark stai ns i n the bore are normal and wi l l not
i mpai r cyl i nder operati on.
The cyl i nder bore can be l i ghtl y pol i shed but onl y
wi th crocus cl oth. Repl ace the cyl i nder i f the bore i s
scored, pi tted or heavi l y corroded. Honi ng the bore to
restore the surface i s not recommended.
I nspect the cyl i nder pi stons. The pi ston surfaces
shoul d be smooth and free of scratches, scori ng and
corrosi on. Repl ace the pi stons i f worn, scored, or cor-
roded. Do attempt to restore the surface by sandi ng
or pol i shi ng.
Di scard the ol d pi ston cups and the spri ng and
expander. These parts are not reusabl e. The ori gi nal
dust boots may be reused but onl y i f they are i n good
condi ti on.
ASSEMBLY
(1) Lubri cate wheel cyl i nder bore, pi stons, pi ston
cups and spri ng and expander wi th cl ean brake fl ui d.
Fig. 56 ROTOR
1 - CALIPER MOUNTING BOLTS
2 - ROTOR
3 - CALIPER
Fig. 57 Wheel Cylinder Components–Typical
1 - SPRING
2 - CYLINDER
3 - PISTON CLIP
4 - BOOT
5 - PUSH ROD
6 - PISTON
7 - BLEED SCREW
8 - CUP EXPANDERS
TJ BRAKES - BASE 5 - 31
ROTORS (Continued)
(2) I nstal l fi rst pi ston i n cyl i nder bore. Then
i nstal l fi rst cup i n bore and agai nst pi ston. Be sure
lip of piston cup is facing inward (toward
spring and expander) and flat side is against
piston.
(3) I nstal l spri ng and expander fol l owed by
remai ni ng pi ston cup and pi ston.
(4) I nstal l boots on each end of cyl i nder and i nsert
push rods i n boots.
(5) I nstal l cyl i nder bl eed screw.
INSTALLATION
(1) Appl y bead of si l i cone seal er around cyl i nder
mounti ng surface of support pl ate.
(2) I nstal l cyl i nder mounti ng bol ts and ti ghten to
10 N·m (7 ft. l bs.).
(3) I nstal l brake l i ne to cyl i nder and ti ghten to 16
N·m (12 ft. l bs.).
(4) I nstal l brake shoe return spri ng.
(5) I nstal l brake drum.
(6) I nstal l wheel and ti re assembl y. (Refer to 22 -
TI RES/WHEELS/WHEELS - STANDARD PROCE-
DURE).
(7) Bl eed base brake system. (Refer to 5 - BRAKES
- STANDARD PROCEDURE).
SUPPORT PLATE
REMOVAL
(1) Remove wheel and ti re assembl y.
(2) Remove the di sc brake cal i per (Refer to 5 -
BRAKES/HYDRAULI C/MECHANI CAL/DI SC
BRAKE CALI PERS - REMOVAL).
(3) Remove the rotor (Fi g. 58), (Refer to 5 -
BRAKES/HYDRAULI C/MECHANI CAL/ROTORS -
REMOVAL).
(4) Remove the axl e shaft (Fi g. 59), (Refer to 3 -
DI FFERENTI AL & DRI VELI NE/REAR AXLE -
AXLE SHAFTS - REMOVAL).
(5) Remove the park brake shoes (Fi g. 59), (Refer
to 5 - BRAKES/PARKI NG BRAKE/SHOES -
REMOVAL).
(6) Remove the parki ng brake cabl e from the
brake l ever.
(7) Remove the bol ts attachi ng the support pl ate to
the axl e and remove the support pl ate.
INSTALLATION
(1) I nstal l support pl ate on axl e fl ange. Ti ghten
attachi ng bol ts to 115 N·m (85 ft. l bs.).
(2) I nstal l the park brake shoes (Fi g. 59), (Refer to
5 - BRAKES/PARKI NG BRAKE/SHOES - I NSTAL-
LATI ON).
(3) I nstal l parki ng brake cabl e i n the brake l ever.
(4) I nstal l axl e shaft, (Fi g. 58), (Refer to 3 - DI F-
FERENTI AL & DRI VELI NE/REAR AXLE - AXLE
SHAFTS - I NSTALLATI ON).
(5) Adjust brake shoes to drum wi th brake gauge
(Refer to 5 - BRAKES/PARKI NG BRAKE/SHOES -
ADJUSTMENTS).
Fig. 58 PARK BRAKE SHOES INSTALLED
1 - SUPPORT PLATE
2 - PARK BRAKE SHOES
3 - AXLE
Fig. 59 BRAKE SHOES
1 - SUPPORT PLATE
2 - PARK BRAKE SHOES
3 - EQUALIZER
4 - SPRINGS
5 - HOLD DOWN CLIPS
6 - ADJUSTER
5 - 32 BRAKES - BASE TJ
WHEEL CYLINDERS (Continued)
(6) I nstal l the rotor (Refer to 5 - BRAKES/HY-
DRAULI C/MECHANI CAL/ROTORS - I NSTALLA-
TI ON).
(7) I nstal l the cal i per (Refer to 5 - BRAKES/HY-
DRAULI C/MECHANI CAL/DI SC BRAKE CALI PERS
- I NSTALLATI ON).
(8) I nstal l the wheel and ti re assembl y (Refer to 22
- TI RES/WHEELS/WHEELS - STANDARD PROCE-
DURE).
PARKING BRAKE
DESCRIPTION
The parki ng bake i s a hand l ever and cabl e oper-
ated system used to appl y the rear brakes.
OPERATION
A hand operated l ever i n the passenger compart-
ment i s the mai n appl i cati on devi ce. The front cabl e
i s connected between the hand l ever and the ten-
si oner. The tensi oner rod i s attached to the equal i zer
whi ch i s the connecti ng poi nt for the rear cabl es (Fi g.
60).
The rear cabl es are connected to the actuati ng
l ever on each secondary brake shoe. The l evers are
attached to the brake shoes by a pi n ei ther pressed
i nto, or wel ded to the l ever. A cl i p i s used to secure
the pi n i n the brake shoe. The pi n al l ows each l ever
to pi vot i ndependentl y of the brake shoe.
To appl y the parki ng brakes, the hand l ever i s
pul l ed upward. Thi s pul l s the rear brake shoe actu-
ati ng l evers forward, by means tensi oner and cabl es.
As the actuati ng l ever i s pul l ed forward, the parki ng
brake strut (whi ch i s connected to both shoes), exerts
a l i near force agai nst the pri mary brake shoe. Thi s
acti on presses the pri mary shoe i nto contact wi th the
drum. Once the pri mary shoe contacts the drum,
force i s exerted through the strut. Thi s force i s trans-
ferred through the strut to the secondary brake shoe
causi ng i t to pi vot i nto the drum as wel l .
A gear type ratcheti ng mechani sm i s used to hol d
the l ever i n an appl i ed posi ti on. Parki ng brake
rel ease i s accompl i shed by the hand l ever rel ease
button.
A parki ng brake swi tch i s mounted on the parki ng
brake l ever and i s actuated by movement of the
l ever. The swi tch, whi ch i s i n ci rcui t wi th the red
warni ng l i ght i n the dash, wi l l i l l umi nate the warn-
i ng l i ght whenever the parki ng brakes are appl i ed.
Parki ng brake adjustment i s control l ed by a cabl e
tensi oner mechani sm. The cabl e tensi oner, once
adjusted at the factory, shoul d not need further
adjustment under normal ci rcumstances. Adjustment
may be requi red i f a new tensi oner, or cabl es are
i nstal l ed, or di sconnected.
DIAGNOSIS AND TESTING - PARKING BRAKE
NOTE: Parking brake adjustment is controlled by a
cable tensioner. Once the tensioner is adjusted at
the factory, it should not require further attention.
However, there are two instances when adjustment
will be required. The first is when a new tensioner,
or cables have been installed. And the second, is
when the tensioner and cables are disconnected for
access to other brake components.
The parki ng brake swi tch i s i n ci rcui t wi th the red
warni ng l amp i n the dash. The swi tch wi l l cause the
l amp to i l l umi nate onl y when the parki ng brakes are
appl i ed. I f the l amp remai ns on after parki ng brake
rel ease, the swi tch or wi res are faul ty, or cabl e ten-
si oner adjustment i s i ncorrect.
I n most cases, the actual cause of an i mproperl y
functi oni ng parki ng brake (too l oose/too ti ght/won’t
hol d), can be traced to a parki ng brake component.
The l eadi ng cause of i mproper parki ng brake oper-
ati on, i s excessi ve cl earance between the parki ng
brake shoes and the shoe braki ng surface. Excessi ve
cl earance i s a resul t of l i ni ng and/or drum wear,
drum surface machi ned oversi ze, or i noperati ve
adjuster components.
Excessi ve parki ng brake l ever travel (someti mes
descri bed as a l oose l ever or too l oose condi ti on), i s
the resul t of worn brake shoes, i mproper brake shoe
adjustment, or i mproperl y assembl ed brake parts.
A condi ti on where the parki ng brakes do not hol d,
wi l l most probabl y be due to a wheel brake compo-
nent.
Fig. 60 Parking Brake Components
1 - FRONT CABLE
2 - L.R. CABLE
3 - R.R. CABLE
4 - EQUALIZER
5 - TENSIONER ROD
TJ BRAKES - BASE 5 - 33
SUPPORT PLATE (Continued)
I tems to l ook for when di agnosi ng a parki ng brake
probl em, are:
• Rear brake shoe wear.
• Drum surface machi ned oversi ze.
• Front cabl e not secured to l ever.
• Rear cabl e not attached to l ever.
• Rear cabl e sei zed.
• Brake shoes reversed.
• Parki ng brake strut not seated i n shoes.
• Parki ng brake l ever not seated.
• Parki ng brake l ever bi nd.
• Adjuster screws sei zed.
• Adjuster screws reversed.
Parki ng brake adjustment and parts repl acement
procedures are descri bed i n the Parki ng Brake sec-
ti on.
SHOES
DESCRIPTION
Drum i n hat park brakes are dual shoe, i nternal
expandi ng uni ts wi th an automati c sel f adjusti ng
mechani sm (Fi g. 61).
OPERATION
When the parki ng brake pedal i s depressed the
brake cabl e pul l s the brake shoes outward agai nst
the brake drum. When the brake pedal i s rel eased
the return spri ngs attached to the brake shoes pul l
the shoes back to there ori gi nal posi ti on.
REMOVAL
(1) Rai se and support the vehi cl e.
(2) Remove the ti re and wheel assembl y.
(3) Remove the di sc brake cal i per, (Fi g. 62), (Refer
to 5 - BRAKES/HYDRAULI C/MECHANI CAL/DI SC
BRAKE CALI PERS - REMOVAL).
(4) Remove the di sc brake rotor, (Fi g. 62), (Refer to
5 - BRAKES/HYDRAULI C/MECHANI CAL/ROTORS
- REMOVAL).
(5) Di sassembl e the rear park brake shoes (Fi g.
63).
CLEANING - REAR DRUM IN HAT BRAKE
Cl ean the i ndi vi dual brake components, i ncl udi ng
the support pl ate exteri or, wi th a water dampened
cl oth or wi th brake cl eaner. Do not use any other
cl eani ng agents. Remove l i ght rust and scal e from
the brake shoe contact pads on the support pl ate
wi th fi ne sandpaper.
INSPECTION - REAR DRUM IN HAT BRAKE
As a general rul e, ri veted brake shoes shoul d be
repl aced when worn to wi thi n 0.78 mm (1/32 i n.) of
the ri vet heads. Bonded l i ni ng shoul d be repl aced
when worn to a thi ckness of 1.6 mm (1/16 i n.).
Exami ne the l i ni ng contact pattern to determi ne i f
the shoes are bent or the drum i s tapered. The l i ni ng
shoul d exhi bi t contact across i ts enti re wi dth. Shoes
exhi bi ti ng contact onl y on one si de shoul d be
repl aced and the drum checked for runout or taper
(Fi g. 64).
Fig. 61 BRAKE SHOES
1 - SUPPORT PLATE
2 - PARK BRAKE SHOES
3 - EQUALIZER
4 - SPRINGS
5 - HOLD DOWN CLIPS
6 - ADJUSTER
Fig. 62 PARK BRAKE SHOES INSTALLED
1 - SUPPORT PLATE
2 - PARK BRAKE SHOES
3 - AXLE
5 - 34 BRAKES - BASE TJ
PARKING BRAKE (Continued)
I nspect the adjuster screw assembl y. Repl ace the
assembl y i f the star wheel or threads are damaged,
or the components are severel y rusted or corroded
(Fi g. 64).
Di scard the brake spri ngs and retai ner components
i f worn, di storted or col l apsed. Al so repl ace the
spri ngs i f a brake drag condi ti on had occurred. Over-
heati ng wi l l di stort and weaken the spri ngs.
I nspect the brake shoe contact pads on the support
pl ate, repl ace the support pl ate i f any of the pads are
worn or rusted through. Al so repl ace the pl ate i f i t i s
bent or di storted (Fi g. 64).
INSTALLATION
NOTE: On a new vehicle or after parking brake lin-
ing replacement, it is recommended that the park-
ing brake system be conditioned prior to use. This
is done by making one stop from 25 mph on dry
pavement or concrete using light to moderate force
on the parking brake lever.
(1) Reassembl e the rear park brake shoes (Fi g. 63).
(2) Adjust the rear brake shoes (Refer to 5 -
BRAKES/PARKI NG BRAKE/SHOES - ADJUST-
MENTS).
(3) I nstal l the di sc brake rotor (Refer to 5 -
BRAKES/HYDRAULI C/MECHANI CAL/ROTORS -
I NSTALLATI ON).
(4) I nstal l the di sc brake cal i per (Refer to 5 -
BRAKES/HYDRAULI C/MECHANI CAL/DI SC
BRAKE CALI PERS - I NSTALLATI ON).
(5) I nstal l the ti re and wheel assembl y (Refer to 22
- TI RES/WHEELS/WHEELS - STANDARD PROCE-
DURE).
(6) Lower the vehi cl e.
ADJ USTMENTS
ADJUSTMENT - REAR DRUM IN HAT PARK
BRAKE (ROTOR REMOVED)
Under normal ci rcumstances, the onl y ti me adjust-
ment i s requi red i s when the shoes are repl aced,
removed for access to other parts, or when one or
both rotors are repl aced.
Adjustment can be made wi th a standard brake
gauge or wi th adjusti ng tool . Adjustment i s per-
formed wi th the compl ete brake assembl y i nstal l ed
on the backi ng pl ate.
CAUTION: Before adjusting the park brake shoes be
sure that the park brake pedal is in the fully
released position. If park brake pedal is not in the
fully released position, the park brake shoes can
not be accurately adjusted.
Fig. 63 BRAKE SHOES
1 - SUPPORT PLATE
2 - PARK BRAKE SHOES
3 - EQUALIZER
4 - SPRINGS
5 - HOLD DOWN CLIPS
6 - ADJUSTER
Fig. 64 BRAKE SHOES
1 - SUPPORT PLATE
2 - PARK BRAKE SHOES
3 - EQUALIZER
4 - SPRINGS
5 - HOLD DOWN CLIPS
6 - ADJUSTER
TJ BRAKES - BASE 5 - 35
SHOES (Continued)
(1) Rai se vehi cl e.
(2) Remove ti re and wheel .
(3) Remove di sc brake cal i per from cal i per adapter
(Refer to 5 - BRAKES/HYDRAULI C/MECHANI CAL/
DI SC BRAKE CALI PERS - REMOVAL).
(4) Remove rotor from the axl eshaft (Refer to 5 -
BRAKES/HYDRAULI C/MECHANI CAL/ROTORS -
REMOVAL).
NOTE: When measuring the brake drum diameter,
the diameter should be measured in the center of
the area in which the park brake shoes contact the
surface of the brake drum.
(5) Usi ng Brake Shoe Gauge, Speci al Tool C-3919, or
equi val ent, accurately measure the i nsi de di ameter
of the park brake drum porti on of the rotor (Fi g. 65).
(6) Usi ng a rul er that reads i n 64th of an i nch,
accuratel y read the measurement of the i nsi de di am-
eter of the park brake drum from the speci al tool
(Fi g. 66).
(7) Reduce the i nsi de di ameter measurement of
the brake drum that was taken usi ng Speci al Tool
C-3919 by 1/64 of an i nch. Reset Gauge, Brake Shoe,
Speci al Tool C-3919 or the equi val ent used, so that
the outsi de measurement jaws are set to the reduced
measurement (Fi g. 67).
(8) Pl ace Gauge, Brake Shoe, Speci al Tool C-3919,
or equi val ent over the park brake shoes. The speci al
tool must be l ocated di agonal l y across at the top of
one shoe and bottom of opposi te shoe (wi dest poi nt)
of the park brake shoes.
(9) Usi ng the star wheel adjuster, adjust the park
brake shoes unti l the l i ni ng on the park brake shoes
just touches the jaws on the speci al tool .
(10) Repeat step 8 above and measure shoes i n
both di recti ons.
(11) I nstal l brake rotor on the axl eshaft (Refer to 5
- BRAKES/HYDRAULI C/MECHANI CAL/ROTORS -
I NSTALLATI ON).
(12) Rotate rotor to veri fy that the park brake
shoes are not draggi ng on the brake drum. I f park
brake shoes are draggi ng, remove rotor and back off
star wheel adjuster one notch and recheck for brake
shoe drag agai nst drum. Conti nue wi th the previ ous
step unti l brake shoes are not draggi ng on brake
drum.
(13) I nstal l di sc brake cal i per on cal i per adapter
(Refer to 5 - BRAKES/HYDRAULI C/MECHANI CAL/
DI SC BRAKE CALI PERS - I NSTALLATI ON).
(14) I nstal l wheel and ti re.
(15) Ti ghten the wheel mounti ng nuts i n the
proper sequence unti l al l nuts are torqued to hal f the
speci fi ed torque. Then repeat the ti ghteni ng sequence
to the ful l speci fi ed torque of 129 N·m (95 ft. l bs.).
(16) Lower vehi cl e.
Fig. 65 MEASURING PARK BRAKE DRUM
DIAMETER
Fig. 66 READING PARK BRAKE DRUM DIAMETER
1 - SPECIAL TOOL C-3919
2 - RULER
Fig. 67 SETTING GAUGE TO PARK BRAKE SHOE
MEASUREMENT
1 - RULER
2 - SPECIAL TOOL C-3919
5 - 36 BRAKES - BASE TJ
SHOES (Continued)
CAUTION: Before moving vehicle, pump brake
pedal several times to ensure the vehicle has a firm
enough pedal to stop the vehicle.
NOTE: After parking brake lining replacement, it is
recommended that the parking brake system be
conditioned prior to use. This is done by making
one stop from 25 mph on dry pavement or concrete
using light to moderate force on the parking brake
hand lever.
(17) Road test the vehi cl e to ensure proper func-
ti on of the vehi cl e’s brake system.
ADJUSTMENT - WITH ADJUSTING TOOL
Adjustment can be made wi th a standard brake
gauge or wi th adjusti ng tool . Adjustment i s per-
formed wi th the compl ete brake assembl y i nstal l ed
on the backi ng pl ate.
(1) Be sure parki ng brake l ever i s ful l y rel eased.
(2) Rai se vehi cl e so rear wheel s can be rotated
freel y.
(3) Remove pl ug from each access hol e i n brake
support pl ates.
(4) Loosen parki ng brake cabl e adjustment nut
unti l there i s sl ack i n front cabl e.
(5) I nsert adjusti ng tool through support pl ate
access hol e and engage tool i n teeth of adjusti ng
screw star wheel (Fi g. 68).
(6) Rotate adjuster screw star wheel (move tool
handl e upward) unti l sl i ght drag can be fel t when
wheel i s rotated.
(7) Push and hol d adjuster l ever away from star
wheel wi th thi n screwdri ver.
(8) Back off adjuster screw star wheel unti l brake
drag i s el i mi nated.
(9) Repeat adjustment at opposi te wheel . Be sure
adjustment i s equal at both wheel s.
(10) I nstal l support pl ate access hol e pl ugs.
(11) Adjust parki ng brake cabl e and l ower vehi cl e.
(12) Depress park brake l ever and make sure park
brakes hol d the vehi cl e stai onary.
(13) Rel ease park brake l ever.
CABLES
REMOVAL
REMOVAL - DRUM BRAKES
(1) Rai se vehi cl e and l oosen equal i zer nuts unti l
rear cabl es are sl ack.
(2) Di sengage cabl e from equal i zer and remove
cabl e.
(3) Remove cabl e bracket from upper suspensi on
arm (Fi g. 69).
(4) Remove rear wheel and brake drum.
(5) Remove secondary brake shoe and di sconnect
cabl e from l ever on brake shoe.
(6) Compress cabl e retai ner wi th worm dri ve hose
cl amp (Fi g. 70) and remove cabl e from backi ng pl ate.
Fig. 68 Brake Adjustment
1 - STAR WHEEL
2 - LEVER
3 - BRAKE SHOE WEB
4 - SCREWDRIVER
5 - ADJUSTING TOOL
6 - ADJUSTER SPRING
Fig. 69 Parking Brake Cable Bracket
1 - UPPER SUSPENSION ARM
2 - WIRING BRACKET
3 - PARKING BRAKE CABLE BRACKET
TJ BRAKES - BASE 5 - 37
SHOES (Continued)
REMOVAL - DISC BRAKES
(1) Rai se and support the vehi cl e.
(2) Lockout the parki ng brake cabl e.
(3) Loosen the brake cabl e at the equal i zer and
adjuster nut.
(4) Remove the cabl e from the front cabl e.
(5) Remove the cabl e from the equal i zer.
(6) Remove the cabl e from the frame bracket.
(7) Remove the cabl e from the axl e bracket.
(8) Remove the brake cabl e from the brake l ever.
(Fi g. 71)
INSTALLATION
INSTALLATION - DRUM BRAKES
(1) I nstal l new cabl e i n backi ng pl ate. Be sure
cabl e retai ner i s seated.
(2) Attach cabl e to l ever on brake shoe and i nstal l
brake shoe on backi ng pl ate.
(3) Adjust brake shoes to drum wi th brake gauge.
(4) I nstal l brake drum and wheel .
(5) I nstal l cabl e/bracket on upper suspensi on arm.
(6) Engage cabl e i n equal i zer and i nstal l equal i zer
nuts.
(7) Adjust parki ng brakes.
INSTALLATION - DISC BRAKES
(1) I nstal l the brake cabl e to the brake l ever.
(2) I nstal l the cabl e to the axl e bracket (Fi g. 72).
(3) I nstal l the cabl e to the equal i zer (Fi g. 72).
(4) I nstal l the cabl e to the front cabl e.
(5) Adjust the brake cabl e at the equal i zer and
usi ng the adjuster nut.
Fig. 70 Cable Retainer
1 - CABLE RETAINER
2 - REAR CABLE
3 - WORM DRIVE HOSE CLAMP
Fig. 71 CABLE REMOVAL/INSTALLATION
1 - SUPPORT PLAT
2 - PARK BRAKE CABLE
3 - EQUALIZER
Fig. 72 REAR CABLE CONNECTED
1 - BRAKE HOSE
2 - ACTUATOR LEVER
3 - PARK BRAKE CABLE
5 - 38 BRAKES - BASE TJ
CABLES (Continued)
BRAKES - ABS
TABLE OF CONTENTS
page page
BRAKES - ABS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 39
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
DIAGNOSIS AND TESTING - ANTILOCK
BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
STANDARD PROCEDURE - BLEEDING ABS
BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . 40
SPECIFICATIONS
T0RQUE CHART . . . . . . . . . . . . . . . . . . . . . . 40
FRONT WHEEL SPEED SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 41
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 41
G-SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 42
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 42
REAR WHEEL SPEED SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 42
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 43
HCU (HYDRAULIC CONTROL UNIT)
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 43
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 44
BRAKES - ABS
DESCRIPTION
The purpose of the anti l ock system i s to prevent
wheel l ockup duri ng peri ods of hi gh wheel sl i p. Pre-
venti ng l ockup hel ps mai ntai n vehi cl e braki ng acti on
and steeri ng control .
The anti l ock CAB acti vates the system whenever
sensor si gnal s i ndi cate peri ods of hi gh wheel sl i p.
Hi gh wheel sl i p can be descri bed as the poi nt where
wheel rotati on begi ns approachi ng 20 to 30 percent of
actual vehi cl e speed duri ng braki ng. Peri ods of hi gh
wheel sl i p occur when brake stops i nvol ve hi gh pedal
pressure and rate of vehi cl e decel erati on.
Battery vol tage i s suppl i ed to the CAB i gni ti on ter-
mi nal when the i gni ti on swi tch i s turned to Run posi -
ti on. The CAB performs a system i ni ti al i zati on
procedure at thi s poi nt. I ni ti al i zati on consi sts of a
stati c and dynami c sel f check of system el ectri cal
components.
The stati c check occurs after the i gni ti on swi tch i s
turned to Run posi ti on. The dynami c check occurs
when vehi cl e road speed reaches approxi matel y 30
kph (18 mph). Duri ng the dynami c check, the CAB
bri efl y cycl es the pump and sol enoi ds to veri fy oper-
ati on.
I f an ABS component exhi bi ts a faul t duri ng i ni -
ti al i zati on, the CAB i l l umi nates the amber warni ng
l i ght and regi sters a faul t code i n the mi croprocessor
memory.
OPERATION
Duri ng normal braki ng, the master cyl i nder, power
booster and wheel brake uni ts al l functi on as they
woul d i n a vehi cl e wi thout ABS. The HCU compo-
nents are not acti vated.
Duri ng anti l ock braki ng fl ui d pressure i s modu-
l ated accordi ng to wheel speed, degree of sl i p and
rate of decel erati on. A sensor at each wheel converts
wheel speed i nto el ectri cal si gnal s. These si gnal s are
transmi tted to the CAB for processi ng and determi -
nati on of wheel sl i p and decel erati on rate.
The ABS system has three fl ui d pressure control
channel s. The front brakes are control l ed separatel y
and the rear brakes i n tandem. A speed sensor i nput
si gnal i ndi cati ng a hi gh sl i p condi ti on acti vates the
CAB anti l ock program. Two sol enoi d val ves are used
i n each anti l ock control channel . The val ves are al l
l ocated wi thi n the HCU val ve body and work i n pai rs
to ei ther i ncrease, hol d, or decrease appl y pressure as
needed i n the i ndi vi dual control channel s. The sol e-
noi d val ves are not stati c duri ng anti l ock braki ng.
They are cycl ed conti nuousl y to modul ate pressure.
Sol enoi d cycl e ti me i n anti l ock mode can be mea-
sured i n mi l l i seconds.
DIAGNOSIS AND TESTING - ANTILOCK
BRAKES
The ABS brake system performs several sel f-tests
every ti me the i gni ti on swi tch i s turned on and the
vehi cl e i s dri ven. The CAB moni tors the systems
i nput and output ci rcui ts to veri fy the system i s oper-
TJ BRAKES - ABS 5 - 39
ati ng correctl y. I f the on board di agnosti c system
senses that a ci rcui t i s mal functi oni ng the system
wi l l set a troubl e code i n i ts memory.
NOTE: An audible noise may be heard during the
self-test. This noise should be considered normal.
NOTE: The MDS or DRB III scan tool is used to
diagnose the ABS system. For additional informa-
tion refer to the Antilock Brake section in Group
8W. For test procedures refer to the Chassis Diag-
nostic Manual.
STANDARD PROCEDURE - BLEEDING ABS
BRAKE SYSTEM
ABS system bl eedi ng requi res conventi onal bl eed-
i ng methods pl us use of the DRB scan tool . The pro-
cedure i nvol ves performi ng a base brake bl eedi ng,
fol l owed by use of the scan tool to cycl e and bl eed the
HCU pump and sol enoi ds. A second base brake bl eed-
i ng procedure i s then requi red to remove any ai r
remai ni ng i n the system.
(1) Perform base brake bl eedi ng. Refer to base
brake secti on for procedure.
(2) Connect scan tool to the Data Li nk Connector.
(3) Sel ect ANTI LOCK BRAKES, fol l owed by MI S-
CELLANEOUS, then ABS BRAKES. Fol l ow the
i nstructi ons di spl ayed. When scan tool di spl ays TEST
COMPLETE, di sconnect scan tool and proceed.
(4) Perform base brake bl eedi ng a second ti me.
Refer to base brake secti on for procedure.
(5) Top off master cyl i nder fl ui d l evel and veri fy
proper brake operati on before movi ng vehi cl e.
SPECIFICATIONS
T0RQUE CHART
TORQUE SPECIFICATIONS
DESCRIPTION N·m Ft. Lbs. In. Lbs.
G-Sensor
Sensor Bolt
4-5 — 35-45
G-Sensor
Bracket Bolt
8-13 — 75-115
Hydraulic Control Unit
Bracket to HCU Bolts
6.5 — 57
Hydraulic Control Unit
Body Bracket Bolts
16-24 — 142-212
Hydraulic Control Unit
HCU to Body Bracket
Bolts
9-13 — 80-115
Hydraulic Control Unit
Brake Lines
15-18 — 130-160
Controller Anitlock Brakes
Mounting Bolt
7-9 — 60-80
Wheel Speed Sensors
Front Mounting Bolt
4-6 — 34-50
Wheel Speed Sensors
Rear Mounting Bolt
12-14 — 106-124
5 - 40 BRAKES - ABS TJ
BRAKES - ABS (Continued)
FRONT WHEEL SPEED
SENSOR
DESCRIPTION
A speed sensor i s used at each wheel . The front
sensors are mounted to the steeri ng knuckl es. The
rear sensors are mounted to the rear brake backi ng
pl ate.
OPERATION
The sensors convert wheel speed i nto a smal l AC
el ectri cal si gnal . Thi s si gnal i s transmi tted to the
CAB. The CAB convert the AC si gnal i nto a di gi tal
si gnal for each wheel . Thi s vol tage i s generated by
magneti c i nducti on when a tone wheel passes by the
stati onary magneti c of the wheel speed sensor.
A gear type tone ri ng serves as the tri gger mecha-
ni sm for each sensor. The tone ri ngs are mounted at
the outboard ends of the front and rear axl e shafts.
Di fferent sensors are used at the front and rear
wheel s (Fi g. 1). The front/rear sensors have the same
el ectri cal val ues but are not i nterchangeabl e. The
sensors have a resi stance between 900 and 1300
ohms.
FRONT SENSOR AIR GAP
Front sensor ai r gap i s fi xed and not adjustabl e.
Onl y rear sensor ai r gap i s adjustabl e.
Al though front ai r gap i s not adjustabl e, i t can be
checked i f di agnosi s i ndi cates thi s i s necessary. Front
ai r gap shoul d be 0.40 to 1.3 mm (0.0157 to 0.051
i n.). I f gap i s i ncorrect, the sensor i s ei ther l oose, or
damaged.
REAR SENSOR AIR GAP
A rear sensor ai r gap adjustment i s onl y needed
when rei nstal l i ng an ori gi nal sensor. Repl acement
sensors have an ai r gap spacer attached to the sensor
pi ckup face. The spacer establ i shes correct ai r gap
when pressed agai nst the tone ri ng duri ng i nstal l a-
ti on. As the tone ri ng rotates, i t peel s the spacer off
the sensor to create the requi red ai r gap. Rear sensor
ai r gap i s 0.28-1.5 mm (0.011-0.059 i n.).
Sensor ai r gap measurement, or adjustment proce-
dures are provi ded i n thi s secti on. Refer to the front,
or rear sensor removal and i nstal l ati on procedures as
requi red.
REMOVAL
(1) Rai se vehi cl e and turn wheel outward to access
the sensor.
(2) Di sconnect sensor wi re connector at harness
pl ug.
(3) Remove sensor wi re from mounti ng retai ners.
(4) Cl ean sensor and surroundi ng area wi th shop
towel before removal .
(5) Remove bol t attachi ng sensor to steeri ng
knuckl e and remove sensor (Fi g. 2).
INSTALLATION
(1) I f original sensor wi l l be i nstal l ed, wi pe al l
traces of ol d spacer materi al off sensor pi ckup face.
Use a dry shop towel for thi s purpose.
(2) Appl y Mopar Lock N’ Seal or Locti te ௡ 242 on
bol t that secures sensor i n steeri ng knuckl e. Use new
sensor bol t i f ori gi nal bol t i s worn or damaged.
Fig. 1 Typical Wheel Speed Sensors
1 - FRONT SENSOR
2 - REAR SENSOR
3 - PICKUP FACE
Fig. 2 Front Wheel Speed Sensor
1 - WHEEL SPEED SENSOR PIGTAIL
2 - STEERING KNUCKLE
3 - TONE WHEEL
4 - FRONT WHEEL SPEED SENSOR
TJ BRAKES - ABS 5 - 41
(3) Posi ti on sensor on steeri ng knuckl e. Seat sen-
sor l ocati ng tab i n hol e i n knuckl e and i nstal l sensor
attachi ng bol t fi nger ti ght.
(4) Ti ghten sensor attachi ng bol t to 4-6 N·m (34-50
i n. l bs.).
(5) I f ori gi nal sensor has been i nstal l ed, check sen-
sor ai r gap. Ai r gap shoul d be 0.40 to 1.3 mm (0.0157
to 0.051 i n.). I f gap i s i ncorrect, sensor i s ei ther l oose,
or damaged.
(6) Route sensor wi re and i nstal l i nto mounti ng
retai ners.
(7) Connect sensor wi re to harness.
G-SWITCH
DESCRIPTION
The G-swi tch i s l ocated i n front of the consol e/
shi fter mounted to a bracket on the fl oor pan. The
swi tch has di recti onal arrow and must be mounted
wi th the arrow poi nti ng towards the front of the
vehi cl e.
OPERATION
The swi tch (Fi g. 3) , provi des an addi ti onal vehi cl e
decel erati on reference duri ng 4-wheel dri ve opera-
ti on. The swi tch i s moni tored by the CAB at al l
ti mes. The swi tch reference si gnal i s uti l i zed by the
CAB when al l wheel s are decel erati ng at the same
speed.
REMOVAL
(1) From the dri vers si de l i ft carpet back i n front
of the consol e/shi fter.
(2) Di sconnect harness for swi tch.
(3) Remove mounti ng bol ts and remove swi tch
(Fi g. 4).
INSTALLATION
CAUTION: The mercury switch (inside the
G-switch), will not function properly if the switch is
installed incorrectly. Verify that the switch locating
arrow is pointing to the front of the vehicle (Fig. 3).
(1) Posi ti on swi tch on mounti ng bracket.
(2) I nstal l mounti ng bol ts and ti ghten to 4-5 N·m
(35-45 i n. l bs.)
(3) Connect harness to swi tch.
(4) Pl ace carpet back i nto posi ti on.
REAR WHEEL SPEED SENSOR
DESCRIPTION
A speed sensor i s used at each wheel . The front
sensors are mounted to the steeri ng knuckl es. The
rear sensors are mounted to the rear brake backi ng
pl ate.
OPERATION
The sensors convert wheel speed i nto a smal l AC
el ectri cal si gnal . Thi s si gnal i s transmi tted to the
CAB. The CAB convert the AC si gnal i nto a di gi tal
si gnal for each wheel . Thi s vol tage i s generated by
magneti c i nducti on when a tone wheel passes by the
stati onary magneti c of the wheel speed sensor.
A gear type tone ri ng serves as the tri gger mecha-
ni sm for each sensor. The tone ri ngs are mounted at
the outboard ends of the front and rear axl e shafts.
Di fferent sensors are used at the front and rear
wheel s (Fi g. 1). The front/rear sensors have the same
el ectri cal val ues but are not i nterchangeabl e. The
Fig. 3 G-Switch
1 - SWITCH PART NUMBER
2 - ARROW INDICATES FRONT OF SWITCH FOR PROPER
MOUNTING
Fig. 4 G-Switch
1 - ACCELERATION SWITCH
2 - MOUNTING BRACKET
5 - 42 BRAKES - ABS TJ
FRONT WHEEL SPEED SENSOR (Continued)
sensors have a resi stance between 900 and 1300
ohms.
REMOVAL
(1) Di sconnect sensors at rear harness connectors.
(2) Remove wheel and ti re assembl y.
(3) Remove brake drum.
(4) Remove cl i ps securi ng sensor wi res to brake
l i nes, rear axl e and, brake hose.
(5) Unseat sensor wi re support pl ate grommet.
(6) Remove bol t attachi ng sensor to bracket (Fi g.
5) and remove sensor.
INSTALLATION
(1) I f original sensor i s bei ng i nstal l ed, remove
any remai ni ng pi eces of cardboard spacer from sen-
sor pi ckup face. Use dry shop towel onl y to remove
ol d spacer materi al .
(2) I nsert sensor wi re through support pl ate hol e.
Then seat sensor grommet i n support pl ate.
(3) Appl y Mopar Lock N’ Seal or Locti te ௡ 242 to
ori gi nal sensor bol t. Use new bol t i f ori gi nal i s worn
or damaged.
(4) I nstal l sensor bol t fi nger ti ght onl y at thi s
ti me.
(5) I f original rear sensor was i nstal l ed, adjust
sensor ai r gap to 0.28-1.5 mm (0.011-0.059 i n.). Use
feel er gauge to measure ai r gap (Fi g. 6). Ti ghten sen-
sor bol t to 12-14 N·m (106-124 i n. l bs.).
(6) I f new sensor was i nstal l ed, push cardboard
spacer on sensor face agai nst tone ri ng (Fi g. 7). Then
ti ghten sensor bol t to 12-14 N·m (106-124 i n. l bs.).
Correct ai r gap wi l l be establ i shed as tone ri ng
rotates and peel s spacer off sensor face.
(7) Secure the rear sensor wi res to the retai ner
cl i ps. Veri fy that wi re i s cl ear of rotati ng components.
(8) Connect sensor wi re to harness connector.
(9) I nstal l brake drum and wheel and ti re assem-
bl y. (Refer to 22 - TI RES/WHEELS/WHEELS -
STANDARD PROCEDURE).
(10) Lower vehi cl e.
(11) Connect sensor wi re to harness connector.
HCU (HYDRAULIC CONTROL
UNIT)
DESCRIPTION
The HCU consi sts of a val ve body, pump motor,
and wi re harness.
OPERATION
Accumul ators i n the val ve body store extra fl ui d
rel eased to the system for ABS mode operati on. The
pump provi des the fl ui d vol ume needed and i s oper-
ated by a DC type motor. The motor i s control l ed by
the CAB.
Fig. 5 Wheel Speed Sensor
1 - TONE WHEEL
2 - WHEEL SPEED SENSOR
Fig. 6 Setting Air Gap On Original Rear Sensor
1 - WHEEL SPEED SENSOR
2 - BRASS FEELER GAUGE
3 - TONE RING
Fig. 7 New Rear Sensor
1 - REAR SENSOR
2 - AIR GAP SPACER ATTACHED TO SENSOR FACE
TJ BRAKES - ABS 5 - 43
REAR WHEEL SPEED SENSOR (Continued)
The val ves modul ate brake pressure duri ng
anti l ock braki ng and are control l ed by the CAB.
The HCU provi des three channel pressure control
to the front and rear brakes. One channel control s
the rear wheel brakes i n tandem. The two remai ni ng
channel s control the front wheel brakes i ndi vi dual l y.
Duri ng anti l ock braki ng, the sol enoi d val ves are
opened and cl osed as needed. The val ves are not
stati c. They are cycl ed rapi dl y and conti nuousl y to
modul ate pressure and control wheel sl i p and decel -
erati on.
Duri ng normal braki ng, the HCU sol enoi d val ves
and pump are not acti vated. The master cyl i nder and
power booster operate the same as a vehi cl e wi thout
an ABS brake system.
Duri ng anti l ock braki ng, sol enoi d val ve pressure
modul ati on occurs i n three stages, pressure i ncrease,
pressure hol d, and pressure decrease. The val ves are
al l contai ned i n the val ve body porti on of the HCU.
PRESSURE DECREASE
The outl et val ve i s opened and the i nl et val ve i s
cl osed duri ng the pressure decrease cycl e.
A pressure decrease cycl e i s i ni ti ated when speed
sensor si gnal s i ndi cate hi gh wheel sl i p at one or
more wheel s. At thi s poi nt, the CAB cl oses the i nl et
then opens the outl et val ve, whi ch al so opens the
return ci rcui t to the accumul ators. Fl ui d pressure i s
al l owed to bl eed off (decrease) as needed to prevent
wheel l ock.
Once the peri od of hi gh wheel sl i p has ended, the
CAB cl oses the outl et val ve and begi ns a pressure
i ncrease or hol d cycl e as needed.
PRESSURE HOLD
Both sol enoi d val ves are cl osed i n the pressure
hol d cycl e. Fl ui d appl y pressure i n the control chan-
nel i s mai ntai ned at a constant rate. The CAB mai n-
tai ns the hol d cycl e unti l sensor i nputs i ndi cate a
pressure change i s necessary.
PRESSURE INCREASE
The i nl et val ve i s open and the outl et val ve i s
cl osed duri ng the pressure i ncrease cycl e. The pres-
sure i ncrease cycl e i s used to counteract unequal
wheel speeds. Thi s cycl e control s re-appl i cati on of
fl ui d appl y pressure due to changi ng road surfaces or
wheel speed.
REMOVAL
(1) I nstal l prop rod on the brake pedal to keep
pressure on the brake system.
(2) Remove negati ve battery cabl e from the bat-
tery.
(3) Pul l up on the CAB harness connector rel ease
(Fi g. 8)and remove connector.
(4) Remove brake l i nes from the HCU.
(5) Remove HCU/CAB mounti ng nuts and bol t
(Fi g. 9) and remove HCU/CAB.
INSTALLATION
NOTE: If the CAB is being replaced with a new CAB
is must be reprogrammed with the use of a DRB III.
(1) I nstal l HCU/CAB on the mounti ng studs.
(2) I nstal l mounti ng nuts and bol t. Ti ghten to 11.5
N·m (102 i n. l bs.).
(3) I nstal l brake l i nes to the HCU and ti ghten to
19 N·m (170 i n. l bs.).
(4) I nstal l wi ri ng harness connector to the CAB and
push down on the rel ease to secure the connector.
(5) I nstal l negati ve battery cabl e to the battery.
(6) Bl eed ABS brake system (Refer to 5 - BRAKES
- STANDARD PROCEDURE).
Fig. 8 CAB Harness Connector Release
1 - CAB
2 - CAB HARNESS RELEASE
Fig. 9 HCU/CAB Mounting
1 - HCU
2 - CAB
3 - HCU/CAB BRACKET
4 - MOTOR
5 - 44 BRAKES - ABS TJ
HCU (HYDRAULIC CONTROL UNIT) (Continued)
CLUTCH
TABLE OF CONTENTS
page page
CLUTCH
WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . 1
SPECIFICATIONS
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CLUTCH DISC
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CLUTCH RELEASE BEARING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
FLYWHEEL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . 7
PILOT BEARING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
LINKAGE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 9
MASTER CYLINDER
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
CLUTCH PEDAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10
CLUTCH PEDAL POSITION SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 10
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . 11
CLUTCH
WARNING
WARNING: Exercise care when servicing clutch
components. Factory installed clutch discs do not
contain asbestos fibers. Dust and dirt on clutch
parts may contain asbestos fibers from aftermarket
components. Breathing excessive concentrations of
these fibers can cause serious bodily harm. Wear a
respirator during service and never clean clutch
components with compressed air or with a dry
brush. Either clean the components with water
dampened rags or use a vacuum cleaner specifi-
cally designed to remove asbestos fibers and dust.
Do not create dust by sanding a clutch discs.
Replace the disc if the friction material is damaged.
Dispose of all dust and dirt containing asbestos
fibers in sealed bags or containers. This will mini-
mize exposure to yourself and to others. Follow all
recommended safety practices prescribed by the
occupational safety and health administration
(OSHA) and the environmental safety agency (EPA),
for the handling and disposal of products contain-
ing asbestos. Failure to follow these instructions
may result in personal injury or death
DIAGNOSIS AND TESTING
Dri ve the vehi cl e at normal speeds. Shi ft the trans-
mi ssi on through al l gear ranges and observe cl utch
acti on. I f the cl utch chatters, grabs, sl i ps or does not
rel ease properl y, remove and i nspect the cl utch com-
ponents. I f the probl em i s noi se or hard shi fti ng, fur-
ther di agnosi s may be needed as the transmi ssi on or
another dri vel i ne component may be at faul t.
NOTE: Vehicles equipped with a Dual Mass Fly-
wheel may produce a rattle when the engine is shut
off. This noise is considered normal.
CLUTCH CONTAMINATION
Fl ui d contami nati on i s a frequent cause of cl utch
mal functi ons. Oi l , water or cl utch fl ui d on the cl utch
di sc and pressure pl ate surfaces wi l l cause chatter,
sl i p and grab. I nspect components for oi l , hydraul i c
fl ui d or water/road spl ash contami nati on.
Oi l contami nati on i ndi cates a l eak at ei ther the
rear mai n seal or transmi ssi on i nput shaft. Cl utch
fl ui d l eaks are usual l y from damaged sl ave cyl i nder
push rod seal s. Heat bui l dup caused by sl i ppage
between the pressure pl ate, di sc and fl ywheel can
bake the oi l resi due onto the components. The gl aze-
l i ke resi due ranges i n col or from amber to bl ack.
Road spl ash contami nati on i s di rt/water enteri ng
the cl utch housi ng due to l oose bol ts, housi ng cracks.
Dri vi ng through deep water puddl es can force water/
road spl ash i nto the housi ng through such openi ngs.
IMPROPER RELEASE OR CLUTCH ENGAGEMENT
Cl utch rel ease or engagement probl ems are caused
by wear or damage cl utch components. A vi sual
i nspecti on of the rel ease components wi l l usual l y
reveal the probl em part.
TJ CLUTCH 6 - 1
Rel ease probl ems can resul t i n hard shi fti ng and
noi se. Look for l eaks at the cl utch cyl i nders and
i nterconnecti ng l i ne and l oose sl ave cyl i nder bol ts.
Al so worn/l oose rel ease fork, pi vot stud, cl utch di sc,
pressure pl ate or rel ease beari ng.
Engagement probl ems can resul t i n sl i p, chatter/
shudder and noi sy operati on. The causes may be
cl utch di sc contami nati on, wear, di storti on or fl y-
wheel damage. Vi sual l y i nspect to determi ne the
actual cause of the probl em.
CLUTCH MISALIGNMENT
Cl utch components must be i n proper al i gnment
wi th the crankshaft and transmi ssi on i nput shaft.
Mi sal i gnment caused by excessi ve runout or warpage
of any cl utch component wi l l cause grab, chatter and
i mproper cl utch rel ease.
PRESSURE PLATE AND DISC RUNOUT
Check the cl utch di sc before i nstal l ati on. Axi al
(face) runout of a new di sc shoul d not exceed 0.50
mm (0.020 i n.). Measure runout about 6 mm (1/4 i n.)
from the outer edge of the di sc faci ng. Obtai n
another di sc i f runout i s excessi ve.
Check condi ti on of the cl utch before i nstal l ati on. A
warped cover or di aphragm spri ng wi l l cause grab
and i ncompl ete rel ease or engagement. Be careful
when handl i ng the cover and di sc. I mpact can di stort
the cover, di aphragm spri ng, rel ease fi ngers and the
hub of the cl utch di sc.
Use an al i gnment tool when posi ti oni ng the di sc on
the fl ywheel . The tool prevents acci dental mi sal i gn-
ment whi ch coul d resul t i n cover di storti on and di sc
damage.
A frequent cause of cl utch cover di storti on (and
consequent mi sal i gnment) i s i mproper bol t ti ghten-
i ng.
FLYWHEEL RUNOUT
Check fl ywheel runout whenever mi sal i gnment i s
suspected. Fl ywheel runout shoul d not exceed 0.08
mm (0.003 i n.). Measure runout at the outer edge of
the fl ywheel face wi th a di al i ndi cator. Mount the
i ndi cator on a stud i nstal l ed i n pl ace of one of the fl y-
wheel bol ts.
Common causes of runout are:
• heat warpage
• i mproper machi ni ng
• i ncorrect bol t ti ghteni ng
• i mproper seati ng on crankshaft fl ange shoul der
• forei gn materi al on crankshaft fl ange
Fl ywheel machi ni ng i s not recommended. The fl y-
wheel cl utch surface i s machi ned to a uni que contour
and machi ni ng wi l l negate thi s feature. Mi nor fl y-
wheel scori ng can be cl eaned up by hand wi th 180
gri t emery or wi th surface gri ndi ng equi pment.
Remove onl y enough materi al to reduce scori ng
(approxi matel y 0.001 - 0.003 i n.). Heavy stock
removal i s not recommended. Repl ace the fl ywheel
i f scori ng i s severe and deeper than 0.076 mm (0.003
i n.). Excessi ve stock removal can resul t i n fl ywheel
cracki ng or warpage after i nstal l ati on; i t can al so
weaken the fl ywheel and i nterfere wi th proper cl utch
rel ease.
Cl ean the crankshaft fl ange before mounti ng the
fl ywheel . Di rt and grease on the fl ange surface may
cock the fl ywheel causi ng excessi ve runout. Use new
bol ts when remounti ng a fl ywheel and secure the
bol ts wi th Mopar Lock And Seal or equi val ent.
Ti ghten fl ywheel bol ts to speci fi ed torque onl y. Over-
ti ghteni ng can di stort the fl ywheel hub causi ng
runout.
DIAGNOSIS CHART
The di agnosi s charts Di agnosi s Chart descri be
common cl utch probl ems, causes and correcti on. Con-
di ti ons, causes and correcti ve acti on are outl i ned i n
the i ndi cated col umns.
6 - 2 CLUTCH TJ
CLUTCH (Continued)
DIAGNOSIS CHART
CONDITION POSSIBLE CAUSES CORRECTION
Disc facing worn out 1. Normal wear. 1. Replace cover and disc.
2. Driver frequently rides (slips) the
clutch. Results in rapid overheating
and wear.
2. Replace cover and disc.
3. Insufficient clutch cover
diaphragm spring tension.
3. Replace cover and disc.
Clutch disc facing contaminated with
oil, grease, or clutch fluid.
1. Leak at rear main engine seal or
transmission input shaft seal.
1. Replace appropriate seal.
2. Excessive amount of grease
applied to the input shaft splines.
2. Remove grease and apply the
correct amount of grease.
3. Road splash, water entering
housing.
3. Replace clutch disc. Clean clutch
cover and reuse if in good condition.
4. Slave cylinder leaking. 4. Replace hydraulic clutch linkage.
Clutch is running partially
disengaged.
1. Release bearing sticking or
binding and does not return to the
normal running position.
1. Verify failure. Replace the release
bearing and transmission front
bearing retainer as necessary.
Flywheel below minimum thickness
specification.
1. Improper flywheel machining.
Flywheel has excessive taper or
excessive material removal.
1. Replace flywheel.
Clutch disc, cover and/or diaphragm
spring warped or distorted.
1. Rough handling. Impact bent
cover, spring, or disc.
1. Replace disc or cover as
necessary.
2. Improper bolt tightening
procedure.
2. Tighten clutch cover using proper
procedure.
Facing on flywheel side of disc torn,
gouged, or worn.
1. Flywheel surface scored or
nicked.
2. Correct surface condition if
possible. Replace flywheel and disc
as necessary.
2. Clutch disc sticking or binding on
transmission input shaft.
2. Lubricate splines with high
temperature graese.
Clutch disc facing burnt. Flywheel
and cover pressure plate surfaces
heavily glazed.
1. Frequent operation under high
loads or hard acceleration
conditions.
1. Correct condition of flywheel and
pressure plate surface. Replace
clutch cover and disc. Alert driver to
problem cause.
2. Driver frequently rides (slips)
clutch. Results in rapid wear and
overheating of disc and cover.
2. Correct condition of flywheel and
pressure plate surface. Replace
clutch cover and disc. Alert driver to
problem cause.
TJ CLUTCH 6 - 3
CLUTCH (Continued)
CONDITION POSSIBLE CAUSES CORRECTION
Clutch disc binds on input shaft
splines.
1. Clutch disc hub splines damaged
during installation.
1. Clean, smooth, and lubricate hub
splines if possible. Replace disc if
necessary.
2. Input shaft splines rough,
damaged, or corroded.
2. Clean, smooth, and lubricate
shaft splines if possible. Replace
input shaft if necessary.
Clutch disc rusted to flywheel and/or
pressure plate.
1. Clutch not used for and extended
period of time (e.g. long term
vehicle storage).
1. Sand rusted surfaces with 180
grit sanding paper. Replace clutch
cover and flywheel if necessary.
Pilot bearing seized, loose, or rollers
are worn.
1. Bearing cocked during
installation.
1. Install and lubricate a new
bearing.
2. Bearing defective. 2. Install and lubricate a new
bearing.
3. Bearing not lubricated. 3. Install and lubricate a new
bearing.
4. Clutch misalignment. 4. Inspect clutch and correct as
necessary. Install and lubricate a
new bearing.
Clutch will not disengage properly. 1. Low clutch fluid level. 1. Replace hydraulic linkage
assembly.
2. Clutch cover loose. 2. Follow proper bolt tightening
procedure.
3. Clutch disc bent or distorted. 3. Replace clutch disc.
4. Clutch cover diaphragm spring
bent or warped.
4. Replace clutch cover.
5. Clutch disc installed backwards. 5. Remove and install clutch disc
correctly.
6. Release fork bent or fork pivot
loose or damaged.
6. Replace fork or pivot as
necessary.
7. Clutch master or slave cylinder
failure.
7. Replace hydraulic linkage
assembly.
Clutch pedal squeak. 1. Pivot pin loose. 1. Tighten pivot pin if possible.
Replace clutch pedal if necessary.
2. Master cylinder bushing not
lubricated.
2. Lubricate master cylinder
bushing.
3. Pedal bushings worn out or
cracked.
3. Replace and lubricate bushings.
Clutch master or slave cylinder
plunger dragging andør binding
1. Master or slave cylinder
components worn or corroded.
1. Replace clutch hydraulic linkage
assembly.
Release bearing is noisy. 1. Release bearing defective or
damaged.
1. Replace release bearing.
6 - 4 CLUTCH TJ
CLUTCH (Continued)
CONDITION POSSIBLE CAUSES CORRECTION
Contact surface of release bearing
damaged.
1. Clutch cover incorrect or release
fingers bent or distorted.
1. Replace clutch cover and release
bearing.
2. Release bearing defective or
damaged.
2. Replace the release bearing.
3. Release bearing misaligned. 3. Check and correct runout of
clutch components. Check front
bearing sleeve for damage/
alignment. Repair as necessary.
Partial engagement of clutch disc.
One side of disc is worn and the
other side is glazed and lightly
worn.
1. Clutch pressure plate position
incorrect.
1. Replace clutch disc and cover.
2. Clutch cover, spring, or release
fingers bent or distorted.
2. Replace clutch disc and cover.
3. Clutch disc damaged or
distorted.
2. Replace clutch disc.
4. Clutch misalignment. 4. Check alignment and runout of
flywheel, disc, pressure plate, andør
clutch housing. Correct as
necessary.
SPECIFICATIONS
CLUTCH
TORQUE SPECIFICATIONS
DESCRIPTION N·m Ft. Lbs. In. Lbs.
Clutch Cover Bolts - 2.4L 31 23 -
Clutch Cover Bolts - 4.0L 50 37 -
Clutch Cylinder Bolts 23 - 200
Clutch Housing to Engine
Bolts
75 55 -
Clutch Housing to Trans
Bolts
46 34 -
Dust Shield Bolts 50 37 -
Flywheel Bolts - 2.4L 95 70 -
Flywheel Bolts - 4.0L 142 105 -
Crossmember Frame
Bolts
41 30 -
TJ CLUTCH 6 - 5
CLUTCH (Continued)
CLUTCH DISC
REMOVAL
(1) Remove transmi ssi on.
(2) Mark posi ti on of pressure pl ate on fl ywheel for
i nstal l ati on reference, i f ori gi nal pressure pl ate wi l l
be reused.
(3) Remove pressure pl ate bol ts and remove cover
and di sc (Fi g. 1).
CAUTION: If original pressure plate will be reused,
loosen cover bolts evenly in rotation to relieve
spring tension equally. Failure to heed caution may
result in damage.
INSTALLATION
(1) Li ghtl y sand fl ywheel face wi th 180 gri t emery
cl oth. Then cl ean surface wi th a wax and grease
remover.
(2) Lubri cate pi l ot beari ng wi th Mopar hi gh tem-
perature beari ng grease.
(3) Posi ti on cl utch di sc on fl ywheel wi th si de
marked fl ywheel posi ti oned agai nst fl ywheel .
NOTE: If disc is not marked, flat side of disc hub
goes towards the flywheel.
(4) I nsert al i gnment tool through di sc and i nto the
pi l ot beari ng on the fl ywheel (Fi g. 2).
(5) Posi ti on pressure pl ate over di sc and on fl y-
wheel (Fi g. 2).
NOTE: Align reference marks if pressure plate is
reused.
(6) I nstal l cl utch cover bol ts fi nger ti ght.
(7) Ti ghten cover bol ts evenl y and i n rotati on a
few threads at a ti me. Ti ghteni ng bol ts to:
• 2.5L Engi ne - 31 N·m (23 ft. l bs.)
• 4.0L Engi ne - 50 N·m (37 ft. l bs.)
CAUTION: Cover bolts must be tightened evenly
and to specified torque. Failure to heed caution
may result in damage.
(8) Li ghtl y coat cl utch di sc hub and transmi ssi on
i nput shaft spl i nes wi th Mopar hi gh temperature
beari ng grease or equi val ent.
CAUTION: Over lubricating shaft splines will result
in grease contamination of disc. Failure to heed
caution may result in damage.
(9) I nstal l transmi ssi on.
Fig. 1 CLUTCH DISC AND PRESSURE PLATE
1 - DISC
2 - PRESSURE PLATE
3 - PRESSURE PLATE COVER
4 - “FLYWHEEL SIDE” STAMPED ON THIS SURFACE
Fig. 2 ALIGNING CLUTCH DISC
1 - FLYWHEEL
2 - PRESSURE PLATE AND DISC
3 - ALIGNMENT TOOL
6 - 6 CLUTCH TJ
CLUTCH RELEASE BEARING
REMOVAL
(1) Remove transmi ssi on.
(2) Di sconnect rel ease beari ng from rel ease l ever
and remove beari ng (Fi g. 3).
(3) I nspect beari ng sl i de surface of transmi ssi on
front beari ng retai ner. Repl ace retai ner i f sl i de sur-
face i s scored, worn or cracked.
(4) I nspect rel ease fork and fork pi vot. Veri fy pi vot
i s secure and i n good condi ti on, fork i s not di storted
or worn and retai ner spri ng i s not bent or damaged.
INSTALLATION
(1) Lubri cate crankshaft pi l ot beari ng, i nput shaft
spl i nes, beari ng retai ner sl i de surface, fork pi vot and
rel ease fork pi vot surface. Lubri cate wi th Mopar hi gh
temperature beari ng grease or equi val ent.
(2) I nstal l new rel ease beari ng. Veri fy beari ng i s
properl y secured to rel ease fork.
(3) I nstal l transmi ssi on.
FLYWHEEL
DESCRIPTION
STANDARD FLYWHEEL
The standard fl ywheel i s used on the 4.0L engi ne.
The fl ywheel (Fi g. 4) i s a heavy pl ate bol ted to the
rear of the crankshaft. The fl ywheel i ncorporates the
ri ng gear to mesh wi th the starter. The rear face of
the fl ywheel serves as the dri vi ng member to the
cl utch di sc.
DUAL MASS FLYWHEEL
The Dual Mass Fl ywheel i s used on the 2.4L
engi ne (Fi g. 5). The fl ywheel i ncorporates the ri ng
gear to mesh wi th the starter. The pri mary fl ywheel
si de i s bol ted to the crankshaft. The secondary fl y-
wheel face serves as the dri vi ng member to the
cl utch di sc. I nternal spri ngs between the fl ywheel s
are use to dampen energy.
OPERATION
The fl ywheel serves to dampen the engi ne fi ri ng
pul ses. The heavy wei ght of the fl ywheel rel ati ve to
the rotati ng mass of the engi ne components serves to
stabi l i ze the fl ow of power to the remai nder of the
dri vetrai n. The crankshaft has the tendency to
attempt to speed up and sl ow down i n response to
the cyl i nder fi ri ng pul ses. The fl ywheel dampens
these i mpul ses by absorbi ng energy when the crank-
shaft speeds and rel easi ng the energy back i nto the
system when the crankshaft sl ows down.
On a Dual Mass Fl ywheel the addi ti onal secondary
mass coupl ed to the transmi ssi on l owers the natural
frequency of the transmi ssi on rotati ng el ements. Thi s
decreases the transmi ssi on gear rattl e. The damper
spri ngs between the two fl ywheel masses repl ace the
cl utch di sc damper spri ngs and assi st i n a smooth
transfer of torque to the transmi ssi on.
CAUTION: The Dual Mass Flywheel is serviced as
an assembly only and should never be taken apart.
Failure to heed caution may result in damage.
DIAGNOSIS AND TESTING
Check fl ywheel runout whenever mi sal i gnment i s
suspected. Fl ywheel runout shoul d not exceed 0.08
mm (0.003 i n.). Measure runout at the outer edge of
Fig. 3 RELEASE BEARING
1 - RETAINER SPRING
2 - PIVOT BALL STUD
3 - CLUTCH HOUSING
4 - RELEASE FORK
5 - RELEASE BEARING
Fig. 4 FLYWHEEL
1 - CRANKSHAFT
2 - RING GEAR
3 - FLYWHEEL
TJ CLUTCH 6 - 7
the fl ywheel face wi th a di al i ndi cator. Mount the
i ndi cator on a stud i nstal l ed i n pl ace of one of the fl y-
wheel bol ts.
Common causes of runout are:
• heat warpage
• i mproper machi ni ng
• i ncorrect bol t ti ghteni ng
• i mproper seati ng on crankshaft fl ange shoul der
• forei gn materi al on crankshaft fl ange
Fl ywheel machi ni ng i s not recommended. The fl y-
wheel cl utch surface i s machi ned to a uni que contour
and machi ni ng wi l l negate thi s feature. Mi nor fl y-
wheel scori ng can be cl eaned up by hand wi th 180
gri t emery or wi th surface gri ndi ng equi pment.
Remove onl y enough materi al to reduce scori ng
(approxi matel y 0.001 - 0.003 i n.). Heavy stock
removal i s not recommended. Repl ace the fl ywheel
i f scori ng i s severe and deeper than 0.076 mm (0.003
i n.). Excessi ve stock removal can resul t i n fl ywheel
cracki ng or warpage after i nstal l ati on; i t can al so
weaken the fl ywheel and i nterfere wi th proper cl utch
rel ease.
Cl ean the crankshaft fl ange before mounti ng the
fl ywheel . Di rt and grease on the fl ange surface may
cock the fl ywheel causi ng excessi ve runout. Use new
bol ts when remounti ng a fl ywheel and secure the
bol ts wi th Mopar Lock And Seal or equi val ent.
Ti ghten fl ywheel bol ts to speci fi ed torque onl y. Over-
ti ghteni ng can di stort the fl ywheel hub causi ng
runout.
PILOT BEARING
REMOVAL
(1) Remove transmi ssi on.
(2) Remove pressure pl ate and cl utch di sc.
(3) Remove pi l ot beari ng wi th an i nternal (bl i nd
hol e) pul l er.
INSTALLATION
(1) Lubri cate new beari ng wi th Mopar hi gh tem-
perature beari ng grease or equi val ent.
(2) Start new beari ng i nto crankshaft by hand.
Then seat beari ng wi th cl utch al i gnment tool (Fi g. 6).
(3) Li ghtl y scuff sand fl ywheel surface wi th 180
gri t emery cl oth. Then cl ean surface wi th wax and
grease remover.
(4) I nstal l cl utch di sc and pressure pl ate.
(5) I nstal l transmi ssi on.
LINKAGE
REMOVAL
NOTE: Clutch master cylinder, slave cylinder and
connecting line are serviced as an assembly only.
Components cannot be overhauled or serviced sep-
arately. Cylinders and connecting line are sealed
units.
Removal /i nstal l ati on procedures for ri ght and l eft
hand dri ve model s are basi cal l y the same.
Fig. 5 DUAL MASS FLYWHEEL
1 - LOCATING STUD
2 - BEARING
3 - SECONDARY FLYWHEEL
4 - DAMPER SPRING
5 - RING GEAR
6 - PRIMARY FLYWHEEL
7 - FRICTION DISC
Fig. 6 PILOT BEARING INSTALLER
1 - PILOT BEARING
2 - ALIGNMENT TOOL
6 - 8 CLUTCH TJ
FLYWHEEL (Continued)
(1) Wi th vehi cl e i n neutral , posi ti on vehi cl e on
hoi st
(2) Remove fasteners attachi ng sl ave cyl i nder to
cl utch housi ng.
(3) Remove sl ave cyl i nder from cl utch housi ng
(Fi g. 7).
(4) Di sengage cl utch fl ui d l i ne from body cl i ps.
(5) Lower vehi cl e.
(6) Veri fy cl utch master cyl i nder reservoi r cap i s
ti ght.
(7) Remove cl utch master cyl i nder attachi ng nuts
(Fi g. 7) or (Fi g. 8).
(8) Di sengage captured bushi ng on cl utch master
cyl i nder actuator from pi vot pi n on pedal arm.
(9) Sl i de actuator off pi vot pi n.
(10) Di sconnect cl utch i nterl ock safety swi tch
wi res.
(11) Remove cl utch hydraul i c l i nkage through
engi ne compartment.
INSTALLATION
NOTE: Clutch master cylinder, slave cylinder and
connecting line are serviced as an assembly only.
Components cannot be overhauled or serviced sep-
arately. Cylinders and connecting line are sealed
units.
Removal /i nstal l ati on procedures for ri ght and l eft
hand dri ve model s are basi cal l y the same.
(1) Ti ghten cl utch master cyl i nder cap.
(2) Posi ti on connecti ng l i ne and sl ave cyl i nder
downward past engi ne and next to cl utch housi ng.
(3) Posi ti on cl utch master cyl i nder on dash panel .
(4) I nstal l cl utch master cyl i nder actuator on
cl utch pedal pi vot pi n.
(5) I nstal l cl utch master cyl i nder and ti ghten nuts
to 38 N·m (28 ft. l bs.).
(6) I nsert sl ave cyl i nder push rod through cl utch
housi ng openi ng and i nto rel ease l ever. Be sure cap
on end of rod i s securel y engaged i n l ever. Check thi s
before i nstal l i ng cyl i nder attachi ng nuts.
(7) I nstal l sl ave cyl i nder and ti ghten nuts to 23
N·m (17 ft. l bs.).
(8) Secure cl utch fl ui d l i ne i n body and transmi s-
si on cl i ps.
(9) Connect cl utch i nterl ock safety swi tch wi res.
MASTER CYLINDER
INSPECTION
The cl utch fl ui d reservoi r, master cyl i nder, sl ave
cyl i nder and fl ui d l i nes are pre-fi l l ed at the factory.
The hydraul i c system shoul d not requi re addi ti onal
fl ui d under normal ci rcumstances. The reservoi r fl ui d
l evel i ncreases as cl utch wear occurs.
CAUTION: Do not overfill or removing fluid from the
reservoir. Failure to heed caution may result in
damage.
Wi pe reservoi r and cover cl ean. Remove cap and
di aphragm, fl ui d l evel shoul d not be above i ndi cator
ri ng l ocated on the outsi de of the reservoi r.
Fig. 7 CLUTCH LINKAGE - LHD
1 - CLUTCH HOUSING
2 - FLUID LINE
3 - BRACKET
4 - FLUID LINE
5 - CLIP
6 - CAPTURED BUSHING
7 - CLUTCH SLAVE CYLINDER
8 - CLUTCH MASTER CYLINDER
9 - DASH PANEL
Fig. 8 CLUTCH LINKAGE - RHD
1 - DASH PANEL
2 - FLUID LINE
3 - CLIP
4 - HOLD DOWN STRAP
5 - CLUTCH MASTER CYLINDER
6 - CAPTURED BUSHING
TJ CLUTCH 6 - 9
LINKAGE (Continued)
CLUTCH PEDAL
REMOVAL
(1) Remove steeri ng col umn l ower cover and knee
bl ocker for access.
(2) Di sconnect cl utch pedal posi ti on swi tch wi res.
(3) Di sengage captured bushi ng l ock tabs attach-
i ng cl utch master cyl i nder actuator to pedal pi vot
(Fi g. 9) or (Fi g. 10).
(4) Remove nuts attachi ng pedal and bracket to
dash panel and upper cowl support (Fi g. 9) or (Fi g.
10).
(5) Separate pedal assembl e from vehi cl e.
INSTALLATION
(1) Pl ace cl utch pedal and bracket over studs on
dash panel and cowl support. I nstal l nuts and
ti ghten to 39 N·m (29 ft. l bs.).
(2) Engage captured bushi ng and actuator on
brake pedal pi vot.
(3) Connect cl utch pedal posi ti on swi tch wi res.
CLUTCH PEDAL POSITION
SWITCH
DESCRIPTION
The Cl utch Pedal Posi ti on Swi tch (CPPS) i s l ocated
under the i nstrument panel , attached to the cl utch
master cyl i nder push rod (Fi g. 11). The wi ri ng har-
ness connector i s i nsi de of the vehi cl e under the l eft
si de of the i nstrument panel (Fi g. 12).
NOTE: Switch is serviced with clutch master cylin-
der only.
Fig. 9 CLUTCH PEDAL MOUNTING - LHD
1 - CLUTCH CYLINDER ACTUATOR
2 - CAPTURED BUSHING
3 - UPPER COWL SUPPORT
4 - PIVOT
5 - CLUTCH PEDAL
6 - BRACKET
7 - DASH PANEL
Fig. 10 CLUTCH PEDAL MOUNTING - RHD
1 - CLUTCH CYLINDER ACTUATOR
2 - CAPTURED BUSHING
3 - UPPER COWL SUPPORT
4 - PIVOT
5 - CLUTCH PEDAL
6 - BRACKET
7 - DASH PANEL
Fig. 11 CLUTCH PEDAL POSITION SWITCH (CPPS)
1 - INSTRUMENT PANEL
2 - SWITCH WIRING HARNESS
3 - CLUTCH PEDAL POSITION SWITCH
4 - CLUTCH MASTER CYLINDER
6 - 10 CLUTCH TJ
OPERATION
The cl utch pedal posi ti on swi tch i s used to prevent
starter motor engagement unl ess the cl utch pedal i s
depressed. An i nput from thi s swi tch i s al so used to
ei ther shut down/prevent operati on of the speed con-
trol system when pedal i s depressed.
DIAGNOSIS AND TESTING
(1) Di sconnect 2-wi re swi tch connector under
i nstrument panel (Fi g. 13).
(2) Check swi tch conti nui ty wi th an ohmmeter
whi l e operati ng cl utch pedal .
• Pedal Depressed - Conti nui ty
• Pedal Rel eased - No Conti nui ty
(3) I f conti nui ty i s not present or al ways present,
repl ace cl utch master cyl i nder. Swi tch i s not servi ced
separatel y.
Fig. 12 CPPS ELECTRICAL CONNECTION
1 - CPPS CONNECTION TO MAIN HARNESS
Fig. 13 CPPS ELECTRICAL CONNECTION
1 - CPPS CONNECTION TO MAIN HARNESS
TJ CLUTCH 6 - 11
CLUTCH PEDAL POSITION SWITCH (Continued)
COOLING
TABLE OF CONTENTS
page page
COOLING
DESCRIPTION
DESCRIPTION - COOLING SYSTEM 2.4L
ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DESCRIPTION - 4.0L ENGINE . . . . . . . . . . . . . 1
DESCRIPTION - HOSE CLAMPS . . . . . . . . . . . 2
OPERATION - HOSE CLAMPS . . . . . . . . . . . . . . 2
DIAGNOSIS AND TESTING
ON-BOARD DIAGNOSTICS - OBD . . . . . . . . . . 2
DIAGNOSIS AND TESTING - PRELIMINARY
CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DIAGNOSIS AND TESTING - COOLING
SYSTEM - TESTING FOR LEAKS . . . . . . . . . . 9
DIAGNOSIS AND TESTING - RADIATOR
COOLANT FLOW CHECK . . . . . . . . . . . . . . . 10
STANDARD PROCEDURE
STANDARD PROCEDURE - DRAINING
COOLING SYSTEM - 2.4L . . . . . . . . . . . . . . . 10
STANDARD PROCEDURE - REFILLING
COOLING SYSTEM - 2.4L . . . . . . . . . . . . . . . 11
STANDARD PROCEDURE - COOLANT
LEVEL CHECK. . . . . . . . . . . . . . . . . . . . . . . . 11
STANDARD PROCEDURE - COOLING
SYSTEM - DRAINING. . . . . . . . . . . . . . . . . . . 11
STANDARD PROCEDURE - COOLING
SYSTEM - REFILLING . . . . . . . . . . . . . . . . . . 12
STANDARD PROCEDURE - COOLING
SYSTEM - REVERSE FLUSHING. . . . . . . . . . 12
SPECIFICATIONS
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
SPECIAL TOOLS
COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
ACCESSORY DRIVE . . . . . . . . . . . . . . . . . . . . . . 14
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . 44
COOLING
DESCRIPTION
DESCRIPTION - COOLING SYSTEM 2. 4L
ENGINE
The cool i ng system consi sts of the fol l owi ng i tems:
• El ectri c cool i ng fan - Standard.
• Radi ator
• Hot bottl e pressure cap
• Thermostat
• Cool ant reserve/overfl ow system
• Radi ator i n-tank transmi ssi on oi l cool er (i f
equi pped wi th an automati c transmi ssi on)
• Cool ant
• Water pump
• Hoses and hose cl amps
DESCRIPTION - 4. 0L ENGINE
The cool i ng system (Fi g. 1) i s desi gned to mai ntai n
engi ne temperature at an effi ci ent l evel duri ng al l
engi ne operati ng condi ti ons.
The components of the cool i ng system are:
• A heavy duty radi ator
• Cool i ng fan (mechani cal )
• Thermal vi scous fan dri ve
• Fan shroud
• Radi ator pressure cap
Fig. 1 Coolant Circulation - 4.0L Engine
1 - FROM THERMOSTAT
2 - TO WATER PUMP
3 - RADIATOR
TJ COOLING 7 - 1
• Thermostat
• Cool ant reserve/overfl ow system
• Automati c transmi ssi on oi l cool er (i nternal to
radi ator)
• Cool ant
• Water pump
• Cool ant hoses and cl amps
DESCRIPTION - HOSE CLAMPS
The cool i ng system uti l i zes both worm dri ve and
spri ng type hose cl amps. I f a spri ng type cl amp
repl acement i s necessary, repl ace wi th the ori gi nal
Mopar௡ equi pment spri ng type cl amp.
CAUTION: A number or letter is stamped into the
tongue of constant tension clamps. If replacement
is necessary, use only a original equipment clamp
with matching number or letter (Fig. 2).
OPERATION - HOSE CLAMPS
The worm type hose cl amp uses a speci fi ed torque
val ue to mai ntai n proper tensi on on a hose connec-
ti on.
The spri ng type hose cl amp appl i es constant ten-
si on on a hose connecti on. To remove a spri ng type
hose cl amp, use Speci al Tool 6094 or equi val ent, con-
stant tensi on cl amp pl i ers (Fi g. 3) to compress the
hose cl amp.
DIAGNOSIS AND TESTING
ON-BOARD DIAGNOSTICS - OBD
COOLING SYSTEM RELATED DIAGNOSTICS
The Powertrai n Control Modul e (PCM) has been
programmed to moni tor the certai n fol l owi ng cool i ng
system components:
• I f the engi ne has remai ned cool for too l ong a
peri od, such as wi th a stuck open thermostat, a Di ag-
nosti c Troubl e Code (DTC) can be set.
• I f an open or shorted condi ti on has devel oped i n
the rel ay ci rcui t control l i ng the el ectri c radi ator fan,
a Di agnosti c Troubl e Code (DTC) can be set.
I f the probl em i s sensed i n a moni tored ci rcui t
often enough to i ndi cate an actual probl em, a DTC i s
stored. The DTC wi l l be stored i n the PCM memory
for eventual di spl ay to the servi ce techni ci an.
ACCESSING DIAGNOSTIC TROUBLE CODES
To read DTC’s and to obtai n cool i ng system data,
(Refer to 25 - EMI SSI ONS CONTROL - DESCRI PTI ON).
DIAGNOSIS AND TESTING - PRELIMINARY
CHECKS
ENGINE COOLING SYSTEM OVERHEATING
Establ i sh what dri vi ng condi ti ons caused the com-
pl ai nt. Abnormal l oads on the cool i ng system such as
the fol l owi ng may be the cause:
• Prol onged i dl e
• Very hi gh ambi ent temperature
• Sl i ght tai l wi nd at i dl e
• Sl ow traffi c
• Traffi c jams
• Hi gh speed or steep grades
Dri vi ng techni ques that avoi d overheati ng are:
Fig. 2 Spring Clamp Size Location
1 - SPRING CLAMP SIZE LOCATION
Fig. 3 Hose Clamp Tool
1 - HOSE CLAMP TOOL 6094
2 - HOSE CLAMP
7 - 2 COOLING TJ
COOLING (Continued)
• I dl e wi th A/C off when temperature gauge i s at
end of normal range.
• I ncreasi ng engi ne speed for more ai r fl ow i s rec-
ommended.
TRAILER TOWING:
Consul t Trai l er Towi ng secti on of owners manual .
Do not exceed l i mi ts.
AIR CONDITIONING; ADD-ON OR AFTER MARKET:
A maxi mum cool i ng package shoul d have been
ordered wi th vehi cl e i f add-on or after market A/C i s
i nstal l ed. I f not, maxi mum cool i ng system compo-
nents shoul d be i nstal l ed for model i nvol ved per
manufacturer’s speci fi cati ons.
RECENT SERVICE OR ACCIDENT REPAIR:
Determi ne i f any recent servi ce has been per-
formed on vehi cl e that may effect cool i ng system.
Thi s may be:
• Engi ne adjustments (i ncorrect ti mi ng)
• Sl i ppi ng engi ne accessory dri ve bel t(s)
• Brakes (possi bl y draggi ng)
• Changed parts. I ncorrect water pump or pump
rotati ng i n wrong di recti on due to bel t not correctl y
routed
• Recondi ti oned radi ator or cool i ng system refi l l -
i ng (possi bl y under fi l l ed or ai r trapped i n system).
NOTE: If investigation reveals none of the previous
items as a cause for an engine overheating com-
plaint, refer to COOLING SYSTEM DIAGNOSIS
CHART BELOW.
These charts are to be used as a qui ck-reference
onl y. Refer to COOLI NG SYSTEM DI AGNOSI S
CHART
COOLING SYSTEM DIAGNOSIS CHART
CONDITION POSSIBLE CAUSES CORRECTION
TEMPERATURE GAUGE READS
LOW
1. Has a Diagnostic Trouble Code
(DTC) been set indicating a stuck
open thermostat?
1. (Refer to 25 - EMISSIONS
CONTROL - DESCRIPTION) for
On-Board Diagnostics and DTC
information. Replace thermostat if
necessary.
2. Is the temperature sending unit
connected?
2. Check the temperature sensor
connector. (Refer to 8 - ELECTRICAL/
INSTRUMENT CLUSTER -
SCHEMATIC - ELECTRICAL) Repair
connector if necessary.
3. Is the temperature gauge operating
OK?
3. Check gauge operation. (Refer to 8
- ELECTRICAL/INSTRUMENT
CLUSTER/ENGINE TEMPERATURE
GAUGE - DESCRIPTION). Repair as
necessary.
4. Coolant level low in cold ambient
temperatures accompanied with poor
heater performance.
4. Check coolant level in the coolant
reserve/overflow tank or degas bottle
and the radiator. Inspect system for
leaks. Repair leaks as necessary.
Refer to the Coolant section of the
manual text for WARNINGS and
CAUTIONS associated with removing
the radiator cap.
5. Improper operation of internal
heater doors or heater controls.
5. Inspect heater and repair as
necessary. (Refer to 24 - HEATING &
AIR CONDITIONING - DIAGNOSIS
AND TESTING) for procedures.
TJ COOLING 7 - 3
COOLING (Continued)
CONDITION POSSIBLE CAUSES CORRECTION
TEMPERATURE GAUGE READS
HIGH OR THE COOLANT WARNING
LAMP ILLUMINATES. COOLANT
MAY OR MAY NOT BE LOST OR
LEAKING FROM THE COOLING
SYSTEM
1. Trailer is being towed, a steep hill
is being climbed, vehicle is operated
in slow moving traffic, or engine is
being idled with very high ambient
(outside) temperatures and the air
conditioning is on. Higher altitudes
could aggravate these conditions.
1. This may be a temporary condition
and repair is not necessary. Turn off
the air conditioning and attempt to
drive the vehicle without any of the
previous conditions. Observe the
temperature gauge. The gauge should
return to the normal range. If the
gauge does not return to the normal
range, determine the cause for
overheating and repair. Refer to
Possible Causes (2-18).
2. Is the temperature gauge reading
correctly?
2. Check gauge. (Refer to 8 -
ELECTRICAL/INSTRUMENT
CLUSTER - SCHEMATIC -
ELECTRICAL). Repair as necessary.
3. Is the temperature warning
illuminating unnecessarily?
3. (Refer to 8 - ELECTRICAL/
INSTRUMENT CLUSTER -
SCHEMATIC - ELECTRICAL).
4. Coolant low in coolant reserve/
overflow tank and radiator?
4. Check for coolant leaks and repair
as necessary. (Refer to 7 - COOLING
- DIAGNOSIS AND TESTING).
5. Pressure cap not installed tightly. If
cap is loose, boiling point of coolant
will be lowered. Also refer to the
following Step 6.
5. Tighten cap
6. Poor seals at the radiator cap. 6. (a) Check condition of cap and cap
seals. Refer to Radiator Cap. Replace
cap if necessary.
(b) Check condition of radiator filler
neck or degas bottle. If neck is bent
or damaged, replace radiator or
degas bottle.
7. Coolant level low in radiator but
not in coolant reserve/overflow tank.
This means the radiator is not
drawing coolant from the coolant
reserve/overflow tank as the engine
cools
7. (a) Check condition of radiator cap
and cap seals. Refer to Radiator Cap
in this Group. Replace cap if
necessary.
(b) Check condition of radiator filler
neck. If neck is bent or damaged,
replace radiator.
(c) Check condition of the hose from
the radiator to the coolant tank. It
should fit tight at both ends without
any kinks or tears. Replace hose if
necessary.
(d) Check coolant reserve/overflow
tank and tanks hoses for blockage.
Repair as necessary.
8. Incorrect coolant concentration 8. Check coolant. (Refer to
LUBRICATION & MAINTENANCE/
FLUID TYPES - DESCRIPTION).
7 - 4 COOLING TJ
COOLING (Continued)
CONDITION POSSIBLE CAUSES CORRECTION
9. Coolant not flowing through system 9. Check for coolant flow at radiator
filler neck with some coolant removed,
engine warm and thermostat open.
Coolant should be observed flowing
through radiator. If flow is not
observed, determine area of
obstruction and repair as necessary.
10. Radiator or A/C condenser fins
are dirty or clogged.
10. Remove insects and debris.
(Refer to 7 - COOLING - STANDARD
PROCEDURE).
11. Radiator core is corroded or
plugged.
11. Have radiator re-cored or
replaced.
12. Fuel or ignition system problems. 12. Refer to 14 - Fuel System or 8 -
Electrical for diagnosis and testing
procedures.
13. Dragging brakes. 13. Check and correct as necessary.
(Refer to 5 - BRAKES - DIAGNOSIS
AND TESTING) for correct
procedures.
14. Bug screen or cardboard is being,
reducing airflow.
14. Remove bug screen or cardboard.
15. Thermostat partially or completely
shut.
15. Check thermostat operation and
replace as necessary. (Refer to 7 -
COOLING/ENGINE/ENGINE
COOLANT THERMOSTAT -
REMOVAL).
16. Viscous fan drive not operating
properly.
16. Check fan drive operation and
replace as necessary. (Refer to 7 -
COOLING/ENGINE/FAN DRIVE
VISCOUS CLUTCH - REMOVAL) .
17. Cylinder head gasket leaking. 17. Check for cylinder head gasket
leaks. (Refer to 7 - COOLING -
DIAGNOSIS AND TESTING).
18. Heater core leaking. 18. Check heater core for leaks.
(Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING -
DIAGNOSIS AND TESTING). Repair
as necessary.
TJ COOLING 7 - 5
COOLING (Continued)
CONDITION POSSIBLE CAUSES CORRECTION
TEMPERATURE GAUGE READING
IS INCONSISTANT (FLUCTUATES,
CYCLES, OR IS ERRATIC
1. During cold weather operation, with
the heater in the high position, the
gauge reading may drop slightly.
1. A normal condition. No correction is
necessary.
2. Temperature gauge or engine
mounted gauge sensor defective or
shorted. Also, corroded or loose
wiring in this circuit.
2. Check operation of gauge and
repair if necessary. (Refer to 8 -
ELECTRICAL/INSTRUMENT
CLUSTER - DIAGNOSIS AND
TESTING).
3. Gauge reading rises when vehicle
is brought to a stop after heavy use
(engine still running)
3. A normal condition. No correction is
necessary. Gauge should return to
normal range after vehicle is driven.
4. Gauge reading high after
re-starting a warmed up (hot) engine.
4. A normal condition. No correction is
necessary. The gauge should return
to normal range after a few minutes of
engine operation.
5. Coolant level low in radiator (air
will build up in the cooling system
causing the thermostat to open late).
5. Check and correct coolant leaks.
(Refer to 7 - COOLING - DIAGNOSIS
AND TESTING).
6. Cylinder head gasket leaking
allowing exhaust gas to enter cooling
system causing a thermostat to open
late.
6. (a) Check for cylinder head gasket
leaks. (Refer to 7 - COOLING -
DIAGNOSIS AND TESTING).
(b) Check for coolant in the engine oil.
Inspect for white steam emitting from
the exhaust system. Repair as
necessary.
7. Water pump impeller loose on
shaft.
7. Check water pump and replace as
necessary. (Refer to 7 - COOLING/
ENGINE/WATER PUMP - REMOVAL).
8. Loose accessory drive belt. (water
pump slipping)
8. (Refer to 7 - COOLING/
ACCESSORY DRIVE/DRIVE BELTS -
DIAGNOSIS AND TESTING). Check
and correct as necessary.
9. Air leak on the suction side of the
water pump allows air to build up in
cooling system causing thermostat to
open late.
9. Locate leak and repair as
necessary.
PRESSURE CAP IS BLOWING OFF
STEAM AND/OR COOLANT TO
COOLANT TANK. TEMPERATURE
GAUGE READING MAY BE ABOVE
NORMAL BUT NOT HIGH. COOLANT
LEVEL MAY BE HIGH IN COOLANT
RESERVE/OVERFLOW TANK
1. Pressure relief valve in radiator
cap is defective.
1. Check condition of radiator cap and
cap seals. (Refer to 7 - COOLING/
ENGINE/RADIATOR PRESSURE
CAP - DIAGNOSIS AND TESTING).
Replace cap as necessary.
COOLANT LOSS TO THE GROUND
WITHOUT PRESSURE CAP
BLOWOFF. GAUGE READING HIGH
OR HOT
1. Coolant leaks in radiator, cooling
system hoses, water pump or engine.
1. Pressure test and repair as
necessary. (Refer to 7 - COOLING -
DIAGNOSIS AND TESTING).
7 - 6 COOLING TJ
COOLING (Continued)
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 coolant not correct.
Mixture is too rich or too lean.
2. Check coolant concentration.
(Refer to LUBRICATION &
MAINTENANCE/FLUID TYPES -
DESCRIPTION).
HOSE OR HOSES COLLAPSE
WHILE ENGINE IS RUNNING
1. Vacuum created in cooling system
on engine cool-down is not being
relieved through coolant reserve/
overflow system.
1. (a) Radiator cap relief valve stuck.
(Refer to 7 - COOLING/ENGINE/
RADIATOR PRESSURE CAP -
DIAGNOSIS AND TESTING). Replace
if necessary
(b) Hose between coolant reserve/
overflow tank and radiator is kinked.
Repair as necessary.
(c) Vent at coolant reserve/overflow
tank is plugged. Clean vent and repair
as necessary.
(d) Reserve/overflow tank is internally
blocked or plugged. Check for
blockage and repair as necessary.
NOISY VISCOUS FAN/DRIVE 1. Fan blades loose. 1. Replace fan blade assembly. (Refer
to 7 - COOLING/ENGINE/RADIATOR
FAN - REMOVAL)
2. Fan blades striking a surrounding
object.
2. Locate point of fan blade contact
and repair as necessary.
3. Air obstructions at radiator or air
conditioning condenser.
3. Remove obstructions and/or clean
debris or insects from radiator or A/C
condenser.
4. Thermal viscous fan drive has
defective bearing.
4. Replace fan drive. Bearing is not
serviceable. (Refer to 7 - COOLING/
ENGINE/FAN DRIVE VISCOUS
CLUTCH - REMOVAL).
5. A certain amount of fan noise may
be evident on models equipped with
a thermal viscous fan drive. Some of
this noise is normal.
5. (Refer to 7 - COOLING/ENGINE/
FAN DRIVE VISCOUS CLUTCH -
DESCRIPTION) for an explanation of
normal fan noise.
TJ COOLING 7 - 7
COOLING (Continued)
CONDITION POSSIBLE CAUSES CORRECTION
INADEQUATE HEATER
PERFORMANCE. THERMOSTAT
FAILED IN OPEN POSITION
1. Has a Diagnostic trouble Code
(DTC) been set?
1. (Refer to 25 - EMISSIONS
CONTROL - DESCRIPTION) for
correct procedures and replace
thermostat if necessary
2. Coolant level low 2. (Refer to 7 - COOLING -
DIAGNOSIS AND TESTING).
3. Obstructions in heater hose/fittings 3. Remove heater hoses at both ends
and check for obstructions
4. Heater hose kinked 4. Locate kinked area and repair as
necessary
5. Water pump is not pumping water
to/through the heater core. When the
engine is fully warmed up, both
heater hoses should be hot to the
touch. If only one of the hoses is hot,
the water pump may not be operating
correctly or the heater core may be
plugged. Accessory drive belt may be
slipping causing poor water pump
operation.
5. (Refer to 7 - COOLING/ENGINE/
WATER PUMP - REMOVAL). If a
slipping belt is detected, (Refer to 7 -
COOLING/ACCESSORY DRIVE/
DRIVE BELTS - DIAGNOSIS AND
TESTING). If heater core obstruction
is detected, (Refer to 24 - HEATING
& AIR CONDITIONING/
PLUMBING/HEATER CORE -
REMOVAL).
STEAM IS COMING FROM THE
FRONT OF VEHICLE NEAR THE
GRILL AREA WHEN WEATHER IS
WET, ENGINE IS WARMED UP AND
RUNNING, AND VEHICLE IS
STATIONARY. TEMPERATURE
GAUGE IS IN NORMAL RANGE
1. During wet weather, moisture
(snow, ice or rain condensation) on
the radiator will evaporate when the
thermostat opens. This opening
allows heated water into the radiator.
When the moisture contacts the hot
radiator, steam may be emitted. This
usually occurs in cold weather with
no fan or airflow to blow it away.
1. Occasional steam emitting from this
area is normal. No repair is
necessary.
COOLANT COLOR 1. Coolant color is not necessarily an
indication of adequate corrosion or
temperature protection. Do not rely
on coolant color for determining
condition of coolant.
1. (Refer to LUBRICATION &
MAINTENANCE/FLUID TYPES -
DESCRIPTION). Adjust coolant
mixture as necessary.
COOLANT LEVEL CHANGES IN
COOLANT RESERVE/OVERFLOW
TANK. TEMPERATURE GAUGE IS IN
NORMAL RANGE
1. Level changes are to be expected
as coolant volume fluctuates with
engine temperature. If the level in the
tank was between the FULL and ADD
marks at normal operating
temperature, the level should return
to within that range after operation at
elevated temperatures.
1. A normal condition. No repair is
necessary.
7 - 8 COOLING TJ
COOLING (Continued)
DIAGNOSIS AND TESTING - COOLING SYSTEM
- TESTING FOR LEAKS
ULTRAVIOLET LIGHT METHOD
Al l Jeep model s have a l eak detecti on addi ti ve
added to the cool i ng system before they l eave the fac-
tory. The addi ti ve i s hi ghl y vi si bl e under ul travi ol et
l i ght (bl ack l i ght). I f the factory ori gi nal cool ant has
been drai ned, pour one ounce of addi ti ve i nto the
cool i ng system. The addi ti ve i s avai l abl e through the
parts department. Pl ace the heater control uni t i n
HEAT posi ti on. Start and operate the engi ne unti l
the radi ator upper hose i s warm to the touch. Ai m
the commerci al l y avai l abl e bl ack l i ght tool at the
components to be checked. I f l eaks are present, the
bl ack l i ght wi l l cause the addi ti ve to gl ow a bri ght
green col or.
The bl ack l i ght can be used al ong wi th a pressure
tester to determi ne i f any external l eaks exi st (Fi g.
4).
PRESSURE TESTER METHOD
The engi ne shoul d be at the normal operati ng tem-
perature. Recheck the system col d i f the cause of
cool ant l oss i s not l ocated duri ng warm engi ne exam-
i nati on.
WARNING: HOT, PRESSURIZED COOLANT CAN
CAUSE INJURY BY SCALDING.
Careful l y remove the radi ator pressure cap from
the fi l l er neck and check the cool ant l evel . Push
down on the cap to di sengage i t from the stop tabs.
Wi pe the i nner part of the fi l l er neck and exami ne
the l ower i nsi de seal i ng seat for ni cks, cracks, pai nt,
di rt and sol der resi due. I nspect the reserve/overfl ow
tank tube for i nternal obstructi ons. I nsert a wi re
through the tube to be sure i t i s not obstructed.
I nspect the cams on the outsi de part of the fi l l er
neck. I f the cams are bent, seati ng of pressure cap
val ve and tester seal wi l l be affected. Repl ace cap i f
cams are bent.
Attach pressure tester 7700 (or an equi val ent) to
the radi ator fi l l er neck (Fi g. 5).
Operate the tester pump to appl y 124 kPa (18 psi )
pressure to the system. I f the hoses enl arge exces-
si vel y or bul ge whi l e testi ng, repl ace as necessary.
Observe the gauge poi nter and determi ne the condi -
ti on of the cool i ng system accordi ng to the fol l owi ng
cri teri a:
• Hol ds Steady: I f the poi nter remai ns steady for
two mi nutes, there are no seri ous cool ant l eaks i n
the system. However, there coul d be an i nternal l eak
that does not appear wi th normal system test pres-
sure. I nspect for i nteri or l eakage or do the I nternal
Leakage Test. Do thi s i f i t i s certai n that cool ant i s
bei ng l ost and no l eaks can be detected.
• Drops Sl owl y: Shows a smal l l eak or seepage i s
occurri ng. Exami ne al l connecti ons for seepage or
sl i ght l eakage wi th a fl ashl i ght. I nspect the radi ator,
hoses, gasket edges and heater. Seal any smal l l eak
hol es wi th a Seal er Lubri cant or equi val ent. Repai r
l eak hol es and rei nspect the system wi th pressure
appl i ed.
• Drops Qui ckl y: Shows that a seri ous l eakage i s
occurri ng. Exami ne the system for seri ous external
l eakage. I f no l eaks are vi si bl e, i nspect for i nternal
Fig. 4 Leak Detection Using Black Light—Typical
1 - TYPICAL BLACK LIGHT TOOL
Fig. 5 Pressurizing System - Typical
1 - TYPICAL COOLING SYSTEM PRESSURE TESTER
TJ COOLING 7 - 9
COOLING (Continued)
l eakage. Large radi ator l eak hol es shoul d be repai red
by a reputabl e radi ator repai r shop.
INTERNAL LEAKAGE INSPECTION
Remove the engi ne oi l pan drai n pl ug and drai n a
smal l amount of engi ne oi l . Cool ant, bei ng heavi er
than engi ne oi l , wi l l drai n fi rst. Another way of test-
i ng i s to operate the engi ne and check for water gl ob-
ul es on the engi ne oi l di psti ck. Al so i nspect the
automati c transmi ssi on oi l di psti ck for water gl ob-
ul es. I nspect the automati c transmi ssi on fl ui d cool er
for l eakage. Operate the engi ne wi thout the pressure
cap on the radi ator unti l thermostat opens.
Attach a pressure tester to the fi l l er neck. I f pres-
sure bui l ds up qui ckl y, a l eak exi sts as a resul t of a
faul ty cyl i nder head gasket or crack i n the engi ne.
Repai r as necessary.
WARNING: DO NOT ALLOW PRESSURE TO
EXCEED 124 KPA (18 PSI). TURN THE ENGINE OFF.
TO RELEASE THE PRESSURE, ROCK THE TESTER
FROM SIDE TO SIDE. WHEN REMOVING THE
TESTER, DO NOT TURN THE TESTER MORE THAN
1/2 TURN IF THE SYSTEM IS UNDER PRESSURE.
I f there i s no i mmedi ate pressure i ncrease, pump
the pressure tester unti l the i ndi cated pressure i s
wi thi n the system range. Vi brati on of the gauge
poi nter i ndi cates compressi on or combusti on l eakage
i nto the cool i ng system.
WARNING: DO NOT DISCONNECT THE SPARK
PLUG WIRES WHILE THE ENGINE IS OPERATING.
CAUTION: Do not operate the engine with a spark
plug shorted for more than a minute. The catalytic
converter may be damaged.
I sol ate the compressi on l eak by shorti ng each
spark pl ug to the cyl i nder bl ock. The gauge poi nter
shoul d stop or decrease vi brati on when spark pl ug
for l eaki ng cyl i nder i s shorted. Thi s happens because
of the absence of combusti on pressure.
COMBUSTION LEAKAGE TEST (WITHOUT
PRESSURE TESTER)
DO NOT WASTE reusabl e cool ant. I f the sol uti on
i s cl ean, drai n the cool ant i nto a cl ean contai ner for
reuse.
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR
DRAINCOCK WITH THE SYSTEM HOT AND UNDER
PRESSURE. SERIOUS BURNS FROM COOLANT
CAN OCCUR.
Remove thermostat (Refer to 7 - COOLI NG/EN-
GI NE/ENGI NE COOLANT THERMOSTAT -
REMOVAL).
Remove accessory dri ve bel t (Refer to 7 - COOL-
I NG/ACCESSORY DRI VE/DRI VE BELTS -
REMOVAL).
Add cool ant to the radi ator to bri ng the l evel to
wi thi n 6.3 mm (1/4 i n) of the top of the thermostat
housi ng.
CAUTION: Avoid overheating. Do not operate the
engine for an excessive period of time. Open the
draincock immediately after the test to eliminate
boil over of coolant.
Start the engi ne and accel erate rapi dl y three ti mes
(to approxi matel y 3000 rpm) whi l e observi ng the
cool ant. I f i nternal engi ne combusti on gases are l eak-
i ng i nto the cool i ng system, bubbl es wi l l appear i n
the cool ant. I f bubbl es do not appear, there i s no
i nternal combusti on gas l eakage.
DIAGNOSIS AND TESTING - RADIATOR
COOLANT FLOW CHECK
The fol l owi ng procedure wi l l determi ne i f cool ant i s
fl owi ng through the cool i ng system.
I f engi ne i s col d, i dl e engi ne unti l normal operati ng
temperature i s reached. Then feel the upper radi ator
hose. I f hose i s hot, the thermostat i s open and water
i s ci rcul ati ng through cool i ng system.
STANDARD PROCEDURE
STANDARD PROCEDURE - DRAINING COOLING
SYSTEM - 2. 4L
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK DRAIN PLUGS (Fig. 6) OR LOOSEN THE
RADIATOR DRAINCOCK WITH SYSTEM HOT AND
UNDER PRESSURE. SERIOUS BURNS FROM
COOLANT CAN OCCUR.
(1) DO NOT remove radi ator cap fi rst. Wi th engi ne
col d, rai se vehi cl e on a hoi st and l ocate radi ator
drai ncock.
NOTE: Radiator draincock is located on the left/
lower side of radiator facing to rear of vehicle.
(2) Attach one end of a hose to the drai ncock. Put
the other end i nto a cl ean contai ner. Open drai ncock
and drai n cool ant from radi ator. Thi s wi l l empty the
cool ant reserve/overfl ow tank. The cool ant does not
have to be removed from the tank unl ess the system
i s bei ng refi l l ed wi th a fresh mi xture. When tank i s
7 - 10 COOLING TJ
COOLING (Continued)
empty, remove radi ator cap and conti nue drai ni ng
cool i ng system.
STANDARD PROCEDURE - REFILLING
COOLING SYSTEM - 2. 4L
(1) Ti ghten the radi ator drai ncock and the cyl i nder
bl ock drai n pl ug(s) (i f removed).
CAUTION: Failure to purge air from the cooling sys-
tem can result in an overheating condition and
severe engine damage.
(2) Fi l l system usi ng a 50/50 mi xture of ethyl ene-
gl ycol anti freeze and l ow mi neral content water. Fi l l
pressure bottl e to servi ce l i ne and i nstal l cap.
NOTE: The engine cooling system will push any
remaining air into the coolant bottle within about an
hour of normal driving. As a result, a drop in cool-
ant level in the pressure bottle may occur. If the
engine cooling system overheats and pushes cool-
ant into the overflow side of the coolant bottle, this
coolant will be sucked back into the cooling system
ONLY IF THE PRESSURE CAP IS LEFT ON THE
BOTTLE. Removing the pressure cap breaks the
vacuum path between the two bottle sections and
the coolant will not return to cooling system.
(3) Wi th heater control uni t i n the HEAT posi ti on,
operate engi ne wi th pressure bottl e cap i n pl ace.
(4) Add cool ant to pressure bottl e as necessary.
Only add coolant to the pressure bottle when
the engine is cold. Coolant level in a warm
engine will be higher due to thermal expansion.
NOTE: The coolant bottle has two chambers. Cool-
ant will normally only be in the outboard (larger) of
the two. The inboard chamber is only to recover
coolant in the event of an overheat or after a recent
service fill. The inboard chamber should normally
be empty. If there is coolant in the overflow side of
the coolant bottle (after several warm/cold cycles of
the engine) and coolant level is above cold full
when cold, disconnect the end of the overflow hose
at the fill neck and lower it into a clean container.
Allow coolant to drain into the container until emp-
tied. Reconnect overflow hose to fill neck.
STANDARD PROCEDURE - COOLANT LEVEL
CHECK
NOTE: Do not remove radiator cap for routine cool-
ant level inspections. The coolant level can be
checked at coolant reserve/overflow tank.
The cool ant reserve/overfl ow system provi des a
qui ck vi sual method for determi ni ng cool ant l evel
wi thout removi ng radi ator pressure cap. Wi th engi ne
i dl i ng and at normal operati ng temperature, observe
cool ant l evel i n reserve/overfl ow tank. The cool ant
l evel shoul d be between ADD and FULL marks.
STANDARD PROCEDURE - COOLING SYSTEM -
DRAINING
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR
DRAINCOCK WITH SYSTEM HOT AND UNDER
PRESSURE. SERIOUS BURNS FROM COOLANT
CAN OCCUR.
DO NOT WASTE reusabl e cool ant. I f the sol uti on
i s cl ean, drai n the cool ant i nto a cl ean contai ner for
reuse.
DO NOT remove the radi ator cap when drai ni ng
the cool ant from the reserve/overfl ow tank. Open the
radi ator drai ncock and when the tank i s empty,
remove the radi ator cap. The cool ant does not have
to be removed from the tank unl ess the system i s
bei ng refi l l ed wi th a fresh mi xture.
(1) Drai n the cool ant from the radi ator by l oosen-
i ng the drai ncock.
(2) Drai n cool ant from engi ne bl ock by removi ng
drai n pl ug at l eft rear si de of bl ock (Fi g. 7).
Fig. 6 Drain Plug - 3.7L Engine
1 - CYLINDER BLOCK DRAIN PLUG
2 - EXHAUST MANIFOLD AND HEAT SHIELD
TJ COOLING 7 - 11
COOLING (Continued)
STANDARD PROCEDURE - COOLING SYSTEM -
REFILLING
(1) Ti ghten the radi ator drai ncock and the cyl i nder
bl ock drai n pl ug(s).
(2) Fi l l system usi ng a 50/50 mi xture of water and
anti freeze. Fi l l the radi ator to the top and i nstal l the
radi ator cap. Add suffi ci ent cool ant to the reserve/
overfl ow tank to rai se the l evel to the FULL mark.
(3) Operate the engi ne wi th both the radi ator cap
and reserve/overfl ow tank cap i n pl ace. After the
engi ne has reached the normal operati ng tempera-
ture, shut the engi ne off and al l ow i t to cool .
(4) Add cool ant to the reserve/overfl ow tank as
necessary. Only add coolant when the engine is
cold. Coolant level in a warm engine will be
higher due to thermal expansion.
STANDARD PROCEDURE - COOLING SYSTEM -
REVERSE FLUSHING
CAUTION: The cooling system normally operates at
97 - 110 C.P.A. 14 - 16 -16 psi) pressure. Exceeding
this pressure may damage the radiator or hoses.
Reverse fl ushi ng of the cool i ng system i s the forc-
i ng of water through the cool i ng system. Thi s i s done
usi ng ai r pressure i n the opposi te di recti on of normal
cool ant fl ow. I t i s usual l y onl y necessary wi th very
di rty systems wi th evi dence of parti al pl uggi ng.
CHEMICAL CLEANING
I f vi sual i nspecti on i ndi cates the formati on of
sl udge or scal y deposi ts, use a radi ator cl eaner
(Mopar Radi ator Kl een or equi val ent) before fl ushi ng.
Thi s wi l l soften scal e and other deposi ts and ai d the
fl ushi ng operati on.
CAUTION: Be sure instructions on the container are
followed.
REVERSE FLUSHING RADIATOR
Di sconnect the radi ator hoses from the radi ator fi t-
ti ngs. Attach a secti on of radi ator hose to the radi a-
tor bottom outl et fi tti ng and i nsert the fl ushi ng gun.
Connect a water suppl y hose and ai r suppl y hose to
the fl ushi ng gun.
CAUTION: The cooling system normally operates at
97 - 110 C.P.A. (14 - 16 psi) pressure. Exceeding this
pressure may damage the radiator or hoses.
Al l ow the radi ator to fi l l wi th water. When radi ator
i s fi l l ed, appl y ai r i n short bl asts al l owi ng radi ator to
refi l l between bl asts. Conti nue thi s reverse fl ushi ng
unti l cl ean water fl ows out through rear of radi ator
cool i ng tube passages. For more i nformati on, refer to
operati ng i nstructi ons suppl i ed wi th fl ushi ng equi p-
ment. Have radi ator cl eaned more extensi vel y by a
radi ator repai r shop.
REVERSE FLUSHING ENGINE
Drai n the cool i ng system (Refer to 7 - COOLI NG -
STANDARD PROCEDURE). Remove the thermostat
housi ng and thermostat. I nstal l the thermostat hous-
i ng. Di sconnect the radi ator upper hose from the
radi ator and attach the fl ushi ng gun to the hose. Di s-
connect the radi ator l ower hose from the water
pump. Attach a l ead away hose to the water pump
i nl et fi tti ng.
CAUTION: Be sure that the heater control valve is
closed (heat off). This is done to prevent coolant
flow with scale and other deposits from entering
the heater core.
Connect the water suppl y hose and ai r suppl y hose to
the fl ushi ng gun. Al l ow the engi ne to fi l l wi th water.
When the engi ne i s fi l l ed, appl y ai r i n short bl asts,
al l owi ng the system to fi l l between ai r bl asts. Conti nue
unti l cl ean water fl ows through the l ead away hose. For
more i nformati on, refer to operati ng i nstructi ons sup-
pl i ed wi th fl ushi ng equi pment.
Remove the l ead away hose, fl ushi ng gun, water
suppl y hose and ai r suppl y hose. Remove the thermo-
stat housi ng (Refer to 7 - COOLI NG/ENGI NE/EN-
GI NE COOLANT THERMOSTAT - REMOVAL).
I nstal l the thermostat and housi ng wi th a repl ace-
ment gasket (Refer to 7 - COOLI NG/ENGI NE/EN-
GI NE COOLANT THERMOSTAT -
Fig. 7 Draining Coolant From Block - 2.4L/4.0L Engines
1 - EXHAUST MANIFOLD
2 - CYLINDER BLOCK COOLANT DRAIN PLUG
7 - 12 COOLING TJ
COOLING (Continued)
I NSTALLATI ON). Connect the radi ator hoses. Refi l l
the cool i ng system wi th the correct anti freeze/water
mi xture (Refer to 7 - COOLI NG - STANDARD PRO-
CEDURE).
SPECIFICATIONS
TORQUE
DESCRIPTION N·m Ft.
Lbs.
In.
Lbs.
Automatic Belt Tensioner to
Mounting Bracket - 2.4L
41 30 -
Bolt, Automatic Belt Tensioner
Pulley - 2.4L
61 45 -
Bolt, Block Heater - 2.4L 2 - 17
Bolts, Condenser to Radiator
Bolts, Coolant Overflow Bottle
to Plenum - 2.4L only
8.5 - 75
Electric Fan to Fan Shroud
bolts
5.5 50
Bolts, 3.7LFan Blade Assy. to
Viscous Drive
23 - 210
Bolts, Fan Shroud to Radiator
Mounting
8 - 70
Bolts, Radiator Upper Isolator
to Crossmember
9.5 - 85
Bolts, Thermostat Housing -
2.4L
28 - 250
Bolts, Water Pump
2.4L 12 - 105
4.0l 23 - 200
SPECIAL TOOLS
COOLING
Pliers 6094
Adapter Pins 8346
Spanner Wrench 6958 with 8346 adapter pins
Pressure Tester 7700–A
Coolant Refractometer 8286
TJ COOLING 7 - 13
COOLING (Continued)
ACCESSORY DRIVE
TABLE OF CONTENTS
page page
ACCESSORY DRIVE
SPECIFICATIONS
BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . 14
BELT TENSIONERS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 14
REMOVAL
REMOVAL - 2.4L ENGINE . . . . . . . . . . . . . . . 15
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
INSTALLATION
INSTALLATION - 2.4L ENGINE . . . . . . . . . . . 15
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 16
DRIVE BELTS - 2.4L
DIAGNOSIS AND TESTING - ACCESSORY
DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . 16
REMOVAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
INSTALLATION
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 19
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 21
ACCESSORY DRIVE
SPECIFICATIONS
BELT TENSION
Bel t tensi on can not be adjusted. Refer to the fol -
l owi ng Bel t Tensi on chart for speci fi cati ons.
DESCRIPTION N·m Lbs. ft.
New Serpentine Belt* 800-900 180-200
Used Serpentine Belt 623-712 140-160
* Belt is considered new if it has been used 15
minutes or less.
BELT TENSIONERS
DESCRIPTION
The automati c bel t tensi oner (Fi g. 1) i s a spri ng
l oaded arm and pul l ey assembl y. The tensi oner
assembl y i s desi gned to appl y constant pressure on
the accessory dri ve bel t to mai ntai n proper bel t ten-
si on. There are three marks on the tensi oner body,
these marks are there to i ndi cate bel t wear and bel t
tensi on.
NOTE: On 4.0L engines, the tensioner arm has
three marks. Upon installation of a new belt, the
double line marks close to each other should be
very close to the mark on the base. The belt should
be replaced if the single line mark lines up with the
mark on the base.
Fig. 1 Accessory Drive Belt Wear Indicator - 4.0L
Engine
1 - INDICATOR MARK
2 - MINIMUM TENSION MARK
3 - MAXIMUM TENSION MARK
7 - 14 ACCESSORY DRIVE TJ
REMOVAL
REMOVAL - 2. 4L ENGINE
NOTE: The belt routing schematics are published
from the latest information available at the time of
publication. If anything differs between these sche-
matics and the Belt Routing Label, use the sche-
matics on Belt Routing Label. This label is located
in the engine compartment.
CAUTION: DO NOT LET TENSIONER ARM SNAP
BACK TO THE FREEARM POSITION, SEVERE DAM-
AGE MAY OCCUR TO THE TENSIONER.
Bel t tensi on i s not adjustabl e. Bel t adjustment i s
mai ntai ned by an automati c (spri ng l oad) bel t ten-
si oner.
(1) Di sconnect negati ve battery cabl e from battery.
(2) Rotate bel t tensi oner unti l i t contacts i ts stop.
Remove bel t, then sl owl y rotate the tensi oner i nto
the freearm posi ti on.
REMOVAL
On 4.0L engines, the tensioner arm has three
marks. Upon installation of a new belt, the dou-
ble line marks close to each other should be
very close to the mark on the base. The belt
should be replaced if the single line mark lines
up with the mark on the base.
I f the above speci fi cati on cannot be met, check for:
• The wrong bel t bei ng i nstal l ed (i ncorrect l ength/
wi dth)
• Worn beari ngs on an engi ne accessory (A/C com-
pressor, power steeri ng pump, water pump, i dl er pul -
l ey or generator)
• A pul l ey on an engi ne accessory bei ng l oose
• Mi sal i gnment of an engi ne accessory
• Bel t i ncorrectl y routed.
NOTE: A used belt should be replaced if tensioner
indexing arrow has moved to the minimum travel
indicator. Tensioner travel stops at this point.
(1) Remove accessory dri ve bel t (Refer to 7 -
COOLI NG/ACCESSORY DRI VE/DRI VE BELTS -
REMOVAL).
(2) Remove tensi oner assembl y from mounti ng
bracket (Fi g. 2).
WARNING: BECAUSE OF HIGH SPRING TENSION,
DO NOT ATTEMPT TO DISASSEMBLE AUTOMATIC
TENSIONER. UNIT IS SERVICED AS AN ASSEMBLY.
INSTALLATION
INSTALLATION - 2. 4L ENGINE
NOTE: The belt routing schematics are published
from the latest information available at the time of
publication. If anything differs between these sche-
matics and the Belt Routing Label, use the sche-
matics on Belt Routing Label. This label is located
in the engine compartment.
Bel t tensi on i s not adjustabl e. Bel t adjustment i s
mai ntai ned by an automati c (spri ng l oad) bel t tensi oner.
(1) Check condi ti on of al l pul l eys.
CAUTION: When installing the serpentine accessory
drive belt, the belt MUST be routed correctly. If not,
the engine may overheat due to the water pump
rotating in the wrong direction.
(2) I nstal l new bel t (Fi g. 3) or (Fi g. 4). Route the
bel t around al l pul l eys except the i dl er pul l ey. Rotate
the tensi oner arm unti l i t contacts i ts stop posi ti on.
Route the bel t around the i dl er and sl owl y l et the
tensi oner rotate i nto the bel t. Make sure the bel t i s
seated onto al l pul l eys.
(3) Wi th the dri ve bel t i nstal l ed, i nspect the bel t
wear i ndi cator. On 2.4L Engi nes the gap between the
tang and the housi ng stop (measurement A) must not
exceed 24 mm (.94 i nches).
Fig. 2 Automatic Belt Tensioner - 4.0L Engine
1 - IDLER PULLEY TIGHTEN TO 47 N·m (35 FT. LBS.)
2 - AUTOMATIC BELT TENSIONER
3 - GENERATOR MOUNTING BRACKET
TJ ACCESSORY DRIVE 7 - 15
BELT TENSIONERS (Continued)
INSTALLATION
(1) I nstal l tensi oner assembl y to mounti ng
bracket, al i gn the two dowel s on the tensi oner wi th
the mounti ng bracket and hand start the bol t.
Ti ghten bol t to 28 N·m (250 i n. l bs.).
(2) I nstal l accessory dri ve bel t (Refer to 7 - COOL-
I NG/ACCESSORY DRI VE/DRI VE BELTS - I NSTAL-
LATI ON).
(3) Check bel t i ndexi ng marks.
DRIVE BELTS - 2.4L
DIAGNOSIS AND TESTING - ACCESSORY
DRIVE BELT
VISUAL DIAGNOSIS
When di agnosi ng serpenti ne accessory dri ve bel ts,
smal l cracks that run across the ri bbed surface of the
bel t from ri b to ri b (Fi g. 5), are consi dered normal .
These are not a reason to repl ace the bel t. However,
cracks runni ng al ong a ri b (not across) are not nor-
mal . Any bel t wi th cracks runni ng al ong a ri b must
be repl aced (Fi g. 5). Al so repl ace the bel t i f i t has
excessi ve wear, frayed cords or severe gl azi ng.
Refer to the ACCESSORY DRI VE BELT DI AGNO-
SI S CHART for further bel t di agnosi s.
Fig. 3 Belt Routing 2.4L With A/C
1 - IDLER PULLEY
2 - GENERATOR PULLEY
3 - IDLER PULLEY
4 - POWER STEERING PUMP PULLEY
5 -CRANKSHAFT PULLEY
6 - TENSIONER
7 - A/C COMPRESSOR PULLEY
8 - ACCESSORY DRIVE BELT
Fig. 4 Belt Routing 2.4L Without A/C
1 - IDLER PULLEY
2 - GENERATOR PULLEY
3 - IDLER PULLEY
4 - POWER STEERING PUMP PULLEY
5 -CRANKSHAFT PULLEY
6 - TENSIONER
7 - NON A/C IDLER PULLEY
8 - ACCESSORY DRIVE BELT
Fig. 5 Belt Wear Patterns
1 - NORMAL CRACKS BELT OK
2 - NOT NORMAL CRACKS REPLACE BELT
7 - 16 ACCESSORY DRIVE TJ
BELT TENSIONERS (Continued)
NOISE DIAGNOSIS
Noi ses generated by the accessory dri ve bel t are
most noti ceabl e at i dl e. Before repl aci ng a bel t to
resol ve a noi se condi ti on, i nspect al l of the accessory
dri ve pul l eys for al i gnment, gl azi ng, or excessi ve end
pl ay.
ACCESSORY DRIVE BELT DIAGNOSIS CHART
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 belt
RIB OR BELT WEAR 1. Pulley misaligned 1. Align pulley(s)
2. Abrasive environment 2. Clean pulley(s). Replace belt if
necessary
3. Rusted pulley(s) 3. Clean rust from pulley(s)
4. Sharp or jagged pulley groove
tips
4. Replace pulley. Inspect belt.
5. Belt rubber deteriorated 5. Replace belt
BELT SLIPS 1. Belt slipping because of
insufficient tension
1. Adjust tension (2.5L)
2. Belt or pulley exposed to
substance that has reduced friction
(belt dressing, oil, ethylene glycol)
2. Replace belt and clean pulleys
3. Driven component bearing failure
(seizure)
3. Replace faulty component or
bearing
4. Belt glazed or hardened from
heat and excessive slippage
4. Replace belt.
LONGITUDAL BELT CRACKING 1. Belt has mistracked from pulley
groove
1. Replace belt
2. Pulley groove tip has worn away
rubber to tensile member
2. Replace belt
ЉGROOVE JUMPINGЉ
(Belt does not maintain correct
position on pulley)
1. Belt tension either too low or too
high
1. Adjust belt tension (2.5L)
2. Pulley(s) not within design
tolerance
2. Replace pulley(s)
3. Foreign object(s) in grooves 3. Remove foreign objects from
grooves
4. Pulley misalignment 4. Align component
5. Belt cordline is broken 5. Replace belt
TJ ACCESSORY DRIVE 7 - 17
DRIVE BELTS - 2.4L (Continued)
CONDITION POSSIBLE CAUSES CORRECTION
BELT BROKEN
(Note: Identify and correct problem
before new belt is installed)
1. Excessive tension 1. Replace belt and adjust tension
to specification
2. Tensile member damaged during
belt installation
2. Replace belt
3. Severe misalignment 3. Align pulley(s)
4. Bracket, pulley, or bearing failure 4. Replace defective component
and belt
NOISE (Objectionable squeal,
squeak, or rumble is heard or felt
while drive belt is in operation)
1. Belt slippage 1. Adjust belt tension (2.5L)
2. Bearing noise 2. Locate and repair
3. Belt misalignment 3. Align belt/pulley(s)
4. Belt to pulley mismatch 4. Install correct belt
5. Driven component induced
vibration
5. Locate defective driven
component and repair
6. System resonant frequency
induced vibration
6. Vary belt tension within
specifications.
TENSION SHEETING FABRIC
FAILURE
(Woven fabric on outside,
circumference of belt has cracked or
separated from body of belt)
1. Tension sheeting contacting
stationary object
1. Correct rubbing condition
2. Excessive heat causing woven
fabric to age
2. Replace belt
3. Tension sheeting splice has
fractured
3. Replace belt
CORD EDGE FAILURE
(Tensile member exposed at edges
of belt or separated from belt body)
1. Excessive tension 1. Adjust belt tension (2.5L)
2. Belt contacting stationary object 2. Replace belt
3. Pulley(s) out of tolerance 3. Replace pulley
4. Insufficient adhesion between
tensile member and rubber matrix
4. Replace belt and adjust tension
to specifications
7 - 18 ACCESSORY DRIVE TJ
DRIVE BELTS - 2.4L (Continued)
REMOVAL
REMOVAL
NOTE: The belt routing schematics are published
from the latest information available at the time of
publication. If anything differs between these sche-
matics and the Belt Routing Label, use the sche-
matics on Belt Routing Label. This label is located
in the engine compartment.
CAUTION: DO NOT LET TENSIONER ARM SNAP
BACK TO THE FREEARM POSITION, SEVERE DAM-
AGE MAY OCCUR TO THE TENSIONER.
Bel t tensi on i s not adjustabl e. Bel t adjustment i s
mai ntai ned by an automati c (spri ng l oad) bel t ten-
si oner.
(1) Di sconnect negati ve battery cabl e from battery.
(2) Rotate bel t tensi oner unti l i t contacts i ts stop.
Remove bel t, then sl owl y rotate the tensi oner i nto
the freearm posi ti on.
REMOVAL
NOTE: The belt routing schematics are published
from the latest information available at the time of
publication. If anything differs between these sche-
matics and the Belt Routing Label, use the sche-
matics on Belt Routing Label. This label is located
in the engine compartment.
CAUTION: DO NOT LET TENSIONER ARM SNAP
BACK TO THE FREEARM POSITION, SEVERE DAM-
AGE MAY OCCUR TO THE TENSIONER.
Bel t tensi on i s not adjustabl e. Bel t adjustment i s
mai ntai ned by an automati c ( spri ng l oad ) bel t ten-
si oner.
(1) Di sconnect negati ve battery cabl e from battery.
(2) Rotate bel t tensi oner unti l i t contacts i ts stop.
Remove bel t, then sl owl y rotate the tensi oner i nto
the freearm posi ti on. (Fi g. 6) or (Fi g. 7).
INSTALLATION
INSTALLATION
NOTE: The belt routing schematics are published
from the latest information available at the time of
publication. If anything differs between these sche-
matics and the Belt Routing Label, use the sche-
matics on Belt Routing Label. This label is located
in the engine compartment.
Fig. 6 4.0L - Without A/C
1 - GENERATOR PULLEY
2 - IDLER PULLEY
3 - POWER STEERING PUMP PULLEY
4 - WATER PUMP PULLEY
5 - CRANKSHAFT PULLEY
6 - TENSIONER PULLEY
Fig. 7 4.0L Engines - With A/C
1 - GENERATOR PULLEY
2 - IDLER PULLEY
3 - POWER STEERING PUMP PULLEY
4 - AIR CONDITIONING COMPRESSOR PULLEY
5 - CRANKSHAFT PULLEY
6 - WATER PUMP PULLEY
7 - TENSIONER PULLEY
TJ ACCESSORY DRIVE 7 - 19
DRIVE BELTS - 2.4L (Continued)
Bel t tensi on i s not adjustabl e. Bel t adjustment i s
mai ntai ned by an automati c (spri ng l oad) bel t ten-
si oner.
(1) Check condi ti on of al l pul l eys.
CAUTION: When installing the serpentine accessory
drive belt, the belt MUST be routed correctly. If not,
the engine may overheat due to the water pump
rotating in the wrong direction.
(2) I nstal l new bel t (Fi g. 8) or (Fi g. 9). Route the
bel t around al l pul l eys except the i dl er pul l ey. Rotate
the tensi oner arm unti l i t contacts i ts stop posi ti on.
Route the bel t around the i dl er and sl owl y l et the
tensi oner rotate i nto the bel t. Make sure the bel t i s
seated onto al l pul l eys.
(3) Wi th the dri ve bel t i nstal l ed, i nspect the bel t
wear i ndi cator. On 2.4L Engi nes the gap between the
tang and the housi ng stop (measurement A) must not
exceed 24 mm (.94 i nches).
Fig. 8 Belt Routing 2.4L With A/C
1 - IDLER PULLEY
2 - GENERATOR PULLEY
3 - IDLER PULLEY
4 - POWER STEERING PUMP PULLEY
5 -CRANKSHAFT PULLEY
6 - TENSIONER
7 - A/C COMPRESSOR PULLEY
8 - ACCESSORY DRIVE BELT
Fig. 9 Belt Routing 2.4L Without A/C
1 - IDLER PULLEY
2 - GENERATOR PULLEY
3 - IDLER PULLEY
4 - POWER STEERING PUMP PULLEY
5 -CRANKSHAFT PULLEY
6 - TENSIONER
7 - NON A/C IDLER PULLEY
8 - ACCESSORY DRIVE BELT
7 - 20 ACCESSORY DRIVE TJ
DRIVE BELTS - 2.4L (Continued)
INSTALLATION
Bel t tensi on i s not adjustabl e. Bel t adjustment i s
mai ntai ned by an automati c ( spri ng l oad ) bel t ten-
si oner.
(1) Check condi ti on of al l pul l eys.
CAUTION: When installing the serpentine accessory
drive belt, the belt MUST be routed correctly. If not,
the engine may overheat due to the water pump
rotating in the wrong direction (Fig. 11) (Fig. 12).
(2) I nstal l new bel t (Fi g. 12) or (Fi g. 11). Route the
bel t around al l pul l eys except the i dl er pul l ey. Rotate
the tensi oner arm unti l i t contacts i ts stop posi ti on.
Route the bel t around the i dl er and sl owl y l et the
tensi oner rotate i nto the bel t. Make sure the bel t i s
seated onto al l pul l eys.
(3) Wi th the dri ve bel t i nstal l ed, i nspect the bel t
wear i ndi cator (Fi g. 10). On 4.0L Engi nes, the i ndi -
cator mark must be between the mi ni mum and max-
i mum marks. I f the measurement exceedes thi s
speci fi cati on repl ace the serpenti ne accessory dri ve
bel t.
Fig. 10 4.0L Engines - With A/C
1 - GENERATOR PULLEY
2 - IDLER PULLEY
3 - POWER STEERING PUMP PULLEY
4 - AIR CONDITIONING COMPRESSOR PULLEY
5 - CRANKSHAFT PULLEY
6 - WATER PUMP PULLEY
7 - TENSIONER PULLEY
Fig. 11 4.0L - Without/A/C
1 - GENERATOR PULLEY
2 - IDLER PULLEY
3 - POWER STEERING PUMP PULLEY
4 - WATER PUMP PULLEY
5 - CRANKSHAFT PULLEY
6 - TENSIONER PULLEY
Fig. 12 4.0L Engines - With A/C
1 - GENERATOR PULLEY
2 - IDLER PULLEY
3 - POWER STEERING PUMP PULLEY
4 - AIR CONDITIONING COMPRESSOR PULLEY
5 - CRANKSHAFT PULLEY
6 - WATER PUMP PULLEY
7 - TENSIONER PULLEY
TJ ACCESSORY DRIVE 7 - 21
DRIVE BELTS - 2.4L (Continued)
ENGINE
TABLE OF CONTENTS
page page
COOLANT
DESCRIPTION
DESCRIPTION - HOAT COOLANT . . . . . . . . . 23
DESCRIPTION - ENGINE COOLANT . . . . . . . 24
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
COOLANT RECOVERY CONTAINER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 24
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 25
ENGINE BLOCK HEATER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 25
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
REMOVAL
REMOVAL - 4.0L . . . . . . . . . . . . . . . . . . . . . . 26
REMOVAL - 2.4L . . . . . . . . . . . . . . . . . . . . . . 26
INSTALLATION
INSTALLATION 4.0L . . . . . . . . . . . . . . . . . . . 26
INSTALLATION - 2.4L . . . . . . . . . . . . . . . . . . 26
ENGINE COOLANT TEMPERATURE SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 27
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 27
ENGINE COOLANT THERMOSTAT
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 28
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
REMOVAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
INSTALLATION
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 29
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 29
FAN DRIVE VISCOUS CLUTCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 30
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
DIAGNOSIS AND TESTING
VISCOUS FAN DRIVE . . . . . . . . . . . . . . . . . . 31
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 32
RADIATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 33
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
DIAGNOSIS AND TESTING - RADIATOR
COOLANT FLOW . . . . . . . . . . . . . . . . . . . . . . 33
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 35
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 36
WATER PUMP - 2.4L
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 36
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
DIAGNOSIS AND TESTING
WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . 36
REMOVAL - 2.4L . . . . . . . . . . . . . . . . . . . . . . . . 37
INSTALLATION
INSTALLATION 2.4L . . . . . . . . . . . . . . . . . . . 37
WATER PUMP - 4.0L
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 37
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 39
RADIATOR PRESSURE CAP
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 40
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - RADIATOR
CAP-TO-FILLER NECK SEAL. . . . . . . . . . . . . 41
DIAGNOSIS AND TESTING - RADIATOR
CAP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 41
RADIATOR FAN
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 42
REMOVAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
REMOVAL - 4.0L . . . . . . . . . . . . . . . . . . . . . . 42
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 42
INSTALLATION
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 43
INSTALLATION - 4.0L . . . . . . . . . . . . . . . . . . 43
RADIATOR FAN RELAY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 43
7 - 22 ENGINE TJ
COOLANT
DESCRIPTION
DESCRIPTION - HOAT COOLANT
WARNING: ANTIFREEZE IS AN ETHYLENE GLYCOL
BASE COOLANT AND IS HARMFUL IF SWAL-
LOWED OR INHALED. IF SWALLOWED, DRINK
TWO GLASSES OF WATER AND INDUCE VOMIT-
ING. IF INHALED, MOVE TO FRESH AIR AREA.
SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT
STORE IN OPEN OR UNMARKED CONTAINERS.
WASH SKIN AND CLOTHING THOROUGHLY AFTER
COMING IN CONTACT WITH ETHYLENE GLYCOL.
KEEP OUT OF REACH OF CHILDREN. DISPOSE OF
GLYCOL BASE COOLANT PROPERLY, CONTACT
YOUR DEALER OR GOVERNMENT AGENCY FOR
LOCATION OF COLLECTION CENTER IN YOUR
AREA. DO NOT OPEN A COOLING SYSTEM WHEN
THE ENGINE IS AT OPERATING TEMPERATURE OR
HOT UNDER PRESSURE, PERSONAL INJURY CAN
RESULT. AVOID RADIATOR COOLING FAN WHEN
ENGINE COMPARTMENT RELATED SERVICE IS
PERFORMED, PERSONAL INJURY CAN RESULT.
CAUTION: Use of Propylene Glycol based coolants
is not recommended, as they provide less freeze
protection and less corrosion protection.
The cool i ng system i s desi gned around the cool ant.
The cool ant must accept heat from engi ne metal , i n
the cyl i nder head area near the exhaust val ves and
engi ne bl ock. Then cool ant carri es the heat to the
radi ator where the tube/fi n radi ator can transfer the
heat to the ai r.
The use of al umi num cyl i nder bl ocks, cyl i nder
heads, and water pumps requi res speci al corrosi on
protecti on. Mopar௡ Anti freeze/Cool ant, 5
Year/100,000 Mi l e Formul a (MS-9769), or the equi va-
l ent ethyl ene gl ycol base cool ant wi th organi c corro-
si on i nhi bi tors (cal l ed HOAT, for Hybri d Organi c
Addi ti ve Technol ogy) i s recommended. Thi s cool ant
offers the best engi ne cool i ng wi thout corrosi on when
mi xed wi th 50% Ethyl ene Gl ycol and 50% di sti l l ed
water to obtai n a freeze poi nt of -37°C (-35°F). I f i t
l oses col or or becomes contami nated, drai n, fl ush,
and repl ace wi th fresh properl y mi xed cool ant sol u-
ti on.
CAUTION: Moparா Antifreeze/Coolant, 5
Year/100,000 Mile Formula (MS-9769) may not be
mixed with any other type of antifreeze. Mixing of
coolants other than specified (non-HOAT or other
HOAT), may result in engine damage that may not
be covered under the new vehicle warranty, and
decreased corrosion protection.
COOLANT PERFORMANCE
The requi red ethyl ene-gl ycol (anti freeze) and water
mi xture depends upon cl i mate and vehi cl e operati ng
condi ti ons. The cool ant performance of vari ous mi x-
tures fol l ows:
Pure Water-Water can absorb more heat than a
mi xture of water and ethyl ene-gl ycol . Thi s i s for pur-
pose of heat transfer onl y. Water al so freezes at a
hi gher temperature and al l ows corrosi on.
100 percent Ethylene-Glycol-The corrosi on
i nhi bi ti ng addi ti ves i n ethyl ene-gl ycol need the pres-
ence of water to di ssol ve. Wi thout water, addi ti ves
form deposi ts i n system. These act as i nsul ati on
causi ng temperature to ri se to as hi gh as 149°C
(300°F). Thi s temperature i s hot enough to mel t pl as-
ti c and soften sol der. The i ncreased temperature can
resul t i n engi ne detonati on. I n addi ti on, 100 percent
ethyl ene-gl ycol freezes at -22°C (-8°F).
50/50 Ethylene-Glycol and Water-I s the recom-
mended mi xture, i t provi des protecti on agai nst freez-
i ng to -37°C (-34°F). The anti freeze concentrati on
must always be a mi ni mum of 44 percent, year-
round i n al l cl i mates. I f percentage i s l ower, engi ne
parts may be eroded by cavi tati on. Maxi mum protec-
ti on agai nst freezi ng i s provi ded wi th a 68 percent
anti freeze concentrati on, whi ch prevents freezi ng
down to -67.7°C (-90°F). A hi gher percentage wi l l
freeze at a warmer temperature. Al so, a hi gher per-
centage of anti freeze can cause the engi ne to over-
heat because speci fi c heat of anti freeze i s l ower than
that of water.
CAUTION: Richer antifreeze mixtures cannot be
measured with normal field equipment and can
cause problems associated with 100 percent ethyl-
ene-glycol.
COOLANT SELECTION AND ADDITIVES
The use of al umi num cyl i nder bl ocks, cyl i nder
heads and water pumps requi res speci al corrosi on
protecti on. Onl y Mopar௡ Anti freeze/Cool ant, 5
Year/100,000 Mi l e Formul a (gl ycol base cool ant wi th
corrosi on i nhi bi tors cal l ed HOAT, for Hybri d Organi c
Addi ti ve Technol ogy) i s recommended. Thi s cool ant
offers the best engi ne cool i ng wi thout corrosi on when
mi xed wi th 50% di sti l l ed water to obtai n to obtai n a
freeze poi nt of -37°C (-35°F). I f i t l oses col or or
becomes contami nated, drai n, fl ush, and repl ace wi th
fresh properl y mi xed cool ant sol uti on.
CAUTION: Do not use coolant additives that are
claimed to improve engine cooling.
TJ ENGINE 7 - 23
DESCRIPTION - ENGINE COOLANT
ETHYLENE-GLYCOL MIXTURES
CAUTION: Richer antifreeze mixtures cannot be
measured with normal field equipment and can
cause problems associated with 100 percent ethyl-
ene-glycol.
The requi red ethyl ene-gl ycol (anti freeze) and water
mi xture depends upon the cl i mate and vehi cl e oper-
ati ng condi ti ons. The recommended mi xture of 50/50
ethyl ene-gl ycol and water wi l l provi de protecti on
agai nst freezi ng to -37 deg. C (-35 deg. F). The anti -
freeze concentrati on must always be a mi ni mum of
44 percent, year-round i n al l cl i mates. If percentage
is lower than 44 percent, engine parts may be
eroded by cavitation, and cooling system com-
ponents may be severely damaged by corrosion.
Maxi mum protecti on agai nst freezi ng i s provi ded
wi th a 68 percent anti freeze concentrati on, whi ch
prevents freezi ng down to -67.7 deg. C (-90 deg. F). A
hi gher percentage wi l l freeze at a warmer tempera-
ture. Al so, a hi gher percentage of anti freeze can
cause the engi ne to overheat because the speci fi c
heat of anti freeze i s l ower than that of water.
Use of 100 percent ethyl ene-gl ycol wi l l cause for-
mati on of addi ti ve deposi ts i n the system, as the cor-
rosi on i nhi bi ti ve addi ti ves i n ethyl ene-gl ycol requi re
the presence of water to di ssol ve. The deposi ts act as
i nsul ati on, causi ng temperatures to ri se to as hi gh as
149 deg. C (300) deg. F). Thi s temperature i s hot
enough to mel t pl asti c and soften sol der. The
i ncreased temperature can resul t i n engi ne detona-
ti on. I n addi ti on, 100 percent ethyl ene-gl ycol freezes
at 22 deg. C (-8 deg. F ).
PROPYLENE-GLYCOL MIXTURES
I t’s overal l effecti ve temperature range i s smal l er
than that of ethyl ene-gl ycol . The freeze poi nt of 50/50
propyl ene-gl ycol and water i s -32 deg. C (-26 deg. F).
5 deg. C hi gher than ethyl ene-gl ycol ’s freeze poi nt.
The boi l i ng poi nt (protecti on agai nst summer boi l -
over) of propyl ene-gl ycol i s 125 deg. C (257 deg. F )
at 96.5 kPa (14 psi ), compared to 128 deg. C (263
deg. F) for ethyl ene-gl ycol . Use of propyl ene-gl ycol
can resul t i n boi l -over or freeze-up on a cool i ng sys-
tem desi gned for ethyl ene-gl ycol . Propyl ene gl ycol
al so has poorer heat transfer characteri sti cs than
ethyl ene gl ycol . Thi s can i ncrease cyl i nder head tem-
peratures under certai n condi ti ons.
Propyl ene-gl ycol /ethyl ene-gl ycol Mi xtures can
cause the destabi l i zati on of vari ous corrosi on i nhi bi -
tors, causi ng damage to the vari ous cool i ng system
components. Al so, once ethyl ene-gl ycol and propy-
l ene-gl ycol based cool ants are mi xed i n the vehi cl e,
conventi onal methods of determi ni ng freeze poi nt wi l l
not be accurate. Both the refracti ve i ndex and spe-
ci fi c gravi ty di ffer between ethyl ene gl ycol and propy-
l ene gl ycol .
OPERATION
Cool ant fl ows through the engi ne bl ock absorbi ng
the heat from the engi ne, then fl ows to the radi ator
where the cool i ng fi ns i n the radi ator transfers the
heat from the cool ant to the atmosphere. Duri ng col d
weather the ethyl ene-gl ycol cool ant prevents water
present i n the cool i ng system from freezi ng wi thi n
temperatures i ndi cated by mi xture rati o of cool ant to
water.
COOLANT RECOVERY
CONTAINER
DESCRIPTION
The cool ant reserve/overfl ow system consi sts of a
radi ator mounted pressuri zed cap, a pl asti c cool ant
recovery bottl e (Fi g. 1), a tube (hose) connecti ng the
radi ator and recovery bottl e, and an overfl ow tube on
the si de of the bottl e.
The reservoi r bottl e al so has an anti -sl osh i nsert
l ocated wi thi n the bottl e, thi s i nsert wi l l ai d i n
reduci ng cool ant l oss from spl ash and spi l l age.
Fig. 1 Coolant Recovery Bottle
1 - RADIATOR PRESSURE CAP
2 - HOSE
3 - COOLANT RECOVERY BOTTLE
7 - 24 ENGINE TJ
COOLANT (Continued)
OPERATION
The system works al ong wi th the radi ator pressure
cap. Thi s i s done by usi ng thermal expansi on and
contracti on of the cool ant to keep the cool ant free of
trapped ai r. I t provi des:
• A vol ume for cool ant expansi on and contracti on.
• A conveni ent and safe method for checki ng/ad-
justi ng cool ant l evel at atmospheri c pressure. Thi s i s
done wi thout removi ng the radi ator pressure cap.
• Some reserve cool ant to the radi ator to cover
mi nor l eaks and evaporati on or boi l i ng l osses.
As the engi ne cool s, a vacuum i s formed i n the
cool i ng system of both the radi ator and engi ne. Cool -
ant wi l l then be drawn from the cool ant tank and
returned to a proper l evel i n the radi ator.
REMOVAL
(1) Di sconnect the hose from radi ator fi l l er neck.
(2) Remove cool ant recovery bottl e (Fi g. 2).
INSTALLATION
(1) Posi ti on the tabs on the overfl ow bottl e i nto the
sl ots on the fan shroud.
(2) Reconnect the overfl ow hose onto the radi ator
fi l l er neck.
(3) Fi l l resrevoi r/overfl ow bottl e.
ENGINE BLOCK HEATER
DESCRIPTION
WARNING: DO NOT OPERATE ENGINE UNLESS
BLOCK HEATER CORD HAS BEEN DISCONNECTED
FROM POWER SOURCE AND SECURED IN PLACE.
An opti onal engi ne bl ock heater (Fi g. 3) i s avai l -
abl e for al l model s. The heater i s equi pped wi th a
power cord. The cord i s attached to an engi ne com-
partment component wi th ti e-straps. The heater
warms the engi ne provi di ng easi er engi ne starti ng
and faster warm-up i n l ow temperatures. The heater
i s mounted i n a core hol e of the engi ne cyl i nder bl ock
(i n pl ace of a freeze pl ug) wi th the heati ng el ement
i mmersed i n engi ne cool ant.
OPERATION
Connecti ng the power cord to a grounded 110-120
vol t AC el ectri cal outl et wi th a grounded, three-wi re
extensi on cord, suppl i es the el ectri ci ty requi red to
heat the el ement thus heati ng the engi ne cool ant.
Fig. 2 Coolant Reserve/Overflow Bottle
1 - RADIATOR PRESSURE CAP
2 - HOSE
3 - COOLANT RECOVERY BOTTLE
Fig. 3 Block Heater - Typical
1 - ENGINE BLOCK HEATER
TJ ENGINE 7 - 25
COOLANT RECOVERY CONTAINER (Continued)
REMOVAL
REMOVAL - 4. 0L
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR
DRAINCOCK WITH THE SYSTEM HOT AND PRES-
SURIZED. SERIOUS BURNS FROM THE COOLANT
CAN OCCUR.
DO NOT WASTE reusabl e cool ant. I f sol uti on i s
cl ean, drai n cool ant i nto a cl ean contai ner for reuse.
(1) Drai n cool ant (Refer to 7 - COOLI NG - STAN-
DARD PROCEDURE).
(2) Unpl ug power cord from bl ock heater.
(3) Loosen screw i n center of bl ock heater (Fi g. 4).
(4) Remove bl ock heater from cyl i nder bl ock.
REMOVAL - 2. 4L
(1) Drai n cool i ng system (Refer to 7 - COOLI NG/
ENGI NE - STANDARD PROCEDURE).
(2) Rai se vehi cl e on hoi st.
(3) Detach power cord pl ug from heater.
(4) Loosen screw i n center of heater. Remove
heater assembl y.
INSTALLATION
INSTALLATION 4. 0L
(1) Thoroughl y cl ean the engi ne core hol e and the
bl ock heater seat.
(2) I nsert bl ock heater assembl y i nto core hol e
wi th el ement l oop poi nti ng Up (Fi g. 4).
(3) Seat bl ock heater fl ush agai nst bl ock face.
Ti ghten mounti ng screw to 4 N·m (31 i n. l bs.) torque.
(4) Fi l l cool i ng system (Refer to 7 - COOLI NG -
STANDARD PROCEDURE), and i nspect for l eaks
(Refer to 7 - COOLI NG - DI AGNOSI S AND TEST-
I NG).
(5) Pl ug power cord i nto bl ock heater. Route cord
away from movi ng parts, l i nkages and exhaust sys-
tem components. Secure cord i n pl ace wi th ti e-straps.
INSTALLATION - 2. 4L
(1) Thoroughl y cl ean core hol e and heater seat.
(2) I nsert heater assembl y (Fi g. 5) wi th el ement
l oop posi ti oned upward .
(3) Wi th heater seated, ti ghten center screw
securel y to assure a posi ti ve seal .
CAUTION: To prevent damage, the power cord must
be secured in it’s retaining clips, and not positioned
so it could contact linkages or exhaust manifold.
(4) Connect power cord to heater.
(5) Lower vehi cl e.
(6) Fi l l cool i ng system (Refer to 7 - COOLI NG/EN-
GI NE - STANDARD PROCEDURE).
Fig. 4 Block Heater and Cord - 4.0L Engine
1 - POWER CORD
2 - BLOCK HEATER
3 - TIE-STRAPS
Fig. 5 ENGINE BLOCK HEATER 2.4L
1 - CORE HOLE
2 - BLOCK HEATER
3 - POWER CORD
7 - 26 ENGINE TJ
ENGINE BLOCK HEATER (Continued)
ENGINE COOLANT
TEMPERATURE SENSOR
DESCRIPTION
The Engi ne Cool ant Temperature (ECT) sensor i s
used to sense engi ne cool ant temperature. The sensor
protrudes i nto an engi ne water jacket.
The ECT sensor i s a two-wi re Negati ve Thermal
Coeffi ci ent (NTC) sensor. Meani ng, as engi ne cool ant
temperature i ncreases, resi stance (vol tage) i n the
sensor decreases. As temperature decreases, resi s-
tance (vol tage) i n the sensor i ncreases.
OPERATION
At key-on, the Powertrai n Control Modul e (PCM)
sends out a regul ated 5 vol t si gnal to the ECT sensor.
The PCM then moni tors the si gnal as i t passes
through the ECT sensor to the sensor ground (sensor
return).
When the engi ne i s col d, the PCM wi l l operate i n
Open Loop cycl e. I t wi l l demand sl i ghtl y ri cher ai r-
fuel mi xtures and hi gher i dl e speeds. Thi s i s done
unti l normal operati ng temperatures are reached.
The PCM uses i nputs from the ECT sensor for the
fol l owi ng cal cul ati ons:
• For engi ne cool ant temperature gauge operati on
through CCD or PCI (J1850) communi cati ons
• I njector pul se-wi dth
• Spark-advance curves
• ASD rel ay shut-down ti mes
• I dl e Ai r Control (I AC) motor key-on steps
• Pul se-wi dth pri me-shot duri ng cranki ng
• O2 sensor cl osed l oop ti mes
• Purge sol enoi d on/off ti mes
• EGR sol enoi d on/off ti mes (i f equi pped)
• Leak Detecti on Pump operati on (i f equi pped)
• Radi ator fan rel ay on/off ti mes (i f equi pped)
• Target i dl e speed
REMOVAL
WARNING: HOT, PRESSURIZED COOLANT CAN
CAUSE INJURY BY SCALDING. COOLING SYSTEM
MUST BE PARTIALLY DRAINED BEFORE REMOV-
ING ECT (ENGINE COOLANT TEMPERATURE) SEN-
SOR.
(1) Parti al l y drai n cool i ng system unti l cool ant
l evel i s bel ow cyl i nder head. (Refer to 7 - COOLI NG -
STANDARD PROCEDURE).
(2) Di sconnect ECT (Engi ne Cool ant Temperature)
sensor wi re connector (Fi g. 6) or (Fi g. 7).
(3) Remove sensor from engi ne.
INSTALLATION
(1) Appl y seal ant to sensor threads (new repl ace-
ment sensors wi l l have seal ant al ready appl i ed).
(2) I nstal l cool ant temperature sensor i nto thermo-
stat housi ng. Ti ghten to 11 N·m (8 ft. l bs.) torque.
(3) Connect wi re connector.
(4) Fi l l cool i ng system. (Refer to 7 - COOLI NG -
STANDARD PROCEDURE).
Fig. 6 ECT SENSOR LOCATION- 2.4L
1 - UPPER TIMING BELT COVER
2 - ELECTRICAL CONNECTOR (ECT)
3 - MOUNTING BOLTS (3)
Fig. 7 ECT SENSOR LOCATION - 4.0L
1 - THERMOSTAT HOUSING
2 - ENGINE COOLANT TEMPERATURE SENSOR
3 - ELECTRICAL CONNECTOR
TJ ENGINE 7 - 27
ENGINE COOLANT
THERMOSTAT
DESCRIPTION
CAUTION: Do not operate an engine without a ther-
mostat, except for servicing or testing.
The thermostat (Fi g. 8) on al l gas powered engi nes
i s l ocated beneath the thermostat housi ng at the
front of the i ntake mani fol d.
The thermostat i s a wax pel l et dri ven, reverse pop-
pet choke type.
Cool ant l eakage i nto the pel l et contai ner wi l l cause
the thermostat to fai l i n the open posi ti on. Thermo-
stats very rarel y sti ck. Do not attempt to free a ther-
mostat wi th a pryi ng devi ce.
The same thermostat i s used for wi nter and sum-
mer seasons. An engi ne shoul d not be operated wi th-
out a thermostat, except for servi ci ng or testi ng.
Operati ng wi thout a thermostat causes l onger engi ne
warmup ti me, unrel i abl e warmup performance,
i ncreased exhaust emi ssi ons and crankcase condensa-
ti on that can resul t i n sl udge formati on.
OPERATION
The wax pel l et i s l ocated i n a seal ed contai ner at
the spri ng end of the thermostat. When heated, the
pel l et expands, overcomi ng cl osi ng spri ng tensi on
and water pump pressure to force the val ve to open.
REMOVAL
REMOVAL
WARNING: DO NOT LOOSEN THE RADIATOR
DRAINCOCK WITH THE SYSTEM HOT AND PRES-
SURIZED. SERIOUS BURNS FROM THE COOLANT
CAN OCCUR.
DO NOT WASTE reusabl e cool ant. I f the sol uti on
i s cl ean, drai n the cool ant i nto a cl ean contai ner for
reuse.
(1) Drai n the cool ant from the radi ator unti l the
l evel i s bel ow the thermostat housi ng (Refer to 7 -
COOLI NG - STANDARD PROCEDURE).
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. ALWAYS WEAR SAFETY GLASSES WHEN
SERVICING CONSTANT TENSION CLAMPS.
CAUTION: A number or letter is stamped into the
tongue of constant tension clamps (Fig. 32). If
replacement is necessary, use only an original
equipment clamp with matching number or letter.
(2) Remove radi ator upper hose and heater hose at
thermostat housi ng.
(3) Di sconnect wi ri ng connector at engi ne cool ant
temperature sensor.
(4) Remove thermostat housi ng mounti ng bol ts,
thermostat housi ng, gasket and thermostat (Fi g. 9).
Di scard ol d gasket.
(5) Cl ean the gasket mati ng surfaces.
Fig. 8 Thermostat—Typical
1 - LONG BOLT
2 - GASKET
3 - THERMOSTAT
4 - THERMOSTAT HOUSING
5 - SHORT BOLT
7 - 28 ENGINE TJ
REMOVAL
(1) Drai n cool i ng system bel ow thermostat housi ng
l evel .
(2) Di sconnect engi ne cool ant temperature sensor.
(3) Di sconnect heater suppl y hose.
(4) Remove housi ng attachi ng bol ts (Fi g. 10).
(5) Remove housi ng, gasket and thermostat (Fi g.
10).
INSTALLATION
INSTALLATION
(1) I nstal l the repl acement thermostat so that the
pel l et, whi ch i s enci rcl ed by a coi l spri ng, faces the
engi ne. Al l thermostats are marked on the outer
fl ange to i ndi cate the proper i nstal l ed posi ti on.
(2) Observe the recess groove i n the engi ne cyl i n-
der head (Fi g. 11).
(3) Posi ti on thermostat i nto thi s groove wi th arrow
and ai r bl eed hol e on outer fl ange poi nti ng up.
(4) I nstal l repl acement gasket and thermostat
housi ng.
CAUTION: Tightening the thermostat housing
unevenly or with the thermostat out of its recess
may result in a cracked housing.
(5) Ti ghten the housi ng bol ts to 20 N·m (15 ft. l bs.)
torque.
(6) I nstal l hoses to thermostat housi ng.
(7) I nstal l el ectri cal connector to cool ant tempera-
ture sensor.
(8) Be sure that the radi ator drai ncock i s ti ghtl y
cl osed. Fi l l the cool i ng system (Refer to 7 - COOLI NG
- STANDARD PROCEDURE).
(9) Start and warm the engi ne. Check for l eaks.
INSTALLATION
(1) Cl ean al l gasket seal i ng surfaces.
(2) Pl ace a new gasket (di pped i n cl ean water) on
the cool ant outl et connector surface. Posi ti on thermo-
stat wi th ai r bl eed at 12 o’cl ock posi ti on i n thermo-
stat housi ng (Fi g. 12).
(3) Posi ti on the cool ant outl et connector and gas-
ket over the thermostat, maki ng sure thermostat i s
seated i n the thermostat housi ng.
(4) Posi ti on outl et connector to thermostat housi ng
and i nstal l bol ts. Ti ghten bol ts to 28 N·m (20 ft. l bs.).
(5) I nstal l radi ator hose to cool ant outl et housi ng.
(6) Connect engi ne cool ant temperature sensor.
Fig. 9 Thermostat Removal/Installation
1 - LONG BOLT
2 - GASKET
3 - THERMOSTAT
4 - THERMOSTAT HOUSING
5 - SHORT BOLT
Fig. 10 Thermostat and Coolant Outlet Connector
1 - TIMING BELT COVER
2 - OUTLET CONNECTOR
3 - THERMOSTAT
4 - HOUSING
TJ ENGINE 7 - 29
ENGINE COOLANT THERMOSTAT (Continued)
(7) Fi l l cool i ng system (Refer to 7 - COOLI NG -
STANDARD PROCEDURE).
FAN DRIVE VISCOUS CLUTCH
DESCRIPTION
CAUTION: Engines equipped with serpentine drive
belts have reverse rotating fans and viscous fan
drives. They are marked with the word REVERSE to
designate their usage. Installation of the wrong fan
or viscous fan drive can result in engine overheat-
ing.
The thermal vi scous fan dri ve (Fi g. 13) and (Fi g.
14) i s a si l i cone-fl ui d-fi l l ed coupl i ng used to connect
the fan bl ades to the water pump shaft. The coupl i ng
al l ows the fan to be dri ven i n a normal manner. Thi s
i s done at l ow engi ne speeds whi l e l i mi ti ng the top
speed of the fan to a predetermi ned maxi mum l evel
at hi gher engi ne speeds.
Fig. 11 Thermostat Recess
1 - GROOVE
Fig. 12 Thermostat Position
1 - LOCATOR NOTCH
2 - AIR BLEED
Fig. 13 Water Pump Mounted Fan Drive - 2.5L
Engine
1 - THERMAL VISCOUS FAN DRIVE
2 - (4) FAN BLADE-TO-VISCOUS DRIVE BOLTS
3 - (4) FAN HUB-TO-PUMP PULLEY STUDS
4 - WATER PUMP
5 - WATER PUMP PULLEY
6 - FAN BLADE
7 - (4) FAN HUB-TO-PUMP PULLEY NUTS
7 - 30 ENGINE TJ
ENGINE COOLANT THERMOSTAT (Continued)
OPERATION
A thermostati c bi metal l i c spri ng coi l i s l ocated on
the front face of the vi scous fan dri ve uni t (a typi cal
vi scous uni t i s shown i n (Fi g. 15) (Fi g. 16). Thi s
spri ng coi l reacts to the temperature of the radi ator
di scharge ai r. I t engages the vi scous fan dri ve for
hi gher fan speed i f the ai r temperature from the
radi ator ri ses above a certai n poi nt. Unti l addi ti onal
engi ne cool i ng i s necessary, the fan wi l l remai n at a
reduced rpm regardl ess of engi ne speed.
Onl y when suffi ci ent heat i s present, wi l l the vi s-
cous fan dri ve engage. Thi s i s when the ai r fl owi ng
through the radi ator core causes a reacti on to the
bi metal l i c coi l . I t then i ncreases fan speed to provi de
the necessary addi ti onal engi ne cool i ng.
Once the engi ne has cool ed, the radi ator di scharge
temperature wi l l drop. The bi metal l i c coi l agai n
reacts and the fan speed i s reduced to the previ ous
di sengaged speed.
DIAGNOSIS AND TESTING
VISCOUS FAN DRIVE
NOISE
NOTE: It is normal for fan noise to be louder (roar-
ing) when:
• The under hood temperature i s above the
engagement poi nt for the vi scous dri ve coupl i ng. Thi s
may occur when ambi ent (outsi de ai r temperature) i s
very hi gh.
• Engi ne l oads and temperatures are hi gh such as
when towi ng a trai l er.
• Cool si l i cone fl ui d wi thi n the fan dri ve uni t i s
bei ng redi stri buted back to i ts normal di sengaged
(warm) posi ti on. Thi s can occur duri ng the fi rst 15
seconds to one mi nute after engi ne start-up on a col d
engi ne.
LEAKS
Vi scous fan dri ve operati on i s not affected by smal l
oi l stai ns near the dri ve beari ng. I f l eakage appears
excessi ve, repl ace the fan dri ve uni t.
TESTING
I f the fan assembl y free-wheel s wi thout drag (the
fan bl ades wi l l revol ve more than fi ve turns when
Fig. 14 Water Pump Mounted Fan Drive - 4.0L
Engine
1 - FAN AND FAN DRIVE
2 - WATER PUMP PULLEY
Fig. 15 Viscous Fan Drive - 2.5L Engine
1 - VISCOUS FAN DRIVE
2 - MOUNTING HUB
3 - THERMOSTATIC SPRING
Fig. 16 Viscous Fan Drive - 4.0L Engine
1 - VISCOUS FAN DRIVE
2 - THERMOSTATIC SPRING
3 - MOUNTING NUT TO WATER PUMP HUB
TJ ENGINE 7 - 31
FAN DRIVE VISCOUS CLUTCH (Continued)
spun by hand), repl ace the fan dri ve. Thi s spi n test
must be performed when the engi ne i s cool .
For the fol l owi ng test, the cool i ng system must be
i n good condi ti on. I t al so wi l l ensure agai nst exces-
si vel y hi gh cool ant temperature.
WARNING: BE SURE THAT THERE IS ADEQUATE
FAN BLADE CLEARANCE BEFORE DRILLING.
(1) Dri l l a 3.18 mm (1/8 i n.) di ameter hol e i n the
top center of the fan shroud.
(2) Obtai n a di al thermometer wi th an 8 i nch stem
(or equi val ent). I t shoul d have a range of -18° - 105°C
(-4°- 220° F). I nsert thermometer through the hol e i n
the shroud. Be sure that there i s adequate cl earance
from the fan bl ades.
(3) Connect a tachometer and an engi ne i gni ti on
ti mi ng l i ght (ti mi ng l i ght i s to be used as a strobe
l i ght).
(4) Bl ock the ai r fl ow through the radi ator. Secure
a sheet of pl asti c i n front of the radi ator (or ai r con-
di ti oner condenser). Use tape at the top to secure the
pl asti c and be sure that the ai r fl ow i s bl ocked.
(5) Be sure that the ai r condi ti oner (i f equi pped) i s
turned off.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHING.
(6) Start the engi ne and operate at 2400 rpm.
Wi thi n ten mi nutes the ai r temperature (i ndi cated on
the di al thermometer) shoul d be up to 88° C (190° F).
Fan dri ve engagement shoul d have started to occur
at between 74° - 85° C (165° - 185° F). Engagement
i s di sti ngui shabl e by a defi ni te increase i n fan fl ow
noi se (roari ng). The ti mi ng l i ght al so wi l l i ndi cate an
i ncrease i n the speed of the fan.
(7) When the ai r temperature reaches 88° C (190°
F), remove the pl asti c sheet. Fan dri ve disengage-
ment shoul d have started to occur at between 57° -
82° C (135° - 180° F). A defi ni te decrease of fan fl ow
noi se (roari ng) shoul d be noti ced. I f not, repl ace the
defecti ve vi scous fan dri ve uni t.
CAUTION: Engines equipped with serpentine drive
belts have reverse rotating fans and viscous fan
drives. They are marked with the word REVERSE to
designate their usage. Installation of the wrong fan
or viscous fan drive can result in engine overheat-
ing.
CAUTION: If the viscous fan drive is replaced
because of mechanical damage, the cooling fan
blades should also be inspected. Inspect for fatigue
cracks, loose blades, or loose rivets that could
have resulted from excessive vibration. Replace fan
blade assembly if any of these conditions are
found. Also inspect water pump bearing and shaft
assembly for any related damage due to a viscous
fan drive malfunction.
REMOVAL
(1) The thermal vi scous fan dri ve/fan bl ade assem-
bl y i s attached (threaded) to water pump hub shaft.
Remove fan bl ade/vi scous fan dri ve assembl y from
water pump by turni ng mounti ng nut countercl ock-
wi se as vi ewed from front. Threads on vi scous fan
dri ve are RIGHT HAND. Usi ng a sui tabl e fan
wrench l oosen the fan dri ve (Fi g. 17).
(2) Remove accessory dri ve bel t (Refer to 7 -
COOLI NG/ACCESSORY DRI VE/DRI VE BELTS -
REMOVAL).
(3) Some model s wi th certai n engi nes may requi re
the removal of the fan shroud to remove the vi scous
fan dri ve. The fan shroud and fan bl ade/vi scous fan
dri ve shoul d be removed from the vehi cl e as one
assembl y.
(4) After removi ng fan bl ade/vi scous fan dri ve
assembl y, do not pl ace thermal vi scous fan dri ve i n
hori zontal posi ti on. I f stored hori zontal l y, si l i cone
fl ui d i n vi scous fan dri ve coul d drai n i nto i ts beari ng
assembl y and contami nate l ubri cant.
INSTALLATION
(1) Assembl e fan bl ade to vi scous fan dri ve.
Ti ghten mounti ng bol ts to 27 N·m (20 ft. l bs.) torque.
(2) Thread the fan and fan dri ve onto the water
pump pul l ey.
Fig. 17 Fan and Fan Drive - 4.0L Engine
1 - FAN AND FAN DRIVE
2 - WATER PUMP PULLEY
7 - 32 ENGINE TJ
FAN DRIVE VISCOUS CLUTCH (Continued)
CAUTION: When installing a serpentine accessory
drive belt, the belt MUST be routed correctly. If not,
the engine may overheat due to the water pump
rotating in the wrong direction.
(3) I nstal l accessory dri ve bel t (Refer to 7 - COOL-
I NG/ACCESSORY DRI VE/DRI VE BELTS - I NSTAL-
LATI ON).
RADIATOR
DESCRIPTION
CAUTION: Plastic tanks, while stronger than brass,
are subject to damage by impact, such as
wrenches, mishandling, etc.
A heavy duty down-fl ow al umi num/pl asti c radi ator
i s used (Fi g. 18). The radi ator consi sts of an al umi -
num core and pl asti c end tanks, whi ch are fastened
to the core wi th cl i nch tabs and seal ed wi th a hi gh
temperature rubber gasket. On automati c transmi s-
si on equi pped vehi cl es, the l ower tank contai ns a
concentri c-tube transmi ssi on oi l cool er.
I f the pl asti c tank has been damaged, i ndi vi dual
parts are not avai l abl e, and the radi ator must be
repl aced.
OPERATION
As ai r passes through the radi ator core, the heat
wi thi n the cool ant i s di ssi pated i nto the ambi ent ai r.
DIAGNOSIS AND TESTING - RADIATOR
COOLANT FLOW
The fol l owi ng procedure wi l l determi ne i f cool ant i s
fl owi ng through the cool i ng system.
I f engi ne i s col d, i dl e engi ne unti l normal operati ng
temperature i s reached. Then feel the upper radi ator
hose. I f hose i s hot, the thermostat i s open and water
i s ci rcul ati ng through cool i ng system.
REMOVAL
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR
DRAINCOCK WITH THE SYSTEM HOT AND PRES-
SURIZED. SERIOUS BURNS FROM THE COOLANT
CAN OCCUR.
Do not waste reusabl e cool ant. I f the sol uti on i s
cl ean, drai n the cool ant i nto a cl ean contai ner for
reuse.
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. 19). ALWAYS WEAR SAFETY GLASSES
WHEN SERVICING CONSTANT TENSION CLAMPS.
CAUTION: A number or letter is stamped into the
tongue of constant tension clamps (Fig. 20). If
replacement is necessary, use only an original
equipment clamp with matching number or letter.
Fig. 19 Hose Clamp Tool - Typical
1 - HOSE CLAMP TOOL 6094
2 - HOSE CLAMP
Fig. 18 Downflow Radiator - Typical
1 - DOWNFLOW RADIATOR
2 - INTEGRAL TRANSMISSION OIL COOLER (INTERNAL TO
RADIATOR)
TJ ENGINE 7 - 33
FAN DRIVE VISCOUS CLUTCH (Continued)
CAUTION: When removing the radiator or A/C con-
denser for any reason, note the location of all radi-
ator-to-body and radiator-to-A/C condenser rubber
air seals (Fig. 21). These are used at the top, bot-
tom and sides of the radiator and A/C condenser.
To prevent overheating, these seals must be
installed to their original positions.
(1) Di sconnect negati ve battery cabl e at battery.
(2) Observe the previ ous WARNING. Remove the
radi ator cap.
(3) Remove the condenser l ower seal from the
l ower core support (Fi g. 22).
(4) Drai n cool i ng system (Refer to 7 - COOLI NG -
STANDARD PROCEDURE) drai n cool ant i nto a
cl ean contai ner for reuse.
(5) Remove radi ator upper and l ower hose cl amps.
Remove radi ator hoses.
(6) Di sconnect cool ant reserve/overfl ow tank hose
from radi ator.
(7) 2.4L ONLY - Remove the el ectri c cool i ng fan
(Refer to 7 - COOLI NG/ENGI NE/RADI ATOR FAN -
REMOVAL).
(8) 4.0L ONLY - Remove the reservoi r tank and
power steeri ng reservoi r and posi ti on out of the way.
(9) 4.0L ONLY - Remove the four fan shroud
mounti ng bol ts (Fi g. 23). Posi ti on the fan shroud
back over the fan bl ades.
(10) I f equi pped, di sconnect and pl ug automati c
transmi ssi on fl ui d cool er l i nes.
(11) Remove si x radi ator mounti ng bol ts. Posi ti on
the front axl e vent hose (Fi g. 23) to the si de.
(12) The l ower part of radi ator i s equi pped wi th
two al i gnment dowel pi ns (Fi g. 24). They are l ocated
on the bottom of radi ator tank and fi t i nto rubber
grommets. These rubber grommets are pressed i nto
the radi ator l ower crossmember.
(13) Li ft radi ator strai ght up and out of vehi cl e
taki ng care not to damage radi ator fi ns.
Fig. 20 Clamp Number/Letter Location - Typical
1 - TYPICAL CONSTANT TENSION HOSE CLAMP
2 - CLAMP NUMBER/LETTER LOCATION
3 - TYPICAL HOSE
Fig. 21 Air Seals - Typical
1 - AIR DAM
2 - RADIATOR
3 - AIR DAM
4 - A/C CONDENSER
5 - AIR SEAL
Fig. 22 Condenser Lower Seal
7 - 34 ENGINE TJ
RADIATOR (Continued)
(14) When removi ng radi ator, note posi ti on of the
rubber seal s l ocated on the top and bottom of radi a-
tor (on certai n model s onl y) (Fi g. 23). To prevent pos-
si bl e overheati ng, these seal s must be i nstal l ed to
thei r ori gi nal posi ti ons.
CLEANING
Cl ean radi ator fi ns. Wi th the engi ne col d, appl y
col d water and compressed ai r to the back (engi ne
si de) of the radi ator to fl ush the radi ator and/or A/C
condenser of debri s.
INSPECTION
The radi ator cool i ng fi ns shoul d be checked for
damage or deteri orati on. I nspect cool i ng fi ns to make
sure they are not bent or crushed, these areas resul t
i n reduced heat exchange causi ng the cool i ng system
to operate at hi gher temperatures. I nspect the pl asti c
end tanks for cracks, damage or l eaks.
I nspect the radi ator neck for damage or di storti on.
Fig. 23 Radiator - Remove/Install
1 - A/C CONDENSER SEALS
2 - FAN SHROUD (4.0L)
3 - FAN SHROUD (2.5L)
4 - TRANSMISSION OIL COOLER LINES RETAINER CLIPS
5 - COOLANT RECOVERY BOTTLE
6 - TRANSMISSION COOLER LINES (IF EQUIPPED)
7 - FRONT AXLE VENT HOSE
Fig. 24 Radiator Alignment Dowels - Typical
1 - RADIATOR
2 - ALIGNMENT DOWEL
3 - RADIATOR LOWER ISOLATOR
4 - RADIATOR LOWER CROSSMEMBER
TJ ENGINE 7 - 35
RADIATOR (Continued)
INSTALLATION
CAUTION: Before installing the radiator or A/C con-
denser, be sure the radiator-to-body and radiator-to-
A/C condenser rubber air seals are properly
fastened to their original positions. These are used
at the top, bottom and sides of the radiator and A/C
condenser. To prevent overheating, these seals
must be installed to their original positions.
(1) Gui de the two radi ator al i gnment dowel s i nto
the rubber grommets l ocated i n l ower radi ator cross-
member. I nstal l and ti ghten the si x mounti ng bol ts
(Fi g. 23) to 8 N·m (72 i n. l bs.) torque.
(2) Cl ose radi ator drai ncock.
(3) 2.4L ONLY - I nstal l the el ectri c cool i ng fan
(Refer to 7 - COOLI NG/ENGI NE/RADI ATOR FAN -
I NSTALLATI ON).
(4) Posi ti on fan shroud and power steeri ng reser-
voi r tank (i f equi pped). I nstal l and ti ghten four
mounti ng bol ts to 8 N·m (72 i n. l bs.) torque.
(5) I f equi pped, remove pl ugs and connect auto-
mati c transmi ssi on fl ui d cool er l i nes and constant
tensi on cl amps.
CAUTION: The tangs on the hose clamps must be
positioned straight down.
(6) Connect radi ator hoses and i nstal l hose cl amps.
(7) Posi ti on and i nstal l the condenser l ower seal
(Fi g. 22).
(8) Connect battery negati ve cabl e.
(9) Fi l l cool i ng system wi th correct cool ant (Refer
to 7 - COOLI NG - STANDARD PROCEDURE).
(10) Connect cool ant recovery bottl e hose.
(11) I nstal l radi ator cap.
(12) Check and adjust automati c transmi ssi on
fl ui d l evel (i f equi pped).
(13) Start engi ne and check for l eaks.
WATER PUMP - 2.4L
DESCRIPTION
The water pump has a cast al umi num body and
housi ng wi th a stamped steel i mpel l er. The water
pump bol ts di rectl y to the bl ock (Fi g. 25). The cyl i n-
der bl ock to water pump seal i s provi ded by a rubber
O-ri ng. The water pump i s dri ven by the engi ne ti m-
i ng bel t.
OPERATION
The water pump i s the heart of the cool i ng system.
The cool ant i s pumped through the engi ne bl ock, cyl -
i nder head, heater core, and radi ator.
DIAGNOSIS AND TESTING
WATER PUMP
A qui ck fl ow test to determi ne i f the water pump i s
worki ng effecti vel y i s to check heater system for
proper operati on. A defecti ve pump wi l l not provi de
an adequate fl ow of heated cool ant through the sys-
tem.
WARNING: DO NOT REMOVE THE COOLING SYS-
TEM PRESSURE CAP WITH THE SYSTEM HOT AND
UNDER PRESSURE BECAUSE SERIOUS BURNS
FROM COOLANT CAN OCCUR.
Another fl ow test to hel p determi ne water pump
operati on i s as fol l ows:
(1) Remove cool i ng system pressure cap.
(2) Remove a smal l amount of cool ant from the
system.
(3) Start the engi ne and warm up unti l thermostat
opens.
(4) Wi th the thermostat open and cool ant l evel l ow,
vi sual l y i nspect for cool ant fl ow. I f fl ow i s present,
the water pump i s pumpi ng cool ant through the sys-
tem.
Fig. 25 Water Pump
1 - CYLINDER BLOCK
2 - WATER PUMP
7 - 36 ENGINE TJ
RADIATOR (Continued)
REMOVAL - 2. 4L
(1) Drai n cool i ng system (Refer to 7 - COOLI NG/
ENGI NE - STANDARD PROCEDURE).
(2) Remove ti mi ng bel t (Refer to 9 - ENGI NE/
VALVE TI MI NG/TI MI NG BELT AND SPROCKETS -
REMOVAL).
(3) Remove camshaft sprockets and rear ti mi ng
bel t cover (Refer to 9 - ENGI NE/VALVE TI MI NG/
TI MI NG BELT AND SPROCKETS - REMOVAL).
(4) Remove screws attachi ng water pump to
engi ne. Remove pump (Fi g. 26).
INSTALLATION
INSTALLATION 2. 4L
(1) Appl y Mopar௡ Di el ectri c Grease to new O-ri ng
before i nstal l ati on (Fi g. 27).
(2) I nstal l O-ri ng gasket i n water pump body
groove (Fi g. 27).
CAUTION: Make sure O-ring gasket is properly
seated in water pump groove before tightening
screws. An improperly located O-ring may cause
damage to the O-ring, resulting in a coolant leak.
(3) Assembl e pump body to bl ock (Fi g. 26) and
ti ghten screws to 12 N·m (105 i n. l bs.).
(4) Rotate pump by hand to check for freedom of
movement.
(5) Fi l l cool i ng system (Refer to 7 - COOLI NG/EN-
GI NE - STANDARD PROCEDURE). Pressuri ze cool -
i ng system to 103 Kpa (15 psi ) wi th pressure tester
and check water pump shaft seal and O-ri ng for
l eaks.
(6) I nstal l rear ti mi ng bel t cover and camshaft
sprockets (Refer to 9 - ENGI NE/VALVE TI MI NG/
TI MI NG BELT AND SPROCKETS - I NSTALLA-
TI ON).
(7) I nstal l ti mi ng bel t (Refer to 9 - ENGI NE/
VALVE TI MI NG/TI MI NG BELT AND SPROCKETS -
I NSTALLATI ON).
WATER PUMP - 4.0L
DESCRIPTION
CAUTION: The 4.0L 6-cylinder engines is equipped
with a reverse (counterclockwise) rotating water
pump and thermal viscous fan drive assembly.
REVERSE is stamped or imprinted on the cover of
the viscous fan drive and inner side of the fan. The
letter R is stamped into the back of the water pump
impeller. Engines from previous model years,
depending upon application, may have been
equipped with a forward (clockwise) rotating water
pump. Installation of the wrong water pump or vis-
cous fan drive will cause engine over heating.
Fig. 26 Water Pump
1 - CYLINDER BLOCK
2 - WATER PUMP
Fig. 27 Water Pump Body
1 - IMPELLER
2 - WATER PUMP BODY
3 - O-RING LOCATING GROOVE
TJ ENGINE 7 - 37
WATER PUMP - 2.4L (Continued)
Thi s al umi num water pump (Fi g. 28) i s the heart
of the cool i ng system. The water pump i s l ocated at
the front of the cyl i nder bl ock, above the ti mi ng
chai n cover
The water pump i mpel l er i s pressed onto the rear
of a shaft that rotates i n beari ngs pressed i nto the
housi ng. The housi ng has two smal l hol es to al l ow
seepage to escape. The water pump seal s are l ubri -
cated by the anti freeze i n the cool ant mi xture. No
addi ti onal l ubri cati on i s necessary.
OPERATION
A centri fugal water pump ci rcul ates cool ant
through the water jackets, passages, i ntake mani fol d,
radi ator core, cool i ng system hoses and heater core.
The pump i s dri ven from the engi ne crankshaft by a
si ngl e serpenti ne dri ve bel t on al l engi nes.
REMOVAL
The water pump can be removed wi thout di scharg-
i ng the ai r condi ti oni ng system (i f equi pped).
CAUTION: All engines have a reverse (counterclock-
wise) rotating water pump. The letter R is stamped
into the back of the water pump impeller (Fig. 29) to
identify. Engines from previous model years,
depending upon application, may be equipped with
a forward (clockwise) rotating water pump. Installa-
tion of the wrong water pump will cause engine
over heating.
The water pump i mpel l er i s pressed on the rear of
the pump shaft and beari ng assembl y. The water
pump i s servi ced onl y as a compl ete assembl y.
WARNING: DO NOT REMOVE THE BLOCK DRAIN
PLUG(S) OR LOOSEN RADIATOR DRAINCOCK
WITH THE SYSTEM HOT AND UNDER PRESSURE.
SERIOUS BURNS FROM COOLANT CAN OCCUR.
DO NOT WASTE reusabl e cool ant. I f the sol uti on
i s cl ean, drai n cool ant i nto a cl ean contai ner for
reuse.
(1) Di sconnect negati ve battery cabl e at battery.
(2) Drai n the cool i ng system (Refer to 7 - COOL-
I NG - STANDARD PROCEDURE).
NOTE: The engine accessory drive belt must be
removed prior to removing the fan.
(3) Remove accessory dri ve bel t (Refer to 7 -
COOLI NG/ACCESSORY DRI VE/DRI VE BELTS -
REMOVAL).
(4) The thermal vi scous fan dri ve/fan bl ade assem-
bl y i s attached (threaded) to water pump hub shaft.
Remove fan bl ade/vi scous fan dri ve assembl y from
water pump by turni ng mounti ng nut countercl ock-
wi se as vi ewed from front. Threads on vi scous fan
dri ve are RIGHT HAND. Usi ng a sui tabl e fan
wrench l oosen the fan dri ve (Fi g. 30).
(5) Remove power steeri ng pump (Refer to 19 -
STEERI NG/PUMP - REMOVAL).
Fig. 28 Water Pump - Typical
1 - HEATER HOSE FITTING BORE
2 - WATER PUMP
3 - WATER PUMP HUB
Fig. 29 Water Pump - 4.0L Engine
1 - HEATER HOSE FITTING BORE
2 - WATER PUMP
3 - WATER PUMP HUB
7 - 38 ENGINE TJ
WATER PUMP - 4.0L (Continued)
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. 31). ALWAYS WEAR SAFETY GLASSES
WHEN SERVICING CONSTANT TENSION CLAMPS.
CAUTION: A number or letter is stamped into the
tongue of constant tension clamps (Fig. 32). If
replacement is necessary, use only an original
equipment clamp with matching number or letter.
(6) Remove l ower radi ator hose from water pump.
Remove heater hose from water pump fi tti ng.
(7) After removi ng fan bl ade/vi scous fan dri ve
assembl y, do not pl ace thermal vi scous fan dri ve i n
hori zontal posi ti on. I f stored hori zontal l y, si l i cone
fl ui d i n vi scous fan dri ve coul d drai n i nto i ts beari ng
assembl y and contami nate l ubri cant.
(8) Remove the four pump mounti ng bol ts (Fi g. 33)
and remove pump from vehi cl e. Di scard ol d gasket.
Note that one of the four bol ts i s l onger than the
other bol ts.
(9) I f pump i s to be repl aced, the heater hose fi t-
ti ng must be removed. Note posi ti on of fi tti ng before
removal .
INSTALLATION
(1) I f pump i s bei ng repl aced, i nstal l the heater
hose fi tti ng to the pump. Use a seal ant on the fi tti ng
such as Mopar௡ Thread Seal ant Wi th Tefl on. Refer to
the di recti ons on the package.
(2) Cl ean the gasket mati ng surfaces. I f the ori gi -
nal pump i s used, remove any deposi ts or other for-
ei gn materi al . I nspect the cyl i nder bl ock and water
pump mati ng surfaces for erosi on or damage from
cavi tati on.
(3) I nstal l the gasket and water pump. The si l i -
cone bead on the gasket shoul d be faci ng the water
pump. Al so, the gasket i s i nstal l ed dry. Ti ghten
mounti ng bol ts to 23 N·m (200 i n. l bs.) torque. Rotate
the shaft by hand to be sure i t turns freel y.
(4) Connect the radi ator and heater hoses to the
water pump.
Fig. 30 Fan and Fan Drive Mounting - 4.0L Engine
1 - FAN AND FAN DRIVE
2 - WATER PUMP PULLEY
Fig. 31 Hose Clamp Tool - Typical
1 - HOSE CLAMP TOOL 6094
2 - HOSE CLAMP
Fig. 32 Clamp Number/Letter Location
1 - TYPICAL CONSTANT TENSION HOSE CLAMP
2 - CLAMP NUMBER/LETTER LOCATION
3 - TYPICAL HOSE
TJ ENGINE 7 - 39
WATER PUMP - 4.0L (Continued)
(5) I nstal l power steeri ng pump (Refer to 19 -
STEERI NG/PUMP - I NSTALLATI ON).
(6) Thread the fan and fan hub i nto the water
pump hub shaft.
CAUTION: When installing the serpentine engine
accessory drive belt, the belt MUST be routed cor-
rectly. If not, the engine may overheat due to the
water pump rotating in the wrong direction. for
appropriate belt routing. You may also refer to the
Belt Routing Label in the vehicle engine compart-
ment.
(7) I nstal l accessory dri ve bel t (Refer to 7 - COOL-
I NG/ACCESSORY DRI VE/DRI VE BELTS - I NSTAL-
LATI ON).
(8) Fi l l cool i ng system wi th cool ant (Refer to 7 -
COOLI NG - STANDARD PROCEDURE).
(9) Connect battery cabl e to battery.
(10) Start and warm the engi ne. Check for l eaks.
RADIATOR PRESSURE CAP
DESCRIPTION
Al l radi ators are equi pped wi th a pressure cap
(Fi g. 34). Thi s cap rel eases pressure at some poi nt
wi thi n a range of 124-145 kPa (18-21 psi ). The pres-
sure rel i ef poi nt (i n pounds) i s engraved on top of the
cap
The cool i ng system wi l l operate at pressures
sl i ghtl y above atmospheri c pressure. Thi s resul ts i n a
hi gher cool ant boi l i ng poi nt al l owi ng i ncreased radi -
ator cool i ng capaci ty. The cap contai ns a spri ng-
l oaded pressure rel i ef val ve. Thi s val ve opens when
system pressure reaches the rel ease range of 124-145
kPa (18-21 psi ).
A rubber gasket seal s the radi ator fi l l er neck. Thi s
i s done to mai ntai n vacuum duri ng cool ant cool -down
and to prevent l eakage when system i s under pres-
sure.
OPERATION
A vent val ve i n the center of the cap wi l l remai n
shut as l ong as the cool i ng system i s pressuri zed. As
the cool ant cool s, i t contracts and creates a vacuum
i n cool i ng system. Thi s causes the vacuum val ve to
open and cool ant i n reserve/overfl ow tank to be
drawn through connecti ng hose i nto radi ator. I f the
vacuum val ve i s stuck shut, or overfl ow hose i s
ki nked, radi ator hoses wi l l col l apse on cool -down.
Fig. 33 Water Pump Remove/Install - 4.0L Engine
1 - HEATER HOSE FITTING
2 - PUMP GASKET
3 - WATER PUMP
4 - LONG BOLT
5 - BOLTS (4) SHORT
Fig. 34 Radiator Pressure Cap - Typical
1 - FILLER NECK SEAL
2 - VACUUM VENT VALVE
3 - PRESSURE RATING
4 - PRESSURE VALVE
7 - 40 ENGINE TJ
WATER PUMP - 4.0L (Continued)
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - RADIATOR
CAP-TO-FILLER NECK SEAL
The pressure cap upper gasket (seal ) pressure
rel i ef can be tested by removi ng overfl ow hose from
radi ator fi l l er neck ni ppl e. Attach hose of pressure
tester tool 7700 (or equi val ent) to ni ppl e. I t wi l l be
necessary to di sconnect hose from i ts adapter for
fi l l er neck. Pump ai r i nto radi ator. The pressure cap
upper gasket shoul d rel i eve at 69-124 kPa (10-18 psi )
and hol d pressure at a mi ni mum of 55 kPa (8 psi ).
WARNING: THE WARNING WORDS - DO NOT OPEN
HOT - ON RADIATOR PRESSURE CAP, ARE A
SAFETY PRECAUTION. WHEN HOT, PRESSURE
BUILDS UP IN COOLING SYSTEM. TO PREVENT
SCALDING OR INJURY, RADIATOR CAP SHOULD
NOT BE REMOVED WHILE SYSTEM IS HOT AND/OR
UNDER PRESSURE.
Do not remove radi ator cap at any ti me except for
the fol l owi ng purposes:
(1) Check and adjust anti freeze freeze poi nt.
(2) Refi l l system wi th new anti freeze.
(3) Conducti ng servi ce procedures.
(4) Checki ng for vacuum l eaks.
WARNING: IF VEHICLE HAS BEEN RUN RECENTLY,
WAIT AT LEAST 15 MINUTES BEFORE REMOVING
RADIATOR CAP. WITH A RAG, SQUEEZE RADIATOR
UPPER HOSE TO CHECK IF SYSTEM IS UNDER
PRESSURE. PLACE A RAG OVER CAP AND WITH-
OUT PUSHING CAP DOWN, ROTATE IT COUNTER-
CLOCKWISE TO FIRST STOP. ALLOW FLUID TO
ESCAPE THROUGH THE COOLANT RESERVE/
OVERFLOW HOSE INTO RESERVE/OVERFLOW
TANK. SQUEEZE RADIATOR UPPER HOSE TO
DETERMINE WHEN PRESSURE HAS BEEN
RELEASED. WHEN COOLANT AND STEAM STOP
BEING PUSHED INTO TANK AND SYSTEM PRES-
SURE DROPS, REMOVE RADIATOR CAP COM-
PLETELY.
DIAGNOSIS AND TESTING - RADIATOR CAP
Remove cap from radi ator. Be sure that seal i ng
surfaces are cl ean. Moi sten rubber gasket wi th water
and i nstal l cap on pressure tester 7700 or an equi v-
al ent (Fi g. 35).
Operate tester pump to bri ng pressure to 117 kPa
(17 psi ) on gauge. I f pressure cap fai l s to hol d pres-
sure of at l east 110 kPa (16 psi ) repl ace cap. Refer to
the fol l owi ng CAUTION.
The pressure cap may test properl y whi l e posi -
ti oned on tool 7700 (or equi val ent). I t may not hol d
pressure or vacuum when i nstal l ed on radi ator. I f so,
i nspect radi ator fi l l er neck and cap’s top gasket for
damage. Al so i nspect for di rt or di storti on that may
prevent cap from seal i ng properl y.
CAUTION: Radiator pressure testing tools are very
sensitive to small air leaks, which will not cause
cooling system problems. A pressure cap that does
not have a history of coolant loss should not be
replaced just because it leaks slowly when tested
with this tool. Add water to tool. Turn tool upside
down and recheck pressure cap to confirm that cap
needs replacement.
CLEANING
Use onl y a mi l d soap and water to cl ean the radi -
ator cap. Usi ng any type sol vent may cause damage
to the seal i n the radi ator cap.
INSPECTION
Hol d cap at eye l evel , ri ght si de up. The vent val ve
(Fi g. 34) at bottom of cap shoul d open. I f rubber gas-
ket has swol l en and prevents vent val ve from open-
i ng, repl ace cap.
Hol d cap at eye l evel , upsi de down. I f any l i ght can
be seen between vent val ve and rubber gasket,
repl ace cap. Do not use a replacement cap that
has a spring to hold vent shut. A repl acement cap
must be the type desi gned for a cool ant reserve/over-
fl ow system wi th a compl etel y seal ed di aphragm
Fig. 35 Pressure Testing Radiator Cap - Typical
1 - PRESSURE CAP
2 - TYPICAL COOLING SYSTEM PRESSURE TESTER
TJ ENGINE 7 - 41
RADIATOR PRESSURE CAP (Continued)
spri ng and a rubber gasket. Thi s gasket i s used to
seal to radi ator fi l l er neck top surface. Use of proper
cap wi l l al l ow cool ant return to radi ator.
RADIATOR FAN
DESCRIPTION
The el ectri c cool i ng fan repl aces the engi ne dri ven
mechani cal fan. The el ectri c cool i ng fan i s i ntegral to
the fan shroud and i s l ocated between the radi ator
and the engi ne.
The el ectri c fan i s control l ed by the el ectroni c con-
trol modul e (ECM).
The el ectri c cool i ng fan i s not servi ceabl e. Any fai l -
ure of the fan bl ade, el ectri c motor or fan shroud
requi res repl acement of the fan modul e.
CAUTION: Do not attempt to service the electric
cooling fan or fan blades separately, replace the
cooling module as an assembly. Failure to do so
may cause severe damage to the electric cooling
fan assembly.
REMOVAL
REMOVAL
(1) Remove the cool ant recovery bottl e and posi ti on
out of the way (Fi g. 36).
(2) Remove and posi ti on the power steeri ng reser-
voi r out of the way.
(3) Di sconnect the el ectri cal connector.
(4) Remove the mounti ng screws.
(5) Remove the cool i ng fan assembl y (Fi g. 37).
REMOVAL - 4. 0L
(1) Remove the thermal vi scous fan dri ve/fan bl ade
assembl y (Refer to 7 - COOLI NG/ENGI NE/FAN
DRI VE VI SCOUS CLUTCH - REMOVAL).
(2) Remove the four fan retai ni ng bol ts.
(3) Seperate the fan bl ade from the thermal vi s-
cous fan dri ve.
CLEANING
Cl ean the fan bl ades usi ng a mi l d soap and water.
Do not use an abrasi ve to cl ean the bl ades.
INSPECTION
WARNING: DO NOT ATTEMPT TO BEND OR
STRAIGHTEN FAN BLADES IF FAN IS NOT WITHIN
SPECIFICATIONS.
Fig. 36 Coolant Recovery Bottle
1 - COOLANT RECOVERY BOTTLE
2 - COOLING FAN ASSEMBLY
2 - POWER STEERING RESERVOIR
Fig. 37 Electrical Connector
1 - ELECTRICAL CONNECTOR
2 - MOUNTING SCREW
7 - 42 ENGINE TJ
RADIATOR PRESSURE CAP (Continued)
CAUTION: If fan blade assembly is replaced
because of mechanical damage, water pump and
viscous fan drive should also be inspected. These
components could have been damaged due to
excessive vibration.
(1) Remove fan bl ade assembl y from vi scous fan
dri ve uni t (four bol ts).
(2) Lay fan on a fl at surface wi th l eadi ng edge fac-
i ng down. Wi th ti p of bl ade touchi ng fl at surface,
repl ace fan i f cl earance between opposi te bl ade and
surface i s greater than 2.0 mm (.090 i nch). Rocki ng
moti on of opposi te bl ades shoul d not exceed 2.0 mm
(.090 i nch). Test al l bl ades i n thi s manner.
(3) I nspect fan assembl y for cracks, bends, l oose
ri vets or broken wel ds. Repl ace fan i f any damage i s
found.
INSTALLATION
INSTALLATION
(1) Posi ti on the cool i ng fan assembl y.
(2) I nstal l four mounti ng screws. Ti ghten to 5.5
N·m (50 i n. l bs.)
(3) Connect the el ectri cal connector.
(4) I nstal l the power steeri ng reservoi r.
(5) I nstal l the cool ant recovery bottl e.
INSTALLATION - 4. 0L
(1) Posi ti on the fan bl ade on the thermal vi scous
fan dri ve.
(2) I nstal l four mounti ng bol ts. Ti ghten to 23 N·M
(210 i n. l bs.).
(3) I nstal l the thermal vi scous fan dri ve (Refer to 7
- COOLI NG/ENGI NE/FAN DRI VE VI SCOUS
CLUTCH - I NSTALLATI ON).
RADIATOR FAN RELAY
DESCRIPTION
The el ectri c cool i ng fan HI and LOW rel ays are
l ocated i n the Power Di stri buti on Center (PDC) i n
the engi ne compartment. See the fuse and rel ay l ay-
out l abel affi xed to the i nsi de surface of the PDC
cover for cool i ng fan rel ay i denti fi cati on and l ocati on.
The HI and LOW cool i ng fan rel ays cannot be
adjusted or repai red. I f the HI or LOW rel ay i s dam-
aged or faul ty, i t must be repl aced.
TJ ENGINE 7 - 43
RADIATOR FAN (Continued)
TRANSMISSION
TABLE OF CONTENTS
page page
TRANSMISSION COOLER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 44
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
TRANSMISSION COOLER
DESCRIPTION
NOTE: The internal transmission oil cooler located
within the radiator is not serviceable. If it requires
service, the radiator must be replaced.
Al l model s equi pped wi th an automati c transmi s-
si on are equi pped wi th a transmi ssi on oi l cool er
(water-to-oi l ) mounted i nternal l y wi thi n the radi ator
tank (Fi g. 1). Thi s i nternal cool er i s suppl i ed as stan-
dard equi pment on al l model s equi pped wi th an auto-
mati c transmi ssi on.
OPERATION
Transmi ssi on oi l i s cool ed when i t passes through
thi s separate cool er. I n case of a l eak i n the i nternal
radi ator mounted transmi ssi on oi l cool er, engi ne cool -
ant may become mi xed wi th transmi ssi on fl ui d or
transmi ssi on fl ui d may enter the cool i ng system.
Both cool i ng system and transmi ssi on shoul d be
drai ned and i nspected i f the i nternal radi ator
mounted transmi ssi on cool er i s l eaki ng.
Fig. 1 Radiator with Integral Transmission Oil
Cooler
1 - DOWNFLOW RADIATOR
2 - INTEGRAL TRANSMISSION OIL COOLER (INTERNAL TO
RADIATOR)
7 - 44 TRANSMISSION TJ
AUDIO/VIDEO
TABLE OF CONTENTS
page page
AUDIO
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DIAGNOSIS AND TESTING - AUDIO . . . . . . . . . . 1
AMPLIFIED SUBWOOFER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 3
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DIAGNOSIS AND TESTING - AMPLIFIED
SUBWOOFER . . . . . . . . . . . . . . . . . . . . . . . . . 3
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ANTENNA BODY & CABLE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DIAGNOSIS AND TESTING - ANTENNA BODY
AND CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . 4
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 5
RADIO
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 6
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
RADIO NOISE SUPPRESSION COMPONENTS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DIAGNOSIS AND TESTING - RADIO NOISE
SUPPRESSION COMPONENTS . . . . . . . . . . . 7
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SPEAKER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
DIAGNOSIS AND TESTING - SPEAKER . . . . . . . 8
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10
AUDIO
DESCRIPTION
Several combi nati ons of radi o recei vers and
speaker systems are offered.
The audi o system i ncl udes the fol l owi ng compo-
nents:
• Ampl i fi ed sub woofer (i f equi pped)
• Antenna
• Radi o noi se suppressi on components
• Radi o recei ver
• Speakers
Certai n functi ons and features of the audi o system
rel y upon resources shared wi th other el ectroni c
modul es i n the vehi cl e over the Programmabl e Com-
muni cati on I nterface (PCI ) bus network. The data
bus network al l ows the shari ng of sensor i nforma-
ti on. For di agnosi s of these el ectroni c modul es or of
the data bus network, the use of a DRB I I I ௡ scan tool
and the proper Di agnosti c Procedures manual are
recommended.
OPERATION
The audi o system components are desi gned to pro-
vi de audi o entertai nment and i nformati on through
the recepti on, tuni ng and ampl i fi cati on of l ocal l y
broadcast radi o si gnal s i n both the Ampl i tude Modu-
l ati ng (AM) and Frequency Modul ati ng (FM) com-
merci al frequency ranges.
The audi o system components operate on battery
current recei ved through a fuse i n the Juncti on Bl ock
(JB) on a fused i gni ti on swi tch output (run-acc) ci r-
cui t so that the system wi l l onl y operate when the
i gni ti on swi tch i s i n the Run or Accessory posi ti ons.
DIAGNOSIS AND TESTING - AUDIO
Any diagnosis of the Audio system should
begin with the use of the DRB III௡ diagnostic
tool. For information on the use of the DRB
III௡, refer to the appropriate Diagnostic Service
Manual.
For compl ete ci rcui t di agrams, refer to the appro-
pri ate wi ri ng i nformati on.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, (REFER TO ELECTRICAL/RESTRAINTS)
BEFORE ATTEMPTING ANY STEERING WHEEL,
STEERING COLUMN, OR INSTRUMENT PANEL
COMPONENT DIAGNOSIS OR SERVICE. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
TJ AUDIO/VIDEO 8A - 1
Audio System Diagnosis
CONDITION POSSIBLE CAUSE CORRECTION
NO AUDIO. 1. Fuse inoperative. 1. Check radio fuse and Ignition-Off Draw fuse in Power
Distribution Center. Replace fuses, if required.
2. Radio connector
damaged.
2. Check for loose or corroded radio connector. Repair, if
required.
3. Wiring damaged. 3. Check for battery voltage at radio connector. Repair wiring, if
required.
4. Ground damaged. 4. Check for continuity between radio chassis and a known good
ground. There should be continuity. Repair ground, if required.
5. Radio inoperative. 5. Exchange or replace radio, if required.
6. Speakers inoperative. 6. Refer to speaker diagnosis.
NO DISPLAY. 1. Fuse inoperative. 1. Check radio fuse and Ignition-Off Draw fuse in Power
Distribution Center. Replace fuses, if required.
2. Radio connector
damaged.
2. Check for loose or corroded radio connector. Repair, if
required.
3. Wiring damaged. 3. Check for battery voltage at radio connector. Repair wiring, if
required.
4. Ground damaged. 4. Check for continuity between radio chassis and a known good
ground. There should be continuity. Repair ground, if required.
5. Radio inoperative. 5. Exchange or replace radio, if required.
CLOCK WILL
NOT KEEP SET
TIME.
1. Fuse inoperative. 1. Check ignition-off draw fuse. Replace fuse, if required.
2. Radio connector
damaged.
2. Check for loose or corroded radio connector. Repair, if
required.
3. Wiring damaged. 3. Check for battery voltage at radio connector. Repair wiring, if
required.
4. Ground damaged. 4. Check for continuity between radio chassis and a known good
ground. There should be continuity. Repair ground, if required.
5. Radio inoperative. 5. Exchange or replace radio, if required.
POOR RADIO
RECEPTION.
1. Antenna inoperative. 1. See antenna diagnosis, in this group. Repair or replace
antenna, if required.
2. Ground damaged. 2. Check for continuity between radio chassis and a known good
ground. There should be continuity. Repair ground, if required..
3. Radio inoperative. 3. Exchange or replace radio, if required.
NO/POOR TAPE
OPERATION.
1. Tape damaged. 1. Insert known good tape and test operation.
2. Foreign objects behind
tape door.
2. Remove foreign objects and test operation.
3. Dirty cassette tape
head.
3. Clean head with Mopar Cassette Head Cleaner.
4. Radio inoperative 4. Exchange or replace radio, if required.
8A - 2 AUDIO/VIDEO TJ
AUDIO (Continued)
Audio System Diagnosis
CONDITION POSSIBLE CAUSE CORRECTION
NO COMPACT
DISC
OPERATION
1. CD damaged. 1. Insert known good CD and test operation.
2. Foreign material on
CD.
2. Clean CD and test operation.
3. Condensation on CD
or optics.
3. Allow temperature of vehicle interior to stabilize and test
operation.
4. Radio inoperative 4. Exchange or replace radio, if required.
AMPLIFIED SUBWOOFER
DESCRIPTION
The avai l abl e ampl i fi ed subwoofer i s mounted
wi thi n the center consol e. The ampl i fi ed subwoofer i s
rated at 80 watts. The ampl i fi ed subwoofer shoul d be
checked i f there i s no bass output noted from the
center consol e speaker. The ampl i fi ed subwoofer can
not be repai red or adjusted, and i f faul ty or damaged,
the uni t must be repl aced.
OPERATION
The ampl i fi ed subwoofer provi des l ow frequency
bass and recei ves i nputs from the front and rear
speaker ci rcui ts.
DIAGNOSIS AND TESTING - AMPLIFIED
SUBWOOFER
Any diagnosis of the Audio system should
begin with the use of the DRB III௡ diagnostic
tool. For information on the use of the DRB
III௡, refer to the appropriate Diagnostic Service
Manual.
For compl ete ci rcui t di agrams, refer to the appro-
pri ate wi ri ng i nformati on.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO ELECTRICAL, RESTRAINTS
BEFORE ATTEMPTING ANY STEERING WHEEL,
STEERING COLUMN, OR INSTRUMENT PANEL
COMPONENT DIAGNOSIS OR SERVICE. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
CAUTION: The speaker output of the radio is a
“floating ground” system. Do not allow any speaker
lead to short to ground, as damage to the radio
may result.
(1) Turn the i gni ti on swi tch to the On posi ti on.
Turn the radi o recei ver on. Adjust the bal ance and
fader control s to check the performance of each i ndi -
vi dual speaker. Note the speaker l ocati ons that are
not performi ng correctl y.
(2) Di sconnect the wi re harness connector from the
ampl i fi ed subwoofer. Turn the i gni ti on swi tch to the
ON posi ti on. Turn the radi o ON. Check the radi o
choke rel ay wi re harness connector. I f not OK, repai r
shorted or open wi res as necessary. I f OK, go to
(STEP #3).
(3) Turn the radi o off. Turn the i gni ti on swi tch to
the Off posi ti on. Di sconnect and i sol ate the battery
negati ve cabl e. Remove the radi o and the ampl i fi ed
subwoofer. Check both the speaker feed (+) ci rcui t
and return (–) ci rcui t cavi ti es for the i noperati ve
speaker l ocati on(s) from the radi o wi re harness con-
nectors and to the ampl i fi ed subwoofer for conti nui ty.
I n each case, there shoul d be conti nui ty. I f not OK,
repai r the shorted speaker feed (+) and/or return (–)
ci rcui t(s) to the speaker as requi red. I f OK, repl ace
the ampl i fi ed subwoofer.
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the center consol e (Refer to 23 -
BODY/I NTERI OR/CENTER CONSOLE -
REMOVAL).
(3) Di sconnect wi re harness retai ner.
(4) Di sconnect wi re harness connector.
(5) Remove the mounti ng screws from the si de of
the consol e.
(6) Open consol e l i d and remove the retai ni ng fas-
teners from the consol e.
(7) Remove ampl i fi ed subwoofer from consol e.
INSTALLATION
(1) I nstal l ampl i fi ed subwoofer to consol e.
(2) I nstal l retai ni ng fasteners to the top of the con-
sol e.
TJ AUDIO/VIDEO 8A - 3
AUDIO (Continued)
(3) I nstal l the mounti ng screws to the si de of the
consol e.
(4) Connect wi re harness connector and retai ner.
(5) I nstal l the center consol e (Refer to 23 - BODY/
I NTERI OR/CENTER CONSOLE - I NSTALLATI ON).
(6) Connect the battery negati ve cabl e.
ANTENNA BODY & CABLE
DESCRIPTION
Al l model s use a fi xed-l ength stai nl ess steel rod-
type antenna mast, i nstal l ed on the ri ght front cowl
si de panel of the vehi cl e. The antenna mast i s con-
nected to the center wi re of the coaxi al antenna
cabl e, and i s not grounded to any part of the vehi cl e.
To el i mi nate stati c, the antenna base must have a
good ground. The antenna coaxi al cabl e shi el d (the
outer wi re mesh of the cabl e) i s grounded to the
antenna base and the radi o chassi s.
The antenna coaxi al cabl e has an addi ti onal di s-
connect, l ocated behi nd the ri ght end of the i nstru-
ment panel between the radi o and the ri ght cowl si de
panel . Thi s addi ti onal di sconnect al l ows the i nstru-
ment panel assembl y to be removed and i nstal l ed
wi thout removi ng the radi o.
DIAGNOSIS AND TESTING - ANTENNA BODY
AND CABLE
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, (REFER TO ELECTRICAL/RESTRAINTS)
BEFORE ATTEMPTING ANY STEERING WHEEL,
STEERING COLUMN, OR INSTRUMENT PANEL
COMPONENT DIAGNOSIS OR SERVICE. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
The fol l owi ng four tests are used to di agnose the
antenna wi th an ohmmeter:
• Test 1 - Mast to ground test
• Test 2 - Ti p-of-mast to ti p-of-conductor test
• Test 3 - Body ground to battery ground test
• Test 4 - Body ground to coaxi al shi el d test.
The ohmmeter test l ead connecti ons for each test
are shown i n Antenna Tests (Fi g. 1).
NOTE: This model has a two-piece antenna coaxial
cable. Tests 2 and 4 must be conducted in two
steps to isolate an antenna cable problem. First,
test the primary antenna cable (integral to the
antenna body and cable) from the coaxial cable
connector behind the right side of the instrument
panel between the radio and the right side cowl
panel, to the antenna body. Then, test the second-
ary antenna cable (instrument panel antenna cable)
from the coaxial connector behind the right side of
the instrument panel between the radio and the
right side cowl panel, to the coaxial cable connec-
tor at the radio.
TEST 1
Test 1 determi nes i f the antenna mast i s i nsul ated
from the base. Proceed as fol l ows:
(1) Unpl ug the antenna coaxi al cabl e connector
from the radi o chassi s and i sol ate.
(2) Connect one ohmmeter test l ead to the ti p of
the antenna mast. Connect the other test l ead to the
antenna base. Check for conti nui ty.
(3) There shoul d be no conti nui ty. I f conti nui ty i s
found, repl ace the faul ty or damaged antenna base
and cabl e assembl y.
TEST 2
Test 2 checks the antenna for an open ci rcui t as
fol l ows:
(1) Unpl ug the antenna coaxi al cabl e connector
from the radi o chassi s.
(2) Connect one ohmmeter test l ead to the ti p of
the antenna mast. Connect the other test l ead to the
center pi n of the antenna coaxi al cabl e connector.
(3) Conti nui ty shoul d exi st (the ohmmeter shoul d
onl y regi ster a fracti on of an ohm). Hi gh or i nfi ni te
resi stance i ndi cates damage to the base and cabl e
assembl y. Repl ace the faul ty base and cabl e, i f
requi red.
TEST 3
Test 3 checks the condi ti on of the vehi cl e body
ground connecti on. Thi s test shoul d be performed
wi th the battery posi ti ve cabl e removed from the bat-
Fig. 1 Antenna Tests
8A - 4 AUDIO/VIDEO TJ
AMPLIFIED SUBWOOFER (Continued)
tery. Di sconnect both battery cabl es, the negati ve
cabl e fi rst. Reconnect the battery negati ve cabl e and
perform the test as fol l ows:
(1) Connect one ohmmeter test l ead to the vehi cl e
fender. Connect the other test l ead to the battery
negati ve post.
(2) The resi stance shoul d be l ess than one ohm.
(3) I f the resi stance i s more than one ohm, check
the brai ded ground strap connected to the engi ne and
the vehi cl e body for bei ng l oose, corroded, or dam-
aged. Repai r or repl ace the ground strap connecti on,
i f requi red.
TEST 4
Test 4 checks the condi ti on of the ground between
the antenna base and the vehi cl e body as fol l ows:
(1) Connect one ohmmeter test l ead to the vehi cl e
fender. Connect the other test l ead to the outer cri mp
on the antenna coaxi al cabl e connector.
(2) The resi stance shoul d be l ess then one ohm.
(3) I f the resi stance i s more then one ohm, cl ean
and/or ti ghten the antenna base to fender mounti ng
hardware.
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, (REFER TO ELECTRICAL/RESTRAINTS)
BEFORE ATTEMPTING ANY STEERING WHEEL,
STEERING COLUMN, OR INSTRUMENT PANEL
COMPONENT DIAGNOSIS OR SERVICE. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the gl ove box from the i nstrument
panel . (Refer to 23 - BODY/I NSTRUMENT PANEL/
GLOVE BOX - REMOVAL).
(3) Reach through the i nstrument panel gl ove box
openi ng to unpl ug the two antenna coaxi al cabl es i n
l i ne connector. Unpl ug the connector by pul l i ng i t
apart whi l e twi sti ng the metal connector hal ves. Do
not pul l on the cabl e.
(4) Unscrew the antenna mast from the antenna
body base on the ri ght outer cowl si de panel (Fi g. 2).
(5) Usi ng a tri m sti ck, gentl y pry the edge of the
antenna base tri m cover to unsnap i t from the
antenna body base.
(6) Remove the three screws that secure the
antenna body base to the ri ght outer cowl si de panel .
(7) From i nsi de the passenger compartment, push
the coaxi al cabl e grommet on the antenna body hal f
of the coaxi al cabl e out through the hol e i n the ri ght
i nner cowl si de panel .
(8) From the outsi de of the vehi cl e, pul l the
antenna body base and cabl e assembl y out through
the hol e i n the ri ght outer cowl si de panel .
INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, (REFER TO ELECTRICAL/RESTRAINTS)
BEFORE ATTEMPTING ANY STEERING WHEEL,
STEERING COLUMN, OR INSTRUMENT PANEL
COMPONENT DIAGNOSIS OR SERVICE. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
(1) From outsi de the vehi cl e, feed the antenna
cabl e and base assembl y through the outer cowl si de
panel and i nto the i nner cowl si de panel hol e.
(2) From i nsi de the passenger compartment, pul l
the cabl e and grommet i nto the hol e i n the i nsi de
cowl si de panel unti l the grommet i s ful l y seated.
(3) I nstal l the three screws retai ni ng the antenna
body base to ri ght outer cowl si de panel . Ti ghten the
screws to 3.3 N·m (30 i n. l bs.).
(4) Snap on the antenna base tri m cover to the
antenna body base.
(5) I nstal l antenna mast. Ti ghten to 5 N·m (46 i n.
l bs.). Ensure that the antenna mast is fully
Fig. 2 Antenna Remove/Install
1 - RIGHT COWL SIDE PANEL
2 - BASE & CABLE
3 - GROMMET
4 - SCREW
5 - COVER
6 - MAST
TJ AUDIO/VIDEO 8A - 5
ANTENNA BODY & CABLE (Continued)
seated on antenna base and that there is no gap
between the mast and base.
(6) Reach through the gl ove box openi ng and con-
nect the two antenna coaxi al cabl es i n l i ne connector.
(7) I nstal l the gl ove box to the i nstrument panel
(Refer to 23 - BODY/I NSTRUMENT PANEL/GLOVE
BOX - I NSTALLATI ON).
(8) Connect the battery negati ve cabl e.
RADIO
DESCRIPTION
Avai l abl e factory-i nstal l ed radi o recei vers for thi s
model i ncl ude:
• AM/FM/cassette wi th CD changer control fea-
ture (RBB sal es code)
• AM/FM/CD wi th CD changer control feature
(RBK sal es code)
• AM/FM/cassette/CD/ wi th CD changer control
feature (RAD, RBT or RBY sal es code) - export onl y
Al l factory-i nstal l ed radi o recei vers can communi -
cate on the Programmabl e Communi cati ons I nterface
(PCI ) data bus network. Al l factory-i nstal l ed recei v-
ers are stereo El ectroni cal l y Tuned Radi os (ETR) and
i ncl ude an el ectroni c di gi tal cl ock functi on.
These radi o recei vers can onl y be servi ced by an
authori zed radi o repai r stati on. See the l atest War-
ranty Pol i ci es and Procedures manual for a current
l i sti ng of authori zed radi o repai r stati ons.
OPERATION
The radi o recei ver operates on i gni ti on swi tched
battery current that i s avai l abl e onl y when the i gni -
ti on swi tch i s i n the On or Accessory posi ti ons. The
el ectroni c di gi tal cl ock functi on of the radi o operates
on fused battery current suppl i ed through the I OD
fuse, regardl ess of the i gni ti on swi tch posi ti on.
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, (REFER TO ELECTRICAL/RESTRAINTS)
BEFORE ATTEMPTING ANY STEERING WHEEL,
STEERING COLUMN, OR INSTRUMENT PANEL
COMPONENT DIAGNOSIS OR SERVICE. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the i nstrument panel top cover from
the i nstrument panel . (Refer to 23 - BODY/I NSTRU-
MENT PANEL/I NSTRUMENT PANEL TOP COVER
- REMOVAL).
(3) Remove the center bezel (Refer to 23 - BODY/
I NSTRUMENT PANEL/I NSTRUMENT PANEL
CENTER BEZEL - REMOVAL).
(4) Remove the screws that secure the radi o to the
i nstrument panel .
(5) I f the vehi cl e i s equi pped wi th the CD radi o, go
to Step 6. I f the vehi cl e i s not equi pped wi th the CD
radi o recei ver, go to Step 8.
(6) Remove the gl ove box from the i nstrument
panel . (Refer to 23 - BODY/I NSTRUMENT PANEL/
GLOVE BOX - REMOVAL).
(7) Reach through the i nstrument panel gl ove box
openi ng to access and remove the nut that secures
the CD radi o bracket and the ground strap to the
back of the radi o.
(8) Pul l the radi o out from the i nstrument panel
far enough to access the wi re harness connectors and
the antenna coaxi al cabl e connector.
(9) Unpl ug the wi re harness connectors from the
rear of the radi o.
CAUTION: Pulling the antenna cable straight out of
the radio without pulling on the locking antenna
connector could damage the cable or radio.
(10) Di sconnect the antenna cabl e by pul l i ng the
l ocki ng antenna connector away from the radi o (Fi g.
3).
(11) Remove the radi o from the i nstrument panel .
Fig. 3 ANTENNA TO RADIO
1 - RADIO
2 - LOCKING ANTENNA CONNECTOR
3 - INSTRUMENT PANEL ANTENNA CABLE
8A - 6 AUDIO/VIDEO TJ
ANTENNA BODY & CABLE (Continued)
INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, (REFER TO ELECTRICAL/RESTRAINTS)
BEFORE ATTEMPTING ANY STEERING WHEEL,
STEERING COLUMN, OR INSTRUMENT PANEL
COMPONENT DIAGNOSIS OR SERVICE. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
(1) Connect the coaxi al antenna cabl e at the rear
of the radi o chassi s.
(2) Connect the radi o wi re harness connectors to
the rear of the radi o.
(3) I nstal l the radi o to the i nstrument panel .
(4) I f equi pped wi th a CD radi o, reach through the
gl ove box openi ng and i nstal l the nut through the CD
radi o bracket stud pl ate. Ensure that antenna i n-l i ne
connector i s properl y mated and has not become di s-
connected or pi nched.
(5) I nstal l gl ove box.
(6) I nstal l the retai ni ng screws. Ti ghten the screws
to 5 N·m (20 i n. l bs).
(7) I nstal l the center bezel to the i nstrument panel
(Refer to 23 - BODY/I NSTRUMENT PANEL/I N-
STRUMENT PANEL CENTER BEZEL - I NSTALLA-
TI ON).
(8) Connect the battery negati ve cabl e.
RADIO NOISE SUPPRESSION
COMPONENTS
DESCRIPTION
Radi o Frequency I nterference (RFI ) and El ectro-
Magneti c I nterference (EMI ) noi se suppressi on i s
accompl i shed pri mari l y through ci rcui try i nternal to
the radi o recei vers. These i nternal suppressi on
devi ces are onl y servi ced as part of the radi o recei ver.
External suppressi on devi ces that are used on thi s
vehi cl e to control RFI or EMI noi se i ncl ude the fol -
l owi ng:
• Radi o antenna base ground
• Radi o recei ver chassi s ground wi re
• Engi ne-to-body ground strap
• Resi stor-type spark pl ugs
• Radi o suppressi on-type secondary i gni ti on wi r-
i ng.
DIAGNOSIS AND TESTING - RADIO NOISE
SUPPRESSION COMPONENTS
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, (REFER TO ELECTRICAL/RESTRAINTS)
BEFORE ATTEMPTING ANY STEERING WHEEL,
STEERING COLUMN, OR INSTRUMENT PANEL
COMPONENT DIAGNOSIS OR SERVICE. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
For compl ete ci rcui t di agrams, refer to the appro-
pri ate wi ri ng i nformati on. The wi ri ng i nformati on
i ncl udes wi ri ng di agrams, proper wi re and connector
repai r procedures, further detai l s on wi re harness
routi ng and retenti on, as wel l as pi n-out and l ocati on
vi ews for the vari ous wi re harness connectors, spl i ces
and grounds. I nspect the ground paths and connec-
ti ons at the fol l owi ng l ocati ons:
• Bl ower motor
• El ectri c fuel pump
• Engi ne-to-body ground strap
• Generator
• I gni ti on modul e
• Radi o antenna base ground
• Radi o recei ver chassi s ground wi re or strap
• Wi per motor.
I f the source of RFI or EMI noi se i s i denti fi ed as a
component on the vehi cl e (i .e., generator, bl ower
motor, etc.), the ground path for that component
shoul d be checked. I f excessi ve resi stance i s found i n
any ground ci rcui t, cl ean, ti ghten, or repai r the
ground ci rcui ts or connecti ons to ground as requi red
before consi deri ng any component repl acement.
• I gni ti on coi l
• Spark pl ugs
• Spark pl ug wi re routi ng and condi ti on.
Reroute the spark pl ug wi res or repl ace the faul ty
components as requi red.
I f the source of the RFI or EMI noi se i s i denti fi ed
as two-way mobi l e radi o or tel ephone equi pment,
check the equi pment i nstal l ati on for the fol l owi ng:
• Power connecti ons shoul d be made di rectl y to
the battery, and fused as cl osel y to the battery as
possi bl e.
• The antenna shoul d be mounted on the roof or
toward the rear of the vehi cl e. Remember that mag-
neti c antenna mounts on the roof panel can adversel y
affect the operati on of an overhead consol e compass,
i f the vehi cl e i s so equi pped.
• The antenna cabl e shoul d be ful l y shi el ded coax-
i al cabl e, shoul d be as short as i s practi cal , and
shoul d be routed away from the factory-i nstal l ed
vehi cl e wi re harnesses whenever possi bl e.
• The antenna and cabl e must be careful l y
matched to ensure a l ow Standi ng Wave Rati o
(SWR).
TJ AUDIO/VIDEO 8A - 7
RADIO (Continued)
REMOVAL
ENGINE-TO-BODY GROUND STRAP
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Remove the screw that secures the engi ne-to-
body ground strap eyel et to the hood panel center
rei nforcement.
(2) Remove the screw that secures the engi ne-to-
body ground strap eyel et to the dash panel .
(3) Remove the nut that secures the engi ne-to-body
ground strap eyel et to the stud on the l eft upper rear
corner of the engi ne cyl i nder head.
(4) Remove the engi ne-to-body ground strap eyel et
from the stud on the l eft upper rear corner of the
engi ne cyl i nder head.
(5) Remove the engi ne-to-body ground strap from
the engi ne compartment.
INSTALLATION
ENGINE-TO-BODY GROUND STRAP
(1) Posi ti on the engi ne-to-body ground strap i n the
engi ne compartment.
(2) Posi ti on the engi ne-to-body ground strap eyel et
over the stud on the l eft upper rear corner of the
engi ne cyl i nder head.
(3) I nstal l and ti ghten the nut that secures the
engi ne-to-body ground strap eyel et to the stud on the
l eft upper rear corner of the engi ne cyl i nder head.
Ti ghten the nut to 5.6 N·m (50 i n. l bs.).
(4) I nstal l and ti ghten the screw that secures the
engi ne-to-body ground strap eyel et to the dash panel .
Ti ghten the screw to 48.5 N·m (430 i n. l bs.).
(5) I nstal l and ti ghten the screw that secures the
engi ne-to-body ground strap eyel et to the hood panel
center rei nforcement. Ti ghten the screw to 1.9 N·m
(17 i n. l bs.).
SPEAKER
DESCRIPTION
The standard equi pment speaker system i ncl udes
four ful l -range speakers. The two front speakers are
mounted behi nd a removabl e bezel l ocated on each
outboard end of the l ower i nstrument panel . Wi th the
premi um speaker system, the standard front speak-
ers are repl ace wi th an encl osure assembl y that
i ncl udes a 4 i nch speaker and a 1 i nch tweeter. The
two rear speakers are mounted behi nd a gri l l e
l ocated on each outboard end of the sport bar, above
the rear seati ng area of the vehi cl e.
OPERATION
Two wi res connected to each speaker, one feed ci r-
cui t (+) and one return ci rcui t (–), al l ow the audi o
output si gnal el ectri cal current to fl ow through the
speaker voi ce coi l .
DIAGNOSIS AND TESTING - SPEAKER
Any diagnosis of the Audio system should
begin with the use of the DRB III௡ diagnostic
tool. For information on the use of the DRB
III௡, refer to the appropriate Diagnostic Service
Manual.
For compl ete ci rcui t di agrams, refer to the appro-
pri ate wi ri ng i nformati on.
WARNING: DISABLE THE AIRBAG SYSTEM
BEFORE ATTEMPTING ANY STEERING WHEEL,
STEERING COLUMN, SEAT BELT TENSIONER, SIDE
AIRBAG, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
CAUTION: The speaker output of the radio is a
“floating ground” system. Do not allow any speaker
lead to short to ground, as damage to the radio
may result.
8A - 8 AUDIO/VIDEO TJ
RADIO NOISE SUPPRESSION COMPONENTS (Continued)
NOTE: If poor sound quality is noted in the audio
system, check the Cabin Equalization curve pro-
grammed in the instrument cluster. Make sure a
base speaker system has the Base Cabin Equaliza-
tion Curve programmed to the vehicle. If the vehicle
has a premium speaker system, make sure the Pre-
mium Cabin Equalization Curve is programmed to
the vehicle
(1) I f al l speakers are i noperati ve, check the fuses
i n the Power Di stri buti on Center (PDC). I f OK, go to
Step 2. I f not OK, repai r the shorted ci rcui t or com-
ponent as requi red and repl ace the faul ty fuse.
(2) Turn the i gni ti on swi tch to the ON posi ti on.
Turn the radi o recei ver ON. Adjust the bal ance and
fader control control s to check the performance of
each i ndi vi dual speaker. Note the speaker l ocati ons
that are not performi ng correctl y. Go to Step 3.
(3) Turn the radi o recei ver OFF. Turn the i gni ti on
OFF. Di sconnect and i sol ate the battery negati ve
cabl e. Remove the radi o recei ver. Go to Step 4.
(4) Check both the speaker feed (+) ci rcui t and
return (-) ci rcui t cavi ti es for the i noperati ve speaker
at the radi o recei ver wi re harness connector for con-
ti nui ty to ground. There shoul d be no conti nui ty. I f
OK, go to Step 5. I f not OK, repai r the shorted
speaker feed (+) and/or return (-) ci rcui ts(s) to the
speaker as requi red.
(5) Di sconnect wi re harness connector at the i nop-
erati ve speaker. Check for conti nui ty between the
speaker feed (+) ci rcui t cavi ti es of the radi o recei ver
wi re harness connector and the speaker wi re harness
connector. Repeat the check between the speaker
return (-) ci rcui t cavi ti es of the radi o recei ver wi re
harness connector and the speaker wi re harness con-
nector. I n each case, there shoul d be conti nui ty. I f
OK, repl ace the faul ty speaker. I f not OK, repai r the
open speaker feed (+) and/or return (-) ci rcui ts(s) as
requi red.
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
FRONT
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the two screws that secure the out-
board end of the speaker bezel to the i nstrument
panel (Fi g. 4).
(3) Usi ng a tri m sti ck, gentl y pry at the top and
bottom edges of the speaker bezel to rel ease the two
snap cl i p retai ners that secure the bezel to the
i nstrument panel .
(4) Remove the speaker bezel from the i nstrument
panel .
(5) Remove the four screws that secure the
speaker to the i nstrument panel (Fi g. 5).
(6) Pul l the speaker away from the i nstrument
panel far enough to access the speaker wi re harness
connector.
(7) Unpl ug the wi re harness connector from the
speaker.
REAR
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove mounti ng screws and speaker gri l l .
(3) Remove speaker from housi ng and di sconnect
wi re harness connector.
Fig. 4 Instrument Panel Speaker Bezel Remove/
Install
1 - PRY HERE
2 - SPEAKER BEZEL
3 - PRY HERE
4 - MOUNTING SCREWS
TJ AUDIO/VIDEO 8A - 9
SPEAKER (Continued)
INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, (REFER TO ELECTRICAL/RESTRAINTS)
BEFORE ATTEMPTING ANY STEERING WHEEL,
STEERING COLUMN, OR INSTRUMENT PANEL
COMPONENT DIAGNOSIS OR SERVICE. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
FRONT
(1) Connect the speaker wi re connector to the
speaker.
(2) Posi ti on the speaker to the i nstrument panel .
(3) I nstal l the four speaker retai ni ng screws.
Ti ghten the screws to 1.1 N·m (10.i n.l bs).
(4) I nstal l the speaker bezel to the i nstrument
panel . Ti ghten the screws to 2.2 N·m (20 i n. l bs.).
(5) Connect the battery negati ve cabl e.
REAR
(1) Connect wi re harness and posi ti on speaker i nto
housi ng.
(2) I nstal l speaker gri l l and mounti ng screws.
(3) Connect battery negati ve cabl e.
Fig. 5 Instrument Panel Speaker Remove/Install
1 - INSTRUMENT PANEL
2 - SPEAKER
3 - SCREW
8A - 10 AUDIO/VIDEO TJ
SPEAKER (Continued)
CHIME/BUZZER
TABLE OF CONTENTS
page page
CHIME WARNING SYSTEM
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DIAGNOSIS AND TESTING - CHIME
WARNING SYSTEM . . . . . . . . . . . . . . . . . . . . . 3
CHIME WARNING SYSTEM
DESCRIPTION
A chi me warni ng system i s standard factory-i n-
stal l ed equi pment on thi s model . The chi me warni ng
system uses a si ngl e chi me tone generator that i s
i ntegral to the i nstrument cl uster to provi de an audi -
bl e i ndi cati on of vari ous vehi cl e condi ti ons that may
requi re the attenti on of the vehi cl e operator. The
chi me warni ng system i ncl udes the fol l owi ng major
components, whi ch are descri bed i n further detai l
el sewhere i n thi s servi ce i nformati on:
• Door Ajar Switch - A door ajar swi tch i s
mounted to each front door hi nge pi l l ar. Thi s swi tch
provi des an i nput to the chi me warni ng system i ndi -
cati ng whether the front doors are open or cl osed.
• Ignition Switch - A key-i n i gni ti on swi tch i s
i ntegral to the i gni ti on swi tch. The key-i n i gni ti on
swi tch provi des an i nput to the chi me warni ng sys-
tem i ndi cati ng whether a key i s present i n the i gni -
ti on l ock cyl i nder.
• Instrument Cluster - The i nstrument cl uster
contai ns an i ntegral chi me tone generator, i ntegrated
ci rcui try, a central processi ng uni t and the program-
mi ng to provi de al l of the proper chi me warni ng sys-
tem features based upon the moni tored i nputs. The
i nstrument cl uster ci rcui try moni tors hard-wi red
swi tch i nputs, as wel l as message i nputs recei ved
from other vehi cl e el ectroni c modul es on the Pro-
grammabl e Communi cati ons I nterface (PCI ) data bus
network.
• Left Multi-Function Switch - The exteri or
l i ghti ng swi tch i s i ntegral to the l eft mul ti -functi on
swi tch. The exteri or l i ghti ng swi tch provi des an
i nput to the chi me warni ng system i ndi cati ng when
the exteri or l amps are turned On or Off.
• Seat Belt Switch - A seat bel t swi tch i s i nte-
gral to the dri ver si de front seat bel t buckl e-hal f
uni t. The seat bel t swi tch provi des an i nput to the
chi me warni ng system i ndi cati ng whether the dri ver
si de front seat bel t i s fastened.
Hard wi red ci rcui try connects many of the chi me
warni ng system components to each other through
the el ectri cal system of the vehi cl e. These hard wi red
ci rcui ts are i ntegral to several wi re harnesses, whi ch
are routed throughout the vehi cl e and retai ned by
many di fferent methods. Refer to the appropri ate
wi ri ng i nformati on.
The i nstrument cl uster chi me warni ng system ci r-
cui try and the i ntegral chi me tone generator cannot
be adjusted or repai red. I f the i nstrument cl uster or
the chi me tone generator are damaged or faul ty, the
i nstrument cl uster must be repl aced.
OPERATION
The chi me warni ng system i s desi gned to provi de
an audi bl e output as an i ndi cati on of vari ous condi -
ti ons that may requi re the attenti on or awareness of
the vehi cl e operator. The chi me warni ng system com-
ponents operate on battery vol tage recei ved through
the I gni ti on-Off Draw (I OD) fuse i n the Power Di stri -
buti on Center (PDC) so that the system may operate
regardl ess of the i gni ti on swi tch posi ti on.
The chi me warni ng system provi des an audi bl e
warni ng to the vehi cl e operator under the fol l owi ng
condi ti ons:
• Air Bag Warning - The i nstrument cl uster
chi me tone generator wi l l generate a si ngl e chi me
tone when the ai rbag i ndi cator i s i l l umi nated for an
ai rbag system faul t condi ti on. The i nstrument cl uster
uses ai rbag i ndi cator l amp-on and l amp-off message
i nputs recei ved from the Ai rbag Control Modul e
(ACM) over the Programmabl e Communi cati ons
I nterface (PCI ) data bus i ndi cati ng that the ai rbag
i ndi cator shoul d be i l l umi nated for an ai rbag system
faul t condi ti on.
• Charging System Warning - The i nstrument
cl uster chi me tone generator wi l l generate a si ngl e
chi me when the check gauges i ndi cator i s i l l umi nated
for a chargi ng system faul t or a system vol tage hi gh
warni ng condi ti on. The i nstrument cl uster uses sys-
tem vol tage status message i nputs recei ved from the
Powertrai n Control Modul e (PCM) over the PCI data
bus to i l l umi nate the check gauges i ndi cator for a
chargi ng system faul t. Thi s chi me feature wi l l onl y
occur once i n an i gni ti on cycl e.
• Driver Door Ajar Warning - The i nstrument
cl uster chi me tone generator wi l l generate repeti ti ve
chi mes at a sl ow rate to announce that the hard
TJ CHIME/BUZZER 8B - 1
wi red i nputs from the dri ver door ajar swi tch and the
i gni ti on swi tch as wel l as an engi ne speed message
i nput recei ved from the PCM over the PCI data bus
i ndi cate that the dri ver door i s opened wi th the i gni -
ti on swi tch i n the On posi ti on and the engi ne i s not
runni ng. The chi mes wi l l conti nue to sound for a
durati on of about twenty mi nutes, unti l the dri ver
door i s cl osed, unti l the i gni ti on swi tch i s turned to
the Off posi ti on, or unti l the engi ne speed message
i ndi cates the engi ne i s runni ng, whi chever occurs
fi rst.
• Engine Coolant Temperature High Warning
- The i nstrument cl uster chi me tone generator wi l l
generate a si ngl e chi me tone when the check gauges
i ndi cator i s i l l umi nated for a hi gh or cri ti cal engi ne
cool ant temperature condi ti on. The i nstrument cl us-
ter uses engi ne cool ant temperature message i nputs
recei ved from the PCM over the PCI data bus to i l l u-
mi nate the check gauges i ndi cator for a cool ant tem-
perature hi gh condi ti on. Thi s chi me feature wi l l onl y
occur once i n an i gni ti on cycl e.
• Fasten Seat Belt Warning - The i nstrument
cl uster chi me tone generator wi l l generate repeti ti ve
chi mes at a sl ow rate each ti me the i gni ti on swi tch i s
turned to the On or Start posi ti ons to announce that
the hard wi red i nputs from the seat bel t swi tch and
the i gni ti on swi tch i ndi cate that the dri ver si de front
seat bel t i s not fastened. The chi mes wi l l conti nue to
sound for a durati on of about si x seconds, unti l the
dri ver si de front seat bel t i s fastened, or unti l the
i gni ti on swi tch i s turned to the Off posi ti on, whi ch-
ever occurs fi rst.
• Head/Park Lights-On Warning - The i nstru-
ment cl uster chi me tone generator wi l l generate
repeti ti ve chi mes at a sl ow rate to announce that the
hard wi red i nputs from the dri ver door ajar swi tch,
the i gni ti on swi tch, and the exteri or l i ghti ng ci rcui try
of the l eft mul ti -functi on swi tch i ndi cate that the
exteri or l amps are turned On wi th the dri ver door
opened and the i gni ti on swi tch i n the Off posi ti on.
The chi mes wi l l conti nue to sound for about three
mi nutes or unti l the exteri or l amps are turned Off,
the dri ver door i s cl osed, or the i gni ti on swi tch i s
turned to the On posi ti on, whi chever occurs fi rst.
• Key-In-Ignition Warning - The i nstrument
cl uster chi me tone generator wi l l generate repeti ti ve
chi mes at a sl ow rate to announce that the hard
wi red i nputs from the dri ver door ajar swi tch, the
i gni ti on swi tch, and the key-i n i gni ti on ci rcui try of
the i gni ti on swi tch i ndi cate that the key i s i n the
i gni ti on l ock cyl i nder wi th the dri ver door opened
and the i gni ti on swi tch i n the Off posi ti on. The
chi mes wi l l conti nue to sound unti l the key i s
removed from the i gni ti on l ock cyl i nder, the dri ver
door i s cl osed, or the i gni ti on swi tch i s turned to the
On posi ti on, whi chever occurs fi rst.
• Low Fuel Warning - The i nstrument cl uster
chi me tone generator wi l l generate one chi me tone
when the l ow fuel i ndi cator i s i l l umi nated by the
i nstrument cl uster. The i nstrument cl uster uses a
percent tank ful l message i nput recei ved from the
PCM over the PCI data bus i ndi cati ng that there i s
l ess than about one-ei ghth tank of fuel remai ni ng to
i l l umi nate the l ow fuel i ndi cator. Thi s chi me feature
wi l l onl y occur once i n an i gni ti on cycl e.
• Low Oil Pressure Warning - The i nstrument
cl uster chi me tone generator wi l l generate repeti ti ve
chi mes at a fast rate when the check gauges i ndi ca-
tor i s i l l umi nated for a l ow oi l pressure condi ti on.
The i nstrument cl uster uses engi ne speed and oi l
pressure message i nputs recei ved from the PCM over
the PCI data bus i ndi cati ng that the engi ne i s run-
ni ng at greater than 300 rpm and that the oi l pres-
sure i s l ow to i l l umi nate the check gauges i ndi cator.
The chi mes wi l l conti nue to sound for fi ve seconds,
unti l the engi ne oi l pressure message i ndi cates that
the oi l pressure i s not l ow, or unti l the engi ne speed
message i ndi cates that the engi ne i s runni ng at l ess
than 300 rpm, whi chever occurs fi rst. Thi s chi me
tone wi l l onl y occur once i n an i gni ti on cycl e.
• Overspeed Warning - The i nstrument cl uster
chi me tone generator wi l l generate repeti ti ve chi mes
at a sl ow rate to announce that a vehi cl e speed mes-
sage i nput recei ved from the PCM over the PCI data
bus i ndi cates that the vehi cl e speed i s above 120
ki l ometers-per-hour (75 mi l es-per-hour). The chi mes
wi l l conti nue to sound unti l the vehi cl e speed mes-
sage i ndi cates that the vehi cl e speed i s bel ow 120
ki l ometers-per-hour (75 mi l es-per-hour). Thi s feature
i s onl y enabl ed on an i nstrument cl uster that has
been programmed wi th a Mi ddl e East Gul f Coast
Country (GCC) country code.
• Park Brake Reminder - The i nstrument cl us-
ter chi me tone generator wi l l generate ten repeti ti ve
chi mes at a sl ow rate to announce that the hard
wi red i nput from the park brake swi tch and a vehi cl e
speed message i nput recei ved from the PCM over the
PCI data bus i ndi cates that the park brake i s appl i ed
and the vehi cl e i s movi ng. Thi s chi me feature wi l l
repeat each ti me the i nput condi ti ons are met.
• Passenger Door Ajar Warning - The i nstru-
ment cl uster chi me tone generator wi l l generate
three sets of two chi mes at a sl ow rate to announce
that the hard wi red i nputs from the passenger door
ajar swi tch and the i gni ti on swi tch as wel l as an
engi ne speed message i nput recei ved from the PCM
over the PCI data bus i ndi cate that the passenger
door i s opened wi th the i gni ti on swi tch i n the On
posi ti on and the engi ne i s not runni ng. Thi s chi me
feature wi l l repeat each ti me the i nput condi ti ons are
met.
8B - 2 CHIME/BUZZER TJ
CHIME WARNING SYSTEM (Continued)
• Sentry Key Immobilizer System “Customer
Learn” Mode Announcement - Thi s chi me feature
i s onl y acti ve on vehi cl es equi pped wi th the opti onal
Sentry Key I mmobi l i zer System (SKI S) and sol d i n
markets where the opti onal “Customer Learn” pro-
grammi ng feature i s avai l abl e. The i nstrument cl us-
ter chi me tone generator wi l l generate one chi me to
announce that a status message i nput recei ved from
the Sentry Key I mmobi l i zer Modul e (SKI M) over the
PCI data bus i ndi cates that the SKI S i s i n the “Cus-
tomer Learn” mode, whi ch i s used for programmi ng
addi ti onal sentry key transponders.
• Turn Signal On Warning - The i nstrument
cl uster chi me tone generator wi l l generate repeti ti ve
chi mes at a sl ow rate to announce that the hard
wi red i nput for the ri ght or l eft turn si gnal i ndi cator
as wel l as vehi cl e di stance and speed message i nputs
recei ved from the PCM over the PCI data bus i ndi -
cate that a turn si gnal has been acti ve conti nuousl y
for 1.6 ki l ometers (1 mi l e) wi th the vehi cl e speed
greater than 22 ki l ometers-per-hour (15 mi l es-per
hour). Vehi cl es bui l t for markets other than the
Uni ted States and Canada have a revi sed di stance
threshol d of 4 ki l ometers for thi s feature. The chi me
wi l l conti nue unti l the turn si gnal i nput becomes
i nacti ve, the status changes, or unti l the vehi cl e
speed message i ndi cates that the speed i s l ess than
22 ki l ometers-per-hour (15 mi l es-per-hour), whi ch-
ever occurs fi rst. The hazard warni ng fl ashers wi l l
not acti vate thi s chi me feature.
The i nstrument cl uster provi des chi me servi ce for
al l avai l abl e features i n the chi me warni ng system.
The i nstrument cl uster rel i es upon i ts i nternal pro-
grammi ng, hard wi red i nputs from numerous
swi tches, and el ectroni c message i nputs recei ved
from other el ectroni c modul es over the PCI data bus
network. Upon recei vi ng the proper i nputs, the
i nstrument cl uster acti vates the i ntegral chi me tone
generator to provi de the audi bl e chi me to the vehi cl e
operator. The chi me tone generator i n the i nstrument
cl uster i s capabl e of produci ng si ngl e chi me tones, or
repeated chi me tones at two di fferent rates: about
fi fty chi me tones per mi nute, or about 180 chi me
tones per mi nute. The i nternal programmi ng of the
i nstrument cl uster determi nes the pri ori ty of each
chi me request i nput that i s recei ved, as wel l as the
rate and durati on of each chi me that i s to be gener-
ated.
The hard wi red chi me warni ng system i nputs to
the i nstrument cl uster, as wel l as other hard wi red
ci rcui ts for thi s system may be di agnosed and tested
usi ng conventi onal di agnosti c tool s and procedures.
However, conventi onal di agnosti c methods may not
prove concl usi ve i n the di agnosi s of the i nstrument
cl uster or the PCI data bus network. The most rel i -
abl e, effi ci ent and accurate means to di agnose the
i nstrument cl uster and the PCI data bus network
i nputs for the chi me warni ng system requi res the use
of a DRBI I I ௡ scan tool . Refer to the appropri ate di ag-
nosti c i nformati on.
DIAGNOSIS AND TESTING - CHIME WARNING
SYSTEM
The chi me warni ng system features dri ven by hard
wi red i nputs to the i nstrument cl uster may be di ag-
nosed and tested usi ng conventi onal di agnosti c tool s
and procedures. However, conventi onal di agnosti c
methods may not prove concl usi ve i n the di agnosi s of
the chi me warni ng system features dri ven by mes-
sage i nputs to the i nstrument cl uster over the Pro-
grammabl e Communi cati ons I nterface (PCI ) data bus
network. The most rel i abl e, effi ci ent and accurate
means to di agnose the i nstrument cl uster and the
PCI data bus network i nputs for the chi me warni ng
system requi res the use of a DRBI I I ௡ scan tool . Refer
to the appropri ate di agnosti c and wi ri ng i nformati on.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
TJ CHIME/BUZZER 8B - 3
CHIME WARNING SYSTEM (Continued)
CONDITION POSSIBLE CAUSES CORRECTION
NO SEAT BELT WARNING
CHIME WITH SEAT BELT
UNBUCKLED, BUT OTHER
CHIME FEATURES OK
1. Seat belt switch ground
circuit open.
1. Check for continuity between the ground circuit
of the floor wire harness connector for the seat
belt switch and a good ground. Repair open
ground circuit, if required.
2. Seat belt switch sense
circuit open.
2. Check for continuity between the seat belt
switch sense circuit of the floor wire harness
connector for the seat belt switch and the
instrument panel wire harness instrument cluster
connector. Repair the open seat belt switch sense
circuit, if required.
3. Faulty seat belt switch. 3. Check for continuity between the ground circuit
and the seat belt switch sense circuit of the seat
belt switch pigtail connector. There should be
continuity with the seat belt unbuckled. Replace
the faulty seat belt, if required.
SEAT BELT WARNING
CHIME WITH SEAT BELT
BUCKLED
1. Seat belt switch sense
circuit shorted.
1. With the floor wire harness connector for the
seat belt switch and the instrument panel wire
harness instrument cluster connector
disconnected, there should be no continuity
between the seat belt switch sense circuit and a
good ground. Repair the shorted seat belt switch
sense circuit, if required.
2. Faulty seat belt switch. 2. Check for continuity between the ground circuit
cavity and the seat belt switch sense circuit of the
seat belt switch pigtail connector. There should
be no continuity with the seat belt buckled.
Replace the faulty seat belt, if required.
NO KEY-IN IGNITION
WARNING CHIME, BUT
OTHER CHIME FEATURES
OK
1. Driver door ajar switch
sense circuit open.
1. Check for continuity between the driver door
ajar switch sense circuit of the connector for the
driver door ajar switch and the cross body wire
harness ignition switch connector. Repair the
open driver door ajar switch sense circuit, if
required.
2. Key-in ignition switch
sense circuit open.
2. Check for continuity between the key-in ignition
switch sense circuit of the cross body wire
harness ignition switch connector and the
instrument panel wire harness instrument cluster
connector. Repair the open key-in ignition switch
sense circuit, if required.
3. Ignition switch ground
circuit open.
3. Check for continuity between the ground circuit
cavity of the cross body wire harness ignition
switch connector and a good ground. Repair the
open ground circuit, if required
4. Faulty ignition switch. 4. Check for continuity between the ground circuit
terminal and the key-in ignition switch sense
circuit terminal in the ignition switch connector.
There should be continuity with a key in the
ignition lock cylinder. Replace the faulty ignition
switch, if required.
8B - 4 CHIME/BUZZER TJ
CHIME WARNING SYSTEM (Continued)
CONDITION POSSIBLE CAUSES CORRECTION
NO HEADLAMPS-ON
WARNING CHIME, BUT
OTHER CHIME FEATURES
OK
1. Driver door ajar switch
sense circuit open.
1. Check for continuity between the driver door
ajar switch sense circuit of the connector for the
driver door ajar switch and the instrument panel
wire harness instrument cluster connector. Repair
the open driver door ajar switch sense circuit, if
required.
2. Headlamp switch output
circuit open.
2. Check for continuity between the headlamp
switch output circuit of the instrument panel wire
harness instrument cluster connector and the
park lamp feed circuit of the cross body wire
harness left multi-function switch connector.
Repair the open headlamp switch output circuit, if
required.
3. Faulty multi-function
switch.
3. Check for continuity between the B(+) circuit
terminal and the park lamp feed circuit terminal in
the left multi-function switch connector. There
should be continuity with the headlamp switch in
the On position. Replace the faulty left multi-
function switch, if required.
NO CHIMES AND OTHER
INSTRUMENT CLUSTER
FEATURES ERRATIC OR
DISABLED
1. Instrument cluster ground
circuit open.
1. Check for continuity between the ground circuit
of the instrument panel wire harness instrument
cluster connector and a good ground. Repair the
open ground circuit, if required.
2. Instrument cluster fused
B(+) circuit open.
2. Check for battery voltage at the B(+) circuit of
the instrument panel wire harness instrument
cluster connector. Repair the open fused B(+)
circuit, if required.
3. Instrument cluster fused
ignition switch output
(run-start) circuit open.
3. With the ignition switch in the On position,
check for battery voltage at the fused ignition
switch output (run-start) circuit of the instrument
panel wire harness instrument cluster connector.
Repair the open fused ignition switch output
(run-start) circuit, if required.
4. Faulty instrument cluster. 4. Replace the faulty instrument cluster, if
required.
NO CHIMES, BUT ALL
OTHER INSTRUMENT
CLUSTER FEATURES OK
1. Faulty instrument cluster. 1. Replace the faulty instrument cluster, if
required.
TJ CHIME/BUZZER 8B - 5
CHIME WARNING SYSTEM (Continued)
ELECTRONIC CONTROL MODULES
TABLE OF CONTENTS
page page
COMMUNICATION
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
CONTROLLER ANTILOCK BRAKE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 2
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DATA LINK CONNECTOR
DESCRIPTION - DATA LINK CONNECTOR . . . . . 3
OPERATION - DATA LINK CONNECTOR . . . . . . 3
POWERTRAIN CONTROL MODULE
DESCRIPTION
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 3
DESCRIPTION - MODES OF OPERATION . . . . 3
DESCRIPTION - 5 VOLT SUPPLIES . . . . . . . . 6
DESCRIPTION - IGNITION CIRCUIT SENSE . . 6
DESCRIPTION - POWER GROUNDS . . . . . . . 6
DESCRIPTION - SENSOR RETURN . . . . . . . . 6
OPERATION
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 6
OPERATION - 5 VOLT SUPPLIES . . . . . . . . . . 7
OPERATION - IGNITION CIRCUIT SENSE . . . . 7
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SENTRY KEY IMMOBILIZER MODULE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
STANDARD PROCEDURE - PCM/SKIM
PROGRAMMING . . . . . . . . . . . . . . . . . . . . . . 10
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12
TRANSMISSION CONTROL MODULE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 13
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
STANDARD PROCEDURE - TCM QUICK
LEARN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
COMMUNICATION
DESCRIPTION
The Dai ml erChrysl er Programmabl e Communi ca-
ti on I nterface (PCI ) data bus system i s a si ngl e wi re
mul ti pl ex system used for vehi cl e communi cati ons on
many Dai ml erChrysl er Corporati on vehi cl es. Mul ti -
pl exi ng i s a system that enabl es the transmi ssi on of
several messages over a si ngl e channel or ci rcui t. Al l
Dai ml erChrysl er vehi cl es use thi s pri nci pl e for com-
muni cati on between vari ous mi croprocessor-based
el ectroni c control modul es. The PCI data bus exceeds
the Soci ety of Automoti ve Engi neers (SAE) J1850
Standard for Cl ass B Mul ti pl exi ng.
Many of the el ectroni c control modul es i n a vehi cl e
requi re i nformati on from the same sensi ng devi ce. I n
the past, i f i nformati on from one sensi ng devi ce was
requi red by several control l ers, a wi re from each con-
trol l er needed to be connected i n paral l el to that sen-
sor. I n addi ti on, each control l er uti l i zi ng anal og
sensors requi red an Anal og/Di gi tal (A/D) converter i n
order to ЉreadЉ these sensor i nputs. Mul ti pl exi ng
reduces wi re harness compl exi ty, sensor current l oads
and control l er hardware because each sensi ng devi ce i s
connected to onl y one control l er, whi ch reads and di s-
tri butes the sensor i nformati on to the other control l ers
over the data bus. Al so, because each control l er on the
data bus can access the control l er sensor i nputs to
every other control l er on the data bus, more functi on
and feature capabi l i ti es are possi bl e.
I n addi ti on to reduci ng wi re harness compl exi ty,
component sensor current l oads and control l er hard-
ware, mul ti pl exi ng offers a di agnosti c advantage. A
mul ti pl ex system al l ows the i nformati on fl owi ng
between control l ers to be moni tored usi ng a di agnos-
ti c scan tool . The Dai ml erChrysl er system al l ows an
el ectroni c control modul e to broadcast message data
out onto the bus where al l other el ectroni c control
modul es can ЉhearЉ the messages that are bei ng sent.
When a modul e hears a message on the data bus
that i t requi res, i t rel ays that message to i ts mi cro-
processor. Each modul e i gnores the messages on the
data bus that are bei ng sent to other el ectroni c con-
trol modul es.
OPERATION
Data exchange between modul es i s achi eved by
seri al transmi ssi on of encoded data over a si ngl e wi re
broadcast network. The wi re col ors used for the PCI
data bus ci rcui ts are yel l ow wi th a vi ol et tracer, or vi o-
l et wi th a yel l ow tracer, dependi ng upon the appl i ca-
ti on. The PCI data bus messages are carri ed over the
bus i n the form of Vari abl e Pul se Wi dth Modul ated
(VPWM) si gnal s. The PCI data bus speed i s an average
10.4 Ki l o-bi ts per second (Kbps). By compari son, the
pri or two-wi re Chrysl er Col l i si on Detecti on (CCD) data
bus system i s desi gned to run at 7.8125 Kbps.
TJ ELECTRONIC CONTROL MODULES 8E - 1
The vol tage network used to transmi t messages
requi res bi asi ng and termi nati on. Each modul e on
the PCI data bus system provi des i ts own bi asi ng
and termi nati on. Each modul e (al so referred to as a
node) termi nates the bus through a termi nati ng
resi stor and a termi nati ng capaci tor. There are two
types of nodes on the bus. The domi nant node termi -
nates the bus through a 1 KW resi stor and a 3300 pF
capaci tor. The Powertrai n Control Modul e (PCM) i s
the onl y domi nant node for the PCI data bus system.
A standard node termi nates the bus through an 11
KW resi stor and a 330 pF capaci tor.
The modul es bi as the bus when transmi tti ng a
message. The PCI bus uses l ow and hi gh vol tage l ev-
el s to generate si gnal s. Low vol tage i s around zero
vol ts and the hi gh vol tage i s about seven and one-
hal f vol ts. The l ow and hi gh vol tage l evel s are gener-
ated by means of vari abl e-pul se wi dth modul ati on to
form si gnal s of varyi ng l ength. The Vari abl e Pul se
Wi dth Modul ati on (VPWM) used i n PCI bus messag-
i ng i s a method i n whi ch both the state of the bus
and the wi dth of the pul se are used to encode bi t
i nformati on. A ЉzeroЉ bi t i s defi ned as a short l ow
pul se or a l ong hi gh pul se. A ЉoneЉ bi t i s defi ned as a
l ong l ow pul se or a short hi gh pul se. A l ow (passi ve)
state on the bus does not necessari l y mean a zero bi t.
I t al so depends upon pul se wi dth. I f the wi dth i s
short, i t stands for a zero bi t. I f the wi dth i s l ong, i t
stands for a one bi t. Si mi l arl y, a hi gh (acti ve) state
does not necessari l y mean a one bi t. Thi s too depends
upon pul se wi dth. I f the wi dth i s short, i t stands for
a one bi t. I f the wi dth i s l ong, i t stands for a zero bi t.
I n the case where there are successi ve zero or one
data bi ts, both the state of the bus and the wi dth of
the pul se are changed al ternatel y. Thi s encodi ng
scheme i s used for two reasons. Fi rst, thi s ensures that
onl y one symbol per transi ti on and one transi ti on per
symbol exi sts. On each transi ti on, every transmi tti ng
modul e must decode the symbol on the bus and begi n
ti mi ng of the next symbol . Si nce ti mi ng of the next
symbol begi ns wi th the l ast transi ti on detected on the
bus, al l of the modul es are re-synchroni zed wi th each
symbol . Thi s ensures that there are no accumul ated
ti mi ng errors duri ng PCI data bus communi cati on.
The second reason for thi s encodi ng scheme i s to
guarantee that the zero bi t i s the domi nant bi t on
the bus. When two modul es are transmi tti ng si mul -
taneousl y on the bus, there must be some form of
arbi trati on to determi ne whi ch modul e wi l l gai n con-
trol . A data col l i si on occurs when two modul es are
transmi tti ng di fferent messages at the same ti me.
When a modul e i s transmi tti ng on the bus, i t i s read-
i ng the bus at the same ti me to ensure message
i ntegri ty. When a col l i si on i s detected, the modul e
that transmi tted the one bi t stops sendi ng messages
over the bus unti l the bus becomes i dl e.
Each modul e i s capabl e of transmi tti ng and recei v-
i ng data si mul taneousl y. The typi cal PCI bus mes-
sage has the fol l owi ng four components:
• Message Header - One to three bytes i n l ength.
The header contai ns i nformati on i denti fyi ng the mes-
sage type and l ength, message pri ori ty, target mod-
ul e(s) and sendi ng modul e.
• Data Byte(s) - Thi s i s the actual message that
i s bei ng sent.
• Cyclic Redundancy Check (CRC) Byte - Thi s
byte i s used to detect errors duri ng a message trans-
mi ssi on.
• In-Frame Response (IFR) byte(s) - I f a
response i s requi red from the target modul e(s), i t can
be sent duri ng thi s frame. Thi s functi on i s descri bed
i n greater detai l i n the fol l owi ng paragraph.
The I FR consi sts of one or more bytes, whi ch are
transmi tted duri ng a message. I f the sendi ng modul e
requi res i nformati on to be recei ved i mmedi atel y, the
target modul e(s) can send data over the bus duri ng
the ori gi nal message. Thi s al l ows the sendi ng modul e
to recei ve ti me-cri ti cal i nformati on wi thout havi ng to
wai t for the target modul e to access the bus. After
the I FR i s recei ved, the sendi ng modul e broadcasts
an End of Frame (EOF) message and rel eases control
of the bus.
The PCI data bus can be moni tored usi ng the
DRBI I I ௡ scan tool . I t i s possi bl e, however, for the bus
to pass al l DRBI I I ௡ tests and sti l l be faul ty i f the
vol tage parameters are al l wi thi n the speci fi ed range
and fal se messages are bei ng sent.
CONTROLLER ANTILOCK
BRAKE
DESCRIPTION
The CAB operates the ABS system, and i s separate
from other vehi cl e el ectri cal ci rcui ts. The CAB i s
l ocated under the i nstrument panel to the ri ght si de
of the steeri ng col umn. I t i s mounted to bracket wi th
one bol t. The bracket i s mounted to the front upper
cowl panel .
OPERATION
The CAB vol tage source i s through the i gni ti on
swi tch i n the RUN posi ti on. The CAB contai ns dual
mi croprocessors. A l ogi c bl ock i n each mi croprocessor
recei ves i denti cal sensor si gnal s. These si gnal s are
processed and compared si mul taneousl y. The CAB
contai ns a sel f check program that i l l umi nates the
ABS warni ng l i ght when a system faul t i s detected.
Faul ts are stored i n a di agnosti c program memory
and are accessi bl e wi th the DRB scan tool . ABS
faul ts remai n i n memory unti l cl eared, or unti l after
8E - 2 ELECTRONIC CONTROL MODULES TJ
COMMUNICATION (Continued)
the vehi cl e i s started approxi matel y 50 ti mes. Stored
faul ts are not erased i f the battery i s di sconnected.
REMOVAL
(1) Remove the negati ve battery cabl e from the
battery.
(2) Pul l up on the CAB harness connector rel ease
(Fi g. 1)and remove connector.
(3) Remove the pump connector from the CAB.
(4) Remove the CAB mounti ng bol ts.
(5) Remove the CAB from the HCU (Fi g. 2).
INSTALLATION
(1) I nstal l CAB to the HCU (Fi g. 2).
(2) I nstal l mounti ng bol ts. Ti ghten to 2 N·m (16 i n.
l bs.).
(3) I nstal l the pump el ecti rcal connector to the
CAB (Fi g. 2).
(4) I nstal l the wi ri ng harness connector to the
CAB and push down on the rel ease to secure the con-
nector.
(5) I nstal l negati ve battery cabl e to the battery.
DATA LINK CONNECTOR
DESCRIPTION - DATA LINK CONNECTOR
The data l i nk connector (DLC) i s l ocated at the
l ower edge of the i nstrument panel near the steeri ng
col umn.
OPERATION - DATA LINK CONNECTOR
The 16–way data l i nk connector (di agnosti c scan
tool connector) l i nks the Di agnosti c Readout Box
(DRB) scan tool or the Mopar Di agnosti c System
(MDS) wi th the Powertrai n Control Modul e (PCM).
POWERTRAIN CONTROL
MODULE
DESCRIPTION
DESCRIPTION
The PCM i s l ocated i n the engi ne compartment
(Fi g. 3). The PCM i s referred to as JTEC.
DESCRIPTION - MODES OF OPERATION
As i nput si gnal s to the Powertrai n Control Modul e
(PCM) change, the PCM adjusts i ts response to the
output devi ces. For exampl e, the PCM must cal cul ate
di fferent i njector pul se wi dth and i gni ti on ti mi ng for
i dl e than i t does for wi de open throttl e (WOT).
The PCM wi l l operate i n two di fferent modes:
Open Loop and Closed Loop.
Duri ng Open Loop modes, the PCM recei ves i nput
si gnal s and responds onl y accordi ng to preset PCM
programmi ng. I nput from the oxygen (O2S) sensors
i s not moni tored duri ng Open Loop modes.
Duri ng Cl osed Loop modes, the PCM wi l l moni tor
the oxygen (O2S) sensors i nput. Thi s i nput i ndi cates
to the PCM whether or not the cal cul ated i njector
pul se wi dth resul ts i n the i deal ai r-fuel rati o. Thi s
rati o i s 14.7 parts ai r-to-1 part fuel . By moni tori ng
the exhaust oxygen content through the O2S sensor,
the PCM can fi ne tune the i njector pul se wi dth. Thi s
i s done to achi eve opti mum fuel economy combi ned
wi th l ow emi ssi on engi ne performance.
The fuel i njecti on system has the fol l owi ng modes
of operati on:
• I gni ti on swi tch ON
• Engi ne start-up (crank)
Fig. 1 CAB HARNESS CONNECTOR RELEASE
1 - ABS MODULE
2 - ELECTRICAL CONNECTOR
Fig. 2 CONTROLLER AND HCU
1 - CONTROLLER ANTILOCK BRAKE MODULE
2 - HYDRAULIC CONTROL UNIT (H.C.U)
3 - ELECTRICAL CONNECTOR
TJ ELECTRONIC CONTROL MODULES 8E - 3
CONTROLLER ANTILOCK BRAKE (Continued)
• Engi ne warm-up
• I dl e
• Crui se
• Accel erati on
• Decel erati on
• Wi de open throttl e (WOT)
• I gni ti on swi tch OFF
The i gni ti on swi tch On, engi ne start-up (crank),
engi ne warm-up, accel erati on, decel erati on and wi de
open throttl e modes are Open Loop modes. The i dl e
and crui se modes, (wi th the engi ne at operati ng tem-
perature) are Cl osed Loop modes.
IGNITION SWITCH (KEY-ON) MODE
Thi s i s an Open Loop mode. When the fuel system
i s acti vated by the i gni ti on swi tch, the fol l owi ng
acti ons occur:
• The PCM pre-posi ti ons the I dl e Ai r Control
(I AC) motor.
• The PCM determi nes atmospheri c ai r pressure
from the MAP sensor i nput to determi ne basi c fuel
strategy.
• The PCM moni tors the engi ne cool ant tempera-
ture sensor i nput. The PCM modi fi es fuel strategy
based on thi s i nput.
• I ntake mani fol d ai r temperature sensor i nput i s
moni tored.
• Throttl e posi ti on sensor (TPS) i s moni tored.
• The auto shutdown (ASD) rel ay i s energi zed by
the PCM for approxi matel y three seconds.
• The fuel pump i s energi zed through the fuel
pump rel ay by the PCM. The fuel pump wi l l operate
for approxi matel y three seconds unl ess the engi ne i s
operati ng or the starter motor i s engaged.
• The O2S sensor heater el ement i s energi zed vi a
the ASD rel ay. The O2S sensor i nput i s not used by
the PCM to cal i brate ai r-fuel rati o duri ng thi s mode
of operati on.
• The Up-shi ft I ndi cator Lamp i s i l l umi nated
(manual transmi ssi on onl y).
ENGINE START-UP MODE
Thi s i s an Open Loop mode. The fol l owi ng acti ons
occur when the starter motor i s engaged.
The PCM recei ves i nputs from:
• Battery vol tage
• Engi ne cool ant temperature sensor
• Crankshaft posi ti on sensor
• I ntake mani fol d ai r temperature sensor
• Mani fol d absol ute pressure (MAP) sensor
• Throttl e posi ti on sensor (TPS)
• Camshaft posi ti on sensor si gnal
The PCM moni tors the crankshaft posi ti on sensor.
I f the PCM does not recei ve a crankshaft posi ti on
sensor si gnal wi thi n 3 seconds of cranki ng the
engi ne, i t wi l l shut down the fuel i njecti on system.
The fuel pump i s acti vated by the PCM through
the fuel pump rel ay.
Vol tage i s appl i ed to the fuel i njectors wi th the
ASD rel ay vi a the PCM. The PCM wi l l then control
the i njecti on sequence and i njector pul se wi dth by
turni ng the ground ci rcui t to each i ndi vi dual i njector
on and off.
The PCM determi nes the proper i gni ti on ti mi ng
accordi ng to i nput recei ved from the crankshaft posi -
ti on sensor.
ENGINE WARM-UP MODE
Thi s i s an Open Loop mode. Duri ng engi ne warm-
up, the PCM recei ves i nputs from:
• Battery vol tage
• Crankshaft posi ti on sensor
• Engi ne cool ant temperature sensor
• I ntake mani fol d ai r temperature sensor
• Mani fol d absol ute pressure (MAP) sensor
• Throttl e posi ti on sensor (TPS)
• Camshaft posi ti on sensor si gnal (i n the di stri bu-
tor)
• Park/neutral swi tch (gear i ndi cator si gnal —auto.
trans. onl y)
• Ai r condi ti oni ng sel ect si gnal (i f equi pped)
• Ai r condi ti oni ng request si gnal (i f equi pped)
Based on these i nputs the fol l owi ng occurs:
• Vol tage i s appl i ed to the fuel i njectors wi th the
ASD rel ay vi a the PCM. The PCM wi l l then control
the i njecti on sequence and i njector pul se wi dth by
Fig. 3 PCM Location
1 - PCM MOUNTING BOLTS (3)
2 - POWERTRAIN CONTROL MODULE (PCM)
3 - BATTERY
4 - (3) 32–WAY CONNECTOR
8E - 4 ELECTRONIC CONTROL MODULES TJ
POWERTRAIN CONTROL MODULE (Continued)
turni ng the ground ci rcui t to each i ndi vi dual i njector
on and off.
• The PCM adjusts engi ne i dl e speed through the
i dl e ai r control (I AC) motor and adjusts i gni ti on ti m-
i ng.
• The PCM operates the A/C compressor cl utch
through the A/C compressor cl utch rel ay. Thi s i s done
i f A/C has been sel ected by the vehi cl e operator and
speci fi ed pressures are met at the hi gh and l ow–pres-
sure A/C swi tches. Refer to Group 24, Heati ng and
Ai r Condi ti oni ng for addi ti onal i nformati on.
• When engi ne has reached operati ng tempera-
ture, the PCM wi l l begi n moni tori ng O2S sensor
i nput. The system wi l l then l eave the warm-up mode
and go i nto cl osed l oop operati on.
IDLE MODE
When the engi ne i s at operati ng temperature, thi s
i s a Cl osed Loop mode. At i dl e speed, the PCM)
recei ves i nputs from:
• Ai r condi ti oni ng sel ect si gnal (i f equi pped)
• Ai r condi ti oni ng request si gnal (i f equi pped)
• Battery vol tage
• Crankshaft posi ti on sensor
• Engi ne cool ant temperature sensor
• I ntake mani fol d ai r temperature sensor
• Mani fol d absol ute pressure (MAP) sensor
• Throttl e posi ti on sensor (TPS)
• Camshaft posi ti on sensor si gnal (i n the di stri bu-
tor)
• Battery vol tage
• Park/neutral swi tch (gear i ndi cator si gnal —auto.
trans. onl y)
• Oxygen sensors
• Power steeri ng pressure swi tch (2.5L engi ne
onl y)
Based on these i nputs, the fol l owi ng occurs:
• Vol tage i s appl i ed to the fuel i njectors wi th the
ASD rel ay vi a the PCM. The PCM wi l l then control
i njecti on sequence and i njector pul se wi dth by turn-
i ng the ground ci rcui t to each i ndi vi dual i njector on
and off.
• The PCM moni tors the O2S sensor i nput and
adjusts ai r-fuel rati o by varyi ng i njector pul se wi dth.
I t al so adjusts engi ne i dl e speed through the i dl e ai r
control (I AC) motor.
• The PCM adjusts i gni ti on ti mi ng by i ncreasi ng
and decreasi ng spark advance.
• The PCM operates the A/C compressor cl utch
through the A/C compressor cl utch rel ay. Thi s i s done
i f A/C has been sel ected by the vehi cl e operator and
speci fi ed pressures are met at the hi gh and l ow–pres-
sure A/C swi tches. Refer to Group 24, Heati ng and
Ai r Condi ti oni ng for addi ti onal i nformati on.
On 2.5L 4–cyl i nder engi nes, a power steeri ng pres-
sure swi tch i s used to suppl y an i nput to the PCM
when steeri ng pump pressure i s hi gh. Thi s wi l l rai se
engi ne speed. Refer to Power Steeri ng Pressure
Swi tch i n thi s group for addi ti onal i nformati on. The
4.0L 6–cylinder engine does not use this switch.
CRUISE MODE
When the engi ne i s at operati ng temperature, thi s
i s a Cl osed Loop mode. At crui si ng speed, the PCM
recei ves i nputs from:
• Ai r condi ti oni ng sel ect si gnal (i f equi pped)
• Ai r condi ti oni ng request si gnal (i f equi pped)
• Battery vol tage
• Engi ne cool ant temperature sensor
• Crankshaft posi ti on sensor
• I ntake mani fol d ai r temperature sensor
• Mani fol d absol ute pressure (MAP) sensor
• Throttl e posi ti on sensor (TPS)
• Camshaft posi ti on sensor si gnal (i n the di stri bu-
tor)
• Park/neutral swi tch (gear i ndi cator si gnal —auto.
trans. onl y)
• Oxygen (O2S) sensors
Based on these i nputs, the fol l owi ng occurs:
• Vol tage i s appl i ed to the fuel i njectors wi th the
ASD rel ay vi a the PCM. The PCM wi l l then adjust
the i njector pul se wi dth by turni ng the ground ci rcui t
to each i ndi vi dual i njector on and off.
• The PCM moni tors the O2S sensor i nput and
adjusts ai r-fuel rati o. I t al so adjusts engi ne i dl e
speed through the i dl e ai r control (I AC) motor.
• The PCM adjusts i gni ti on ti mi ng by turni ng the
ground path to the coi l on and off.
• The PCM operates the A/C compressor cl utch
through the cl utch rel ay. Thi s happens i f A/C has
been sel ected by the vehi cl e operator and requested
by the A/C thermostat.
• The Up-shi ft I ndi cator Lamp i s operated (man-
ual transmi ssi on onl y).
ACCELERATION MODE
Thi s i s an Open Loop mode. The PCM recogni zes
an abrupt i ncrease i n throttl e posi ti on or MAP pres-
sure as a demand for i ncreased engi ne output and
vehi cl e accel erati on. The PCM i ncreases i njector
pul se wi dth i n response to i ncreased throttl e openi ng.
DECELERATION MODE
When the engi ne i s at operati ng temperature, thi s
i s an Open Loop mode. Duri ng hard decel erati on, the
PCM recei ves the fol l owi ng i nputs.
• Ai r condi ti oni ng sel ect si gnal (i f equi pped)
• Ai r condi ti oni ng request si gnal (i f equi pped)
• Battery vol tage
• Engi ne cool ant temperature sensor
• Crankshaft posi ti on sensor
• I ntake mani fol d ai r temperature sensor
• Mani fol d absol ute pressure (MAP) sensor
TJ ELECTRONIC CONTROL MODULES 8E - 5
POWERTRAIN CONTROL MODULE (Continued)
• Throttl e posi ti on sensor (TPS)
• Camshaft posi ti on sensor si gnal (i n the di stri bu-
tor)
• Park/neutral swi tch (gear i ndi cator si gnal —auto.
trans. onl y)
• Vehi cl e speed sensor
I f the vehi cl e i s under hard decel erati on wi th the
proper rpm and cl osed throttl e condi ti ons, the PCM
wi l l i gnore the oxygen sensor i nput si gnal . The PCM
wi l l enter a fuel cut-off strategy i n whi ch i t wi l l not
suppl y a ground to the i njectors. I f a hard decel era-
ti on does not exi st, the PCM wi l l determi ne the
proper i njector pul se wi dth and conti nue i njecti on.
Based on the above i nputs, the PCM wi l l adjust
engi ne i dl e speed through the i dl e ai r control (I AC)
motor.
The PCM adjusts i gni ti on ti mi ng by turni ng the
ground path to the coi l on and off.
WIDE OPEN THROTTLE MODE
Thi s i s an Open Loop mode. Duri ng wi de open
throttl e operati on, the PCM recei ves the fol l owi ng
i nputs.
• Battery vol tage
• Crankshaft posi ti on sensor
• Engi ne cool ant temperature sensor
• I ntake mani fol d ai r temperature sensor
• Mani fol d absol ute pressure (MAP) sensor
• Throttl e posi ti on sensor (TPS)
• Camshaft posi ti on sensor si gnal (i n the di stri bu-
tor)
Duri ng wi de open throttl e condi ti ons, the fol l owi ng
occurs:
• Vol tage i s appl i ed to the fuel i njectors wi th the
ASD rel ay vi a the PCM. The PCM wi l l then control
the i njecti on sequence and i njector pul se wi dth by
turni ng the ground ci rcui t to each i ndi vi dual i njector
on and off. The PCM i gnores the oxygen sensor i nput
si gnal and provi des a predetermi ned amount of addi -
ti onal fuel . Thi s i s done by adjusti ng i njector pul se
wi dth.
• The PCM adjusts i gni ti on ti mi ng by turni ng the
ground path to the coi l on and off.
• The Up-shi ft I ndi cator Lamp i s operated (man-
ual transmi ssi on onl y).
IGNITION SWITCH OFF MODE
When i gni ti on swi tch i s turned to OFF posi ti on,
the PCM stops operati ng the i njectors, i gni ti on coi l ,
ASD rel ay and fuel pump rel ay.
DESCRIPTION - 5 VOLT SUPPLIES
Two di fferent Powertrai n Control Modul e (PCM)
fi ve vol t suppl y ci rcui ts are used; pri mary and sec-
ondary.
DESCRIPTION - IGNITION CIRCUIT SENSE
Thi s ci rcui t ti es the i gni ti on swi tch to the Power-
trai n Control Modul e (PCM).
DESCRIPTION - POWER GROUNDS
The Powertrai n Control Modul e (PCM) has 2 mai n
grounds. Both of these grounds are referred to as
power grounds. Al l of the hi gh-current, noi sy, el ectri -
cal devi ces are connected to these grounds as wel l as
al l of the sensor returns. The sensor return comes
i nto the sensor return ci rcui t, passes through noi se
suppressi on, and i s then connected to the power
ground.
The power ground i s used to control ground ci r-
cui ts for the fol l owi ng PCM l oads:
• Generator fi el d wi ndi ng
• Fuel i njectors
• I gni ti on coi l (s)
• Certai n rel ays/sol enoi ds
• Certai n sensors
DESCRIPTION - SENSOR RETURN
The Sensor Return ci rcui ts are i nternal to the Pow-
ertrai n Control Modul e (PCM).
Sensor Return provi des a l ow–noi se ground refer-
ence for al l engi ne control system sensors. Refer to
Power Grounds for more i nformati on.
OPERATION
OPERATION
The PCM operates the fuel system. The PCM i s a
pre-programmed, tri pl e mi croprocessor di gi tal com-
puter. I t regul ates i gni ti on ti mi ng, ai r-fuel rati o,
emi ssi on control devi ces, chargi ng system, speed con-
trol (i f equi pped), ai r condi ti oni ng compressor cl utch
engagement and i dl e speed. The PCM can adapt i ts
programmi ng to meet changi ng operati ng condi ti ons.
The PCM recei ves i nput si gnal s from vari ous
swi tches and sensors. Based on these i nputs, the
PCM regul ates vari ous engi ne and vehi cl e operati ons
through di fferent system components. These compo-
nents are referred to as PCM Outputs. The sensors
and swi tches that provi de i nputs to the PCM are con-
si dered PCM I nputs.
The PCM adjusts i gni ti on ti mi ng based upon
i nputs i t recei ves from sensors that react to: engi ne
rpm, mani fol d absol ute pressure, engi ne cool ant tem-
perature, throttl e posi ti on, transmi ssi on gear sel ec-
ti on (automati c transmi ssi on), vehi cl e speed, power
steeri ng pump pressure (2.5L onl y), and the brake
swi tch.
The PCM adjusts i dl e speed based on i nputs i t
recei ves from sensors that react to: throttl e posi ti on,
vehi cl e speed, transmi ssi on gear sel ecti on, engi ne
8E - 6 ELECTRONIC CONTROL MODULES TJ
POWERTRAIN CONTROL MODULE (Continued)
cool ant temperature and from i nputs i t recei ves from
the ai r condi ti oni ng cl utch swi tch and brake swi tch.
Based on i nputs that i t recei ves, the PCM adjusts
i gni ti on coi l dwel l . The PCM al so adjusts the gener-
ator charge rate through control of the generator
fi el d and provi des speed control operati on.
NOTE: Powertrain Control Module (PCM) Inputs:
• A/C request (i f equi pped wi th factory A/C)
• A/C sel ect (i f equi pped wi th factory A/C)
• Auto shutdown (ASD) sense
• Battery temperature
• Battery vol tage
• Brake swi tch
• CCD bus (+) ci rcui ts
• CCD bus (-) ci rcui ts
• Camshaft posi ti on sensor si gnal
• Crankshaft posi ti on sensor
• Data l i nk connector for DRB scan tool
• Engi ne cool ant temperature sensor
• Fuel l evel
• Generator (battery vol tage) output
• I gni ti on ci rcui t sense (i gni ti on swi tch i n run
posi ti on)
• I ntake mani fol d ai r temperature sensor
• Leak detecti on pump (i f equi pped)
• Mani fol d Absol ute Pressure (MAP) sensor
• Oi l pressure sensor
• Oxygen sensors
• Park/neutral swi tch (auto. trans. onl y)
• Power ground
• Power steeri ng pressure swi tch (2.5L onl y)
• SCI recei ve (DRB scan tool 16–way connecti on)
• Sensor return
• Si gnal ground
• Speed control mul ti pl exed si ngl e wi re i nput
• Throttl e posi ti on sensor
• Vehi cl e speed sensor
NOTE: Powertrain Control Module (PCM) Outputs:
• A/C cl utch rel ay
• Auto Shutdown (ASD) rel ay
• CCD bus (+/-) ci rcui ts for: speedometer, vol tme-
ter, fuel gauge, oi l pressure gauge/l amp, engi ne temp.
gauge and speed control warn. l amp
• Duty cycl e EVAP cani ster purge sol enoi d
• Fi ve vol t sensor suppl y (pri mary)
• Fi ve vol t sensor suppl y (secondary)
• Fuel i njectors
• Fuel pump rel ay
• Generator fi el d dri ver (-)
• Generator fi el d source (+)
• I dl e Ai r Control (I AC) motor
• I gni ti on coi l
• Leak detecti on pump (i f equi pped)
• Mal functi on i ndi cator l amp (Check engi ne l amp).
Dri ven through CCD ci rcui ts.
• SCI transmi t (DRB scan tool 16–way connecti on)
• Speed control vacuum sol enoi d
• Speed control vent sol enoi d
• Tachometer (i f equi pped). Dri ven through CCD
ci rcui ts.
• Transmi ssi on convertor cl utch sol enoi d
OPERATION - 5 VOLT SUPPLIES
Pri mary 5–vol t suppl y:
• suppl i es the requi red 5 vol t power source to the
Crankshaft Posi ti on (CKP) sensor.
• suppl i es the requi red 5 vol t power source to the
Camshaft Posi ti on (CMP) sensor.
• suppl i es a reference vol tage for the Mani fol d
Absol ute Pressure (MAP) sensor.
• suppl i es a reference vol tage for the Throttl e
Posi ti on Sensor (TPS) sensor.
Secondary 5–vol t suppl y:
• suppl i es the requi red 5 vol t power source to the
oi l pressure sensor.
• suppl i es the requi red 5 vol t power source for the
Vehi cl e Speed Sensor (VSS) (i f equi pped).
• suppl i es the 5 vol t power source to the transmi s-
si on pressure sensor (i f equi pped wi th an RE auto-
mati c transmi ssi on).
OPERATION - IGNITION CIRCUIT SENSE
The i gni ti on ci rcui t sense i nput tel l s the PCM the
i gni ti on swi tch has energi zed the i gni ti on ci rcui t.
Battery vol tage i s al so suppl i ed to the PCM
through the i gni ti on swi tch when the i gni ti on i s i n
the RUN or START posi ti on. Thi s i s referred to as
the Љi gni ti on senseЉ ci rcui t and i s used to Љwake upЉ
the PCM. Vol tage on the i gni ti on i nput can be as l ow
as 6 vol ts and the PCM wi l l sti l l functi on. Vol tage i s
suppl i ed to thi s ci rcui t to power the PCM’s 8-vol t reg-
ul ator and to al l ow the PCM to perform fuel , i gni ti on
and emi ssi ons control functi ons.
REMOVAL
USE THE DRB SCAN TOOL TO REPROGRAM
THE NEW POWERTRAIN CONTROL MODULE
(PCM) WITH THE VEHICLES ORIGINAL IDEN-
TIFICATION NUMBER (VIN) AND THE VEHI-
CLES ORIGINAL MILEAGE. IF THIS STEP IS
NOT DONE, A DIAGNOSTIC TROUBLE CODE
(DTC) MAY BE SET.
The PCM i s l ocated i n the engi ne compartment
(Fi g. 4).
To avoi d possi bl e vol tage spi ke damage to the
PCM, i gni ti on key must be off, and negati ve battery
cabl e must be di sconnected before unpl uggi ng PCM
connectors.
(1) Di sconnect negati ve battery cabl e at battery.
TJ ELECTRONIC CONTROL MODULES 8E - 7
POWERTRAIN CONTROL MODULE (Continued)
(2) Remove pl asti c shi el d from over 32–way con-
nectors. Shi el d snaps to connectors.
(3) Careful l y unpl ug three 32–way connectors (Fi g.
4) from PCM.
(4) Remove three PCM mounti ng bol ts and remove
PCM from vehi cl e.
INSTALLATION
USE THE DRB SCAN TOOL TO REPROGRAM
THE NEW POWERTRAIN CONTROL MODULE
(PCM) WITH THE VEHICLES ORIGINAL IDEN-
TIFICATION NUMBER (VIN) AND THE VEHI-
CLES ORIGINAL MILEAGE. IF THIS STEP IS
NOT DONE, A DIAGNOSTIC TROUBLE CODE
(DTC) MAY BE SET.
(1) I nstal l PCM and mounti ng bol ts to vehi cl e.
(2) Ti ghten bol ts to 4 N·m (35 i n. l bs.).
(3) Check pi n connectors i n PCM and three
32–way connectors for corrosi on or damage. Al so
check pi n hei ghts i n connectors. Pi n hei ghts shoul d
al l be the same. Repai r as necessary before i nstal l i ng
32–way connectors.
(4) I nstal l three 32–way connectors.
(5) I nstal l pl asti c shi el d to 32–way connectors.
Shi el d snaps to connectors.
(6) I nstal l battery cabl e.
(7) Use the DRB scan tool to reprogram new PCM
wi th vehi cl es ori gi nal I denti fi cati on Number (VI N)
and ori gi nal vehi cl e mi l eage.
SENTRY KEY IMMOBILIZER
MODULE
DESCRIPTION
The Sentry Key I mmobi l i zer Modul e (SKI M) i s the
pri mary component of the Sentry Key I mmobi l i zer
System (SKI S) (Fi g. 5). The SKI M i s l ocated i n the
steeri ng col umn, bel ow the i gni ti on l ock cyl i nder
housi ng. The SKI M has an i ntegral hal o-l i ke antenna
ri ng that extends from one end. When the SKI M i s
properl y i nstal l ed on the steeri ng col umn, the
antenna ri ng i s ori ented around the ci rcumference of
the i gni ti on l ock cyl i nder housi ng.
The SKI M cannot be adjusted or repai red. I f faul ty
or damaged, the enti re SKI M uni t must be repl aced.
OPERATION
The Sentry Key I mmobi l i zer Modul e (SKI M) con-
tai ns a Radi o Frequency (RF) transcei ver and a
mi croprocessor. The SKI M transmi ts RF si gnal s to,
and recei ves RF si gnal s from the Sentry Key tran-
sponder through a tuned antenna encl osed wi thi n the
mol ded pl asti c antenna ri ng i ntegral to the SKI M
housi ng. I f thi s antenna ri ng i s not mounted properl y
around the i gni ti on l ock cyl i nder housi ng, communi -
cati on probl ems between the SKI M and the transpon-
der may ari se. These communi cati on probl ems wi l l
resul t i n Sentry Key transponder-rel ated faul ts. The
SKI M al so communi cates over the Programmabl e
Communi cati ons I nterface (PCI ) data bus wi th the
Powertrai n Control Modul e (PCM), the El ectroMe-
chani cal I nstrument Cl uster (EMI C) and/or the
DRBI I I ௡ scan tool .
The SKI M retai ns i n memory the I D numbers of
any Sentry Key transponder that i s programmed i nto
i t. A maxi mum of ei ght Sentry Key transponders can
be programmed i nto the SKI M. For added system
securi ty, each SKI M i s programmed wi th a uni que
Secret Key code. Thi s code i s stored i n memory, sent
over the PCI data bus to the PCM, and i s encoded to
the transponder of every Sentry Key that i s pro-
grammed i nto the SKI M. Therefore, the Secret Key
code i s a common el ement that i s found i n every com-
ponent of the Sentry Key I mmobi l i zer System (SKI S).
Another securi ty code, cal l ed a PI N, i s used to gai n
access to the SKI M Secured Access Mode. The
Secured Access Mode i s requi red duri ng servi ce to
perform the SKI S i ni ti al i zati on and Sentry Key tran-
sponder programmi ng procedures. The SKI M al so
stores the Vehi cl e I denti fi cati on Number (VI N) i n i ts
memory, whi ch i t l earns through a PCI data bus
message from the PCM duri ng SKI S i ni ti al i zati on.
I n the event that a SKI M repl acement i s requi red,
the Secret Key code can be transferred to the new
SKI M from the PCM usi ng the DRBI I I ௡ scan tool
Fig. 4 PCM Location
1 - PCM MOUNTING BOLTS (3)
2 - POWERTRAIN CONTROL MODULE (PCM)
3 - BATTERY
4 - (3) 32–WAY CONNECTOR
8E - 8 ELECTRONIC CONTROL MODULES TJ
POWERTRAIN CONTROL MODULE (Continued)
and the SKI S i ni ti al i zati on procedure. Proper com-
pl eti on of the SKI S i ni ti al i zati on wi l l al l ow the exi st-
i ng Sentry Keys to be programmed i nto the new
SKI M so that new keys wi l l not be requi red. I n the
event that the ori gi nal Secret Key code cannot be
recovered, SKI M repl acement wi l l al so requi re new
Sentry Keys. The DRBI I I ௡ scan tool wi l l al ert the
techni ci an duri ng the SKI S i ni ti al i zati on procedure i f
new Sentry Keys are requi red.
When the i gni ti on swi tch i s On, the SKI M trans-
mi ts an RF si gnal to the transponder i n the i gni ti on
key. The SKI M then wai ts for an RF si gnal response
from the transponder. I f the response recei ved i den-
ti fi es the key as val i d, the SKI M sends a val i d key
message to the PCM over the PCI data bus. I f the
response recei ved i denti fi es the key as i nval i d, or i f
no response i s recei ved from the key transponder, the
SKI M sends an i nval i d key message to the PCM. The
PCM wi l l enabl e or di sabl e engi ne operati on based
upon the status of the SKI M messages. I t i s i mpor-
tant to note that the defaul t condi ti on i n the PCM i s
an i nval i d key; therefore, i f no message i s recei ved
from the SKI M by the PCM, the engi ne wi l l be di s-
abl ed and the vehi cl e i mmobi l i zed after two seconds
of runni ng.
The SKI M al so sends SKI S i ndi cator status mes-
sages to the EMI C. Thi s i ndi cator status message
tel l s the EMI C to turn the i ndi cator on for about
three seconds each ti me the i gni ti on swi tch i s turned
On, as a bul b test. The SKI M sends i ndi cator status
messages to the EMI C to turn the i ndi cator off, turn
the i ndi cator on, or to fl ash the i ndi cator on and off.
I f the SKI S i ndi cator fl ashes upon i gni ti on On or
stays on sol i d after the bul b test, i t si gni fi es a SKI S
faul t. I f the SKI M detects a system mal functi on
and/or the SKI S has become i noperati ve, the SKI S
i ndi cator wi l l stay on sol i d. I f the SKI M detects an
i nval i d key or i f a key transponder-rel ated faul t
exi sts, the SKI S i ndi cator wi l l fl ash. I f the vehi cl e i s
equi pped wi th the Customer Learn transponder pro-
grammi ng feature, the SKI M wi l l al so send messages
to the EMI C to fl ash the SKI S i ndi cator and to gen-
erate a si ngl e audi bl e chi me whenever the Customer
Learn programmi ng mode i s bei ng uti l i zed. (Refer to
8 - ELECTRI CAL/VEHI CLE THEFT SECURI TY -
STANDARD PROCEDURE - SENTRY KEY TRAN-
SPONDER PROGRAMMI NG).
The SKI S performs a sel f-test each ti me the i gni -
ti on swi tch i s turned to the On posi ti on, and wi l l
store faul t i nformati on i n the form of Di agnosti c
Fig. 5 Sentry Key Immobilizer Module - Typical
1 - UPPER SHROUD
2 - STEERING COLUMN
3 - WIRE HARNESS CONNECTOR
4 - SENTRY KEY IMMOBILIZER MODULE
5 - IGNITION LOCK CYLINDER
6 - SCREW
7 - LOWER SHROUD
8 - STEERING WHEEL
TJ ELECTRONIC CONTROL MODULES 8E - 9
SENTRY KEY IMMOBILIZER MODULE (Continued)
Troubl e Codes (DTC’s) i n SKI M memory i f a system
mal functi on i s detected. The SKI M can be di agnosed,
and any stored DTC’s can be retri eved usi ng a
DRBI I I ௡ scan tool . Refer to the appropri ate di agnos-
ti c i nformati on.
STANDARD PROCEDURE - PCM/SKIM
PROGRAMMING
CAUTION: ASSURE THE DRBIIIா IS PROGRAMMED
WITH THE LATEST VERSION OF CURRENT SOFT-
WARE.
NOTE: Before replacing the PCM for a failed driver,
control circuit, or ground circuit, be sure to check
the related component/circuit integrity for failures
not detected due to a double fault in the circuit.
Most PCM driver/control circuit failures are caused
by internal component failures (i.e. relays and sole-
noids) and shorted circuits (i.e. pull-ups, drivers,
and switched circuits). These failures are difficult to
detect when a double fault has occurred and only
one DTC has been set.
When a PCM (JTEC) and the SKI M are repl aced
at the same ti me, perform the fol l owi ng steps i n
order:
(1) Program the new PCM (JTEC).
(2) Program the new SKI M.
(3) Repl ace al l i gni ti on keys and program them to
the new SKI M.
PROGRAMMING THE PCM (JTEC)
The SKI S Secret Key i s an I D code that i s uni que
to each SKI M. Thi s code i s programmed and stored
i n the SKI M, the PCM, and the i gni ti on key tran-
sponder chi p(s). When repl aci ng the PCM, i t i s nec-
essary to program the secret key i nto the new PCM
usi ng the DRBI I I ௡ scan tool . Perform the fol l owi ng
steps to program the secret key i nto the PCM.
(1) Turn the i gni ti on swi tch to the On posi ti on
(transmi ssi on i n Park/Neutral ).
(2) Use the DRBI I I ௡ and sel ect THEFT ALARM,
SKI M, then MI SCELLANEOUS.
(3) Sel ect PCM REPLACED (GAS ENGI NE).
(4) Enter secured access mode by enteri ng the
vehi cl e four-di gi t PI N.
(5) Sel ect ENTER to update PCM VI N.
NOTE: If three attempts are made to enter secured
access mode using an incorrect PIN, secured
access mode will be locked out for one hour. To
exit this lockout mode, turn the ignition switch to
the ON position for one hour, then enter the correct
PIN. (Ensure all accessories are turned off. Also
monitor the battery state and connect a battery
charger if necessary).
(6) Press ENTER to transfer the secret key (the
SKI M wi l l send the secret key to the PCM).
(7) Press PAGE BACK to get to the Sel ect System
menu and sel ect ENGI NE, MI SCELLANEOUS, and
SRI MEMORY CHECK.
(8) The DRBI I I ௡ wi l l ask, “I s odometer readi ng
between XX and XX?” Sel ect the YES or NO button
on the DRBI I I ௡. I f NO i s sel ected, the DRBI I I ௡ wi l l
read, “Enter Odometer Readi ng (From I .P. odome-
ter)”. Enter the odometer readi ng from the i nstru-
ment cl uster and press ENTER.
PROGRAMMING THE SKIM
(1) Turn the i gni ti on swi tch to the On posi ti on
(transmi ssi on i n Park/Neutral ).
(2) Use the DRBI I I ௡ and sel ect THEFT ALARM,
SKI M, then MI SCELLANEOUS.
(3) Sel ect PCM REPLACED (GAS ENGI NE).
(4) Program the vehi cl e four-di gi t PI N i nto SKI M.
(5) Sel ect COUNTRY CODE and enter the correct
country.
NOTE: Be sure to enter the correct country code. If
the incorrect country code is programmed into
SKIM, it cannot be changed and the SKIM must be
replaced.
(6) Sel ect YES to update VI N (the SKI M wi l l l earn
the VI N from the PCM).
(7) Press ENTER to transfer the secret key (the
PCM wi l l send the secret key to the SKI M).
(8) Program i gni ti on keys to the SKI M.
NOTE: If the PCM and the SKIM are replaced at the
same time, all vehicle ignition keys will need to be
replaced and programmed to the new SKIM.
PROGRAMMING IGNITION KEYS TO THE SKIM
(1) Turn the i gni ti on swi tch to the On posi ti on
(transmi ssi on i n Park/Neutral ).
(2) Use the DRBI I I ௡ and sel ect THEFT ALARM,
SKI M, then MI SCELLANEOUS.
(3) Sel ect PROGRAM I GNI TI ON KEY’S.
(4) Enter secured access mode by enteri ng the
vehi cl e four-di gi t PI N.
NOTE: A maximum of eight keys can be learned to
each SKIM. Once a key is learned to a SKIM it (the
key) cannot be transferred to another vehicle.
(5) Obtai n i gni ti on keys to be programmed from
the customer (8 keys maxi mum).
8E - 10 ELECTRONIC CONTROL MODULES TJ
SENTRY KEY IMMOBILIZER MODULE (Continued)
(6) Usi ng the DRBI I I ௡, erase al l i gni ti on keys by
sel ecti ng MI SCELLANEOUS, and ERASE ALL CUR-
RENT I GN. KEYS.
(7) Program al l of the i gni ti on keys.
I f i gni ti on key programmi ng i s unsuccessful , the
DRBI I I ௡ wi l l di spl ay one of the fol l owi ng messages:
• Programming Not Attempted - The DRBI I I ௡
attempts to read the programmed key status and
there are no keys programmed i nto SKI M memory.
• Programming Key Failed (Possible Used
Key FromWrong Vehicle) - SKI M i s unabl e to pro-
gram an i gni ti on key transponder due to one of the
fol l owi ng:
− The i gni ti on key transponder i s faul ty.
− The i gni ti on key transponder i s or has been
al ready programmed to another vehi cl e.
• 8 Keys Already Learned, Programming Not
Done - The SKI M transponder I D memory i s ful l .
• Learned Key In Ignition - The I D for the i gni -
ti on key transponder currentl y i n the i gni ti on l ock
cyl i nder i s al ready programmed i n SKI M memory.
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the steeri ng col umn openi ng cover
from the i nstrument panel . (Refer to 23 - BODY/I N-
STRUMENT PANEL/STEERI NG COLUMN OPEN-
I NG COVER - REMOVAL).
(3) Remove the screws that secure the l ower steer-
i ng col umn shroud to the upper shroud (Fi g. 6).
(4) I f the vehi cl e i s equi pped wi th the opti onal ti l t
steeri ng col umn, move the ti l t steeri ng col umn to the
ful l y l owered posi ti on and l eave the ti l t rel ease l ever
i n the rel eased (down) posi ti on.
(5) Remove the upper and l ower shrouds from the
steeri ng col umn.
(6) On model s equi pped wi th a manual transmi s-
si on, remove the screws that secure the mul ti -func-
ti on swi tch assembl y to the upper steeri ng col umn
housi ng.
(7) Di sconnect the cross body wi re harness connec-
tor for the SKI M from the SKI M connector (Fi g. 7).
(8) The SKI M mounti ng bracket features a cl i p
that secures the SKI M to the i nboard l ower fl ange of
the steeri ng col umn jacket. Pul l downward on the
connector end of the SKI M mounti ng bracket to
rel ease thi s cl i p from the steeri ng col umn jacket.
(9) Rotate the SKI M and i ts mounti ng bracket
downwards and then to the si de away from the steer-
i ng col umn to sl i de the SKI M antenna ri ng from
around the i gni ti on swi tch l ock cyl i nder housi ng. On
model s wi th a manual transmi ssi on, l i ft the mul ti -
functi on swi tch upward off of the upper steeri ng col -
umn housi ng far enough to extract the SKI M
antenna from between the i gni ti on key rel ease but-
ton and the ri ght mul ti -functi on swi tch housi ng.
(10) Remove the SKI M from the steeri ng col umn.
Fig. 6 Steering Column Shrouds Remove/Install
1 - LEFT MULTI-FUNCTION SWITCH
2 - UPPER SHROUD
3 - RIGHT MULTI-FUNCTION SWITCH
4 - CLOCKSPRING
5 - IGNITION LOCK CYLINDER HOUSING
6 - LOWER SHROUD
7 - SCREW (2)
TJ ELECTRONIC CONTROL MODULES 8E - 11
SENTRY KEY IMMOBILIZER MODULE (Continued)
INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Posi ti on the Sentry Key I mmobi l i zer Modul e
(SKI M) (Fi g. 7). On model s wi th a manual transmi s-
si on, l i ft the mul ti -functi on swi tch upward off of the
upper steeri ng col umn housi ng far enough to i nsert
the SKI M antenna formati on between the i gni ti on
key rel ease button and the mul ti -functi on swi tch
housi ng.
(2) Sl i de the SKI M antenna ri ng around the i gni -
ti on swi tch l ock cyl i nder housi ng, then rotate the
SKI M and i ts mounti ng bracket upwards and toward
the steeri ng col umn.
(3) Al i gn the SKI M mounti ng bracket cl i p wi th the
i nboard l ower fl ange of the steeri ng col umn and,
push upward fi rml y on the connector end of the
SKI M mounti ng bracket to engage the cl i p wi th the
steeri ng col umn.
(4) Reconnect the cross body wi re harness connec-
tor for the SKI M to the SKI M connector.
(5) On model s equi pped wi th a manual transmi s-
si on, i nstal l and ti ghten the screws that secure the
mul ti -functi on swi tch assembl y to the upper steeri ng
col umn housi ng. Ti ghten the screws to 2 N·m (20 i n.
l bs.).
(6) Posi ti on both the upper and l ower shrouds onto
the steeri ng col umn (Fi g. 6).
(7) I nstal l and ti ghten the screws that secure the
l ower steeri ng col umn shroud to the upper shroud.
Ti ghten the screws to 2 N·m (18 i n. l bs.).
(8) Move the ti l t steeri ng col umn to the ful l y
rai sed posi ti on and secure i t i n pl ace by movi ng the
ti l t rel ease l ever back to the l ocked (up) posi ti on.
(9) Rei nstal l the steeri ng col umn openi ng cover.
(Refer to 23 - BODY/I NSTRUMENT PANEL/STEER-
I NG COLUMN OPENI NG COVER - I NSTALLATI ON).
Fig. 7 Sentry Key Immobilizer Module - Typical
1 - UPPER SHROUD
2 - STEERING COLUMN
3 - WIRE HARNESS CONNECTOR
4 - SENTRY KEY IMMOBILIZER MODULE
5 - IGNITION LOCK CYLINDER
6 - SCREW
7 - LOWER SHROUD
8 - STEERING WHEEL
8E - 12 ELECTRONIC CONTROL MODULES TJ
SENTRY KEY IMMOBILIZER MODULE (Continued)
(10) Reconnect the battery negati ve cabl e.
NOTE: If the SKIM has been replaced with a new
unit, the Sentry Key Immobilizer System (SKIS)
MUST be initialized before the vehicle can be oper-
ated. (Refer to 8 - ELECTRICAL/VEHICLE THEFT
SECURITY - STANDARD PROCEDURE - SKIS INI-
TIALIZATION).
TRANSMISSION CONTROL
MODULE
DESCRIPTION
The Transmi ssi on Control Modul e (TCM) i s l ocated
i n the engi ne compartment on the l eft (dri ver’s) si de
and i s mounted to the i nner fender (Fi g. 8).
OPERATION
The TCM i s the control l i ng uni t for al l el ectroni c
operati ons of the transmi ssi on. The TCM recei ves
i nformati on regardi ng vehi cl e operati on from both
di rect and i ndi rect i nputs, and sel ects the operati onal
mode of the transmi ssi on. Di rect i nputs are hard-
wi red to, and used speci fi cal l y by the TCM. I ndi rect
i nputs ori gi nate from other components/modul es, and
are shared wi th the TCM vi a the PCI bus.
Some exampl es of direct inputs to the TCM are:
• Battery (B+) vol tage
• I gni ti on “ON” vol tage
• Transmi ssi on Control Rel ay (Swi tched B+)
• Throttl e Posi ti on Sensor
• Crankshaft Posi ti on Sensor (CKP)
• Transmi ssi on Range Sensor (TRS)
• Pressure Swi tches (L/R, 2/4, OD)
• Transmi ssi on Temperature Sensor (I ntegral to
TRS)
• I nput Shaft Speed Sensor
• Output Shaft Speed Sensor
Some exampl es of indirect inputs to the TCM
are:
• Engi ne/Body I denti fi cati on
• Mani fol d Pressure
• Target I dl e
• Torque Reducti on Confi rmati on
• Speed Control ON/OFF Swi tch
• Engi ne Cool ant Temperature
• Ambi ent/Battery Temperature
• Brake Swi tch Status
• DRB௡ I I I Communi cati on
Based on the i nformati on recei ved from these var-
i ous i nputs, the TCM determi nes the appropri ate
shi ft schedul e and shi ft poi nts, dependi ng on the
present operati ng condi ti ons and dri ver demand.
Thi s i s possi bl e through the control of vari ous di rect
and i ndi rect outputs.
Some exampl es of TCM direct outputs are:
• Transmi ssi on Control Rel ay
• Sol enoi ds (L/R, 2/4, OD and UD)
• Vehi cl e Speed (to PCM)
• Torque Reducti on Request (to PCM)
Some exampl es of TCM indirect outputs are:
• Transmi ssi on Temperature (to PCM)
• PRNDL Posi ti on (to BCM)
I n addi ti on to moni tori ng i nputs and control l i ng
outputs, the TCM has other i mportant responsi bi l i -
ti es and functi ons:
• Stori ng and mai ntai ni ng Cl utch Vol ume I ndi ces
(CVI )
• Stori ng and sel ecti ng appropri ate Shi ft Sched-
ul es
• System sel f-di agnosti cs
• Di agnosti c capabi l i ti es (wi th DRB௡ I I I scan tool )
NOTE: If the TCM has been replaced, the “Quick
Learn Procedure” must be performed. (Refer to 8 -
ELECTRICAL/ELECTRONIC CONTROL MODULES/
TRANSMISSION CONTROL MODULE - STANDARD
PROCEDURE)
CLUTCH VOLUME INDEX (CVI)
An i mportant functi on of the TCM i s to moni tor
Cl utch Vol ume I ndex (CVI ). CVI s represent the vol -
ume of fl ui d needed to compress a cl utch pack.
The TCM moni tors gear rati o changes by moni tor-
i ng the I nput and Output Speed Sensors. The I nput,
or Turbi ne Speed Sensor sends an el ectri cal si gnal to
the TCM that represents i nput shaft rpm. The Out-
put Speed Sensor provi des the TCM wi th output
shaft speed i nformati on.
Fig. 8 Transmission Control Module Location
1 - TRANSMISSION CONTROL MODULE
TJ ELECTRONIC CONTROL MODULES 8E - 13
SENTRY KEY IMMOBILIZER MODULE (Continued)
By compari ng the two i nputs, the TCM can deter-
mi ne transmi ssi on gear posi ti on. Thi s i s i mportant to
the CVI cal cul ati on because the TCM determi nes
CVI s by moni tori ng how l ong i t takes for a gear
change to occur (Fi g. 9).
Gear rati os can be determi ned by usi ng the DRB௡
I I I Scan Tool and readi ng the I nput/Output Speed
Sensor val ues i n the “Moni tors” di spl ay. Gear rati o
can be obtai ned by di vi di ng the I nput Speed Sensor
val ue by the Output Speed Sensor val ue.
For exampl e, i f the i nput shaft i s rotati ng at 1000
rpm and the output shaft i s rotati ng at 500 rpm,
then the TCM can determi ne that the gear rati o i s
2:1. I n di rect dri ve (3rd gear), the gear rati o changes
to 1:1. The gear rati o changes as cl utches are appl i ed
and rel eased. By moni tori ng the l ength of ti me i t
takes for the gear rati o to change fol l owi ng a shi ft
request, the TCM can determi ne the vol ume of fl ui d
used to appl y or rel ease a fri cti on el ement.
The vol ume of transmi ssi on fl ui d needed to appl y
the fri cti on el ements are conti nuousl y updated for
adapti ve control s. As fri cti on materi al wears, the vol -
ume of fl ui d need to appl y the el ement i ncreases.
Certai n mechani cal probl ems wi thi n the i nput
cl utch assembl y (broken return spri ngs, out of posi -
ti on snap ri ngs, excessi ve cl utch pack cl earance,
i mproper assembl y, etc.) can cause i nadequate or out-
of-range el ement vol umes. Al so, defecti ve I nput/Out-
put Speed Sensors and wi ri ng can cause these
condi ti ons. The fol l owi ng chart i denti fi es the appro-
pri ate cl utch vol umes and when they are moni tored/
updated:
CLUTCH VOLUMES
Clutch
When Updated
Proper Clutch
Volume
Shift Sequence Oil Temperature Throttle Angle
L/R
2-1 or 3-1 coast
downshift
> 70° < 5° 35 to 83
2/4 1-2 shift
> 110°
5 - 54°
20 to 77
OD 2-3 shift 48 to 150
UD 4-3 or 4-2 shift > 5° 24 to 70
SHIFT SCHEDULES
As menti oned earl i er, the TCM has programmi ng
that al l ows i t to sel ect a vari ety of shi ft schedul es.
Shi ft schedul e sel ecti on i s dependent on the fol l ow-
i ng:
• Shi ft l ever posi ti on
• Throttl e posi ti on
• Engi ne l oad
• Fl ui d temperature
• Software l evel
As dri vi ng condi ti ons change, the TCM appropri -
atel y adjusts the shi ft schedul e. Refer to the fol l ow-
i ng tabl e 42RLE Shi ft Schedul e to determi ne the
appropri ate operati on expected, dependi ng on dri vi ng
condi ti ons.
Fig. 9 Example of CVI Calculation
1 - OUTPUT SPEED SENSOR
2 - OUTPUT SHAFT
3 - CLUTCH PACK
4 - SEPARATOR PLATE
5 - FRICTION DISCS
6 - INPUT SHAFT
7 - INPUT SPEED SENSOR
8 - PISTON AND SEAL
8E - 14 ELECTRONIC CONTROL MODULES TJ
TRANSMISSION CONTROL MODULE (Continued)
42RLE SHIFT SCHEDULE
Schedule Condition Expected Operation
Extreme Cold Oil temperature at start-up below
-16°F
Park, Reverse, Neutral and 2nd
gear only (prevents shifting which
may fail a clutch with frequent
shifts)
Cold Oil temperature at start-up above
-12°F and below 36°F
– Delayed 2-3 upshift
(approximately 22-31 mph)
– Delayed 3-4 upshift (45-53 mph)
– Early 4-3 costdown shift
(approximately 30 mph)
– Early 3-2 coastdown shift
(approximately 17 mph)
– High speed 4-2, 3-2, 2-1 kickdown
shifts are prevented
– No EMCC
Warm Oil temperature at start-up above
36°F and below 80 degree F
– Normal operation (upshift,
kickdowns, and coastdowns)
– No EMCC
Hot Oil temperature at start-up above
80°F
– Normal operation (upshift,
kickdowns, and coastdowns)
– Full EMCC, no PEMCC except to
engage FEMCC (except at closed
throttle at speeds above 70-83 mph)
Overheat Oil temperature above 240°F or
engine coolant temperature above
244°F
– Delayed 2-3 upshift (25-32 mph)
– Delayed 3-4 upshift (41-48 mph)
– 3rd gear FEMCC from 30-48 mph
– 3rd gear PEMCC from 27-31 mph
Super Overheat Oil temperature above 260°F – All ЉOverheatЉ shift schedule
features apply
– 2nd gear PEMCC above 22 mph
– Above 22 mph the torque
converter will not unlock unless the
throttle is closed or if a wide open
throttle 2nd PEMCC to 1 kickdown
is made
TJ ELECTRONIC CONTROL MODULES 8E - 15
TRANSMISSION CONTROL MODULE (Continued)
STANDARD PROCEDURE - TCM QUICK LEARN
The qui ck l earn procedure requi res the use of the
DRB௡ scan tool .
Thi s program al l ows the el ectroni c transmi ssi on
system to recal i brate i tsel f. Thi s wi l l provi de the
proper transmi ssi on operati on. The qui ck l earn pro-
cedure shoul d be performed i f any of the fol l owi ng
procedures are performed:
• Transmi ssi on Assembl y Repl acement
• Transmi ssi on Control Modul e Repl acement
• Sol enoi d Pack Repl acement
• Cl utch Pl ate and/or Seal Repl acement
• Val ve Body Repl acement or Recondi ti on
To perform the Qui ck Learn Procedure, the fol l ow-
i ng condi ti ons must be met:
• The brakes must be appl i ed
• The engi ne speed must be above 500 rpm
• The throttl e angl e (TPS) must be l ess than 3
degrees
• The shi ft l ever posi ti on must stay i n PARK unti l
prompted to shi ft to overdri ve
• The shi ft l ever posi ti on must stay i n overdri ve
after the Shi ft to Overdri ve prompt unti l the DRB௡
i ndi cates the procedure i s compl ete
• The cal cul ated oi l temperature must be above
60° and bel ow 200°
8E - 16 ELECTRONIC CONTROL MODULES TJ
TRANSMISSION CONTROL MODULE (Continued)
ENGINE SYSTEMS
TABLE OF CONTENTS
page page
BATTERY SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 1
CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
BATTERY SYSTEM
TABLE OF CONTENTS
page page
BATTERY SYSTEM
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DIAGNOSIS AND TESTING - BATTERY
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SPECIFICATIONS
BATTERY SYSTEM SPECIFICATIONS . . . . . . . 6
SPECIAL TOOLS
BATTERY SYSTEM SPECIAL TOOLS . . . . . . . 7
BATTERY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
DIAGNOSIS AND TESTING - BATTERY . . . . . . . 8
STANDARD PROCEDURE
STANDARD PROCEDURE - BATTERY
CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
STANDARD PROCEDURE - BUILT-IN
INDICATOR TEST . . . . . . . . . . . . . . . . . . . . . 10
STANDARD PROCEDURE - OPEN-CIRCUIT
VOLTAGE TEST . . . . . . . . . . . . . . . . . . . . . . . 11
STANDARD PROCEDURE - IGNITION-OFF
DRAW TEST . . . . . . . . . . . . . . . . . . . . . . . . . 11
STANDARD PROCEDURE - USING MICRO
420 BATTERY TESTER . . . . . . . . . . . . . . . . . 12
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14
BATTERY HOLDDOWN
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 14
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 15
BATTERY CABLES
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 16
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
DIAGNOSIS AND TESTING - BATTERY
CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 18
BATTERY TRAY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 19
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 20
BATTERY SYSTEM
DESCRIPTION
A si ngl e 12-vol t battery i s standard factory-i n-
stal l ed equi pment on thi s model . Al l of the compo-
nents of the battery system are l ocated wi thi n the
engi ne compartment of the vehi cl e. The battery sys-
tem for thi s vehi cl e covers the fol l owi ng rel ated com-
ponents, whi ch are covered i n further detai l l ater i n
thi s secti on of the servi ce manual :
• Battery - The storage battery provi des a rel i -
abl e means of stori ng a renewabl e source of el ectri cal
energy wi thi n the vehi cl e.
• Battery Cable - The battery cabl es connect the
battery termi nal posts to the vehi cl e el ectri cal sys-
tem.
• Battery Holddown - The battery hol ddown
hardware secures the battery i n the battery tray i n
the engi ne compartment.
TJ ENGINE SYSTEMS 8F - 1
• Battery Tray - The battery tray provi des a
secure mounti ng l ocati on i n the vehi cl e for the bat-
tery and an anchor poi nt for the battery hol ddown
hardware.
For battery system mai ntenance schedul es and
jump starti ng procedures, see the owner’s manual i n
the vehi cl e gl ove box. Opti onal l y, refer to the Lubri -
cati on and Mai ntenance secti on of thi s manual for
the recommended battery mai ntenance schedul es and
for the proper battery jump starti ng procedure. Whi l e
battery chargi ng can be consi dered a mai ntenance
procedure, the battery chargi ng procedure and
rel ated i nformati on are l ocated l ater i n thi s secti on of
thi s servi ce manual . Thi s was done because the bat-
tery must be ful l y-charged before any battery system
di agnosi s or testi ng procedures can be performed.
OPERATION
The battery system i s desi gned to provi de a safe,
effi ci ent, rel i abl e and mobi l e means of del i veri ng and
stori ng el ectri cal energy. Thi s el ectri cal energy i s
requi red to operate the engi ne starti ng system, as
wel l as to operate many of the other vehi cl e acces-
sory systems for l i mi ted durati ons whi l e the engi ne
and/or the chargi ng system are not operati ng. The
battery system i s al so desi gned to provi de a reserve
of el ectri cal energy to suppl ement the chargi ng sys-
tem for short durati ons whi l e the engi ne i s runni ng
and the el ectri cal current demands of the vehi cl e
exceed the output of the chargi ng system. I n addi ti on
to del i veri ng, and stori ng el ectri cal energy for the
vehi cl e, the battery system serves as a capaci tor and
vol tage stabi l i zer for the vehi cl e el ectri cal system. I t
absorbs most abnormal or transi ent vol tages caused
by the swi tchi ng of any of the el ectri cal components
or ci rcui ts i n the vehi cl e.
DIAGNOSIS AND TESTING - BATTERY SYSTEM
The battery, starti ng, and chargi ng systems i n the
vehi cl e operate wi th one another and must be tested
as a compl ete system. I n order for the engi ne to start
and the battery to mai ntai n i ts charge properl y, al l of
the components that are used i n these systems must
perform wi thi n speci fi cati ons. I t i s i mportant that
the battery, starti ng, and chargi ng systems be thor-
oughl y tested and i nspected any ti me a battery needs
to be charged or repl aced. The cause of abnormal bat-
tery di scharge, overchargi ng or earl y battery fai l ure
must be di agnosed and corrected before a battery i s
repl aced and before a vehi cl e i s returned to servi ce.
The servi ce i nformati on for these systems has been
separated wi thi n thi s servi ce manual to make i t eas-
i er to l ocate the speci fi c i nformati on you are seeki ng.
However, when attempti ng to di agnose any of these
systems, i t i s i mportant that you keep thei r i nterde-
pendency i n mi nd.
The di agnosti c procedures used for the battery,
starti ng, and chargi ng systems i ncl ude the most
basi c conventi onal di agnosti c methods, to the more
sophi sti cated On-Board Di agnosti cs (OBD) bui l t i nto
the Powertrai n Control Modul e (PCM). Use of an
i nducti on-type mi l l i ampere ammeter, a vol t/ohmme-
ter, a battery charger, a carbon pi l e rheostat (l oad
tester) and a 12-vol t test l amp may be requi red. Al l
OBD-sensed systems are moni tored by the PCM.
Each moni tored ci rcui t i s assi gned a Di agnosti c Trou-
bl e Code (DTC). The PCM wi l l store a DTC i n el ec-
troni c memory for any fai l ure i t detects. Refer to
Chargi ng System for the proper chargi ng system on-
board di agnosti c test procedures.
MICRO 420 BATTERY TESTER
The Mi cro 420 automoti ve battery tester i s
desi gned to hel p the deal ershi p techni ci ans di agnose
a defecti ve battery. Fol l ow the i nstructi on manual
suppl i ed wi th the tester to properl y di agnose a vehi -
cl e. I f the i nstructi on manual i s not avai l abl e refer to
the standard procedure i n thi s secti on, whi ch
i ncl udes the di recti ons for usi ng the Mi cro 420 bat-
tery tester.
8F - 2 BATTERY SYSTEM TJ
BATTERY SYSTEM (Continued)
BATTERY SYSTEM DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
THE BATTERY SEEMS
WEAK OR DEAD WHEN
ATTEMPTING TO START
THE ENGINE.
1. The electrical system
ignition-off draw is excessive.
1. Refer to the IGNITION-OFF DRAW TEST
Standard Procedure for the proper test
procedures. Repair the excessive ignition-off
draw, as required.
2. The charging system is
faulty.
2. Determine if the charging system is performing
to specifications. Refer to Charging System for
charging system diagnosis and testing
procedures. Repair the faulty charging system, as
required.
3. The battery is discharged. 3. Determine the battery state-of-charge using the
Micro 420 battery tester. Refer to the Standard
Procedures in this section for additional test
procedures. Charge the faulty battery, as
required.
4. The battery terminal
connections are loose or
corroded.
4. Refer to Battery Cables for the proper battery
cable diagnosis and testing procedures. Clean
and tighten the battery terminal connections, as
required.
5. The battery has an
incorrect size or rating for
this vehicle.
5. Refer to Battery System Specifications for the
proper size and rating. Replace an incorrect
battery, as required.
6. The battery is faulty. 6. Determine the battery cranking capacity using
the Micro 420 battery tester. Refer to the
Standard Procedures in this section for additional
test procedures. Replace the faulty battery, as
required.
7. The starting system is
faulty.
7. Determine if the starting system is performing
to specifications. Refer to Starting System for the
proper starting system diagnosis and testing
procedures. Repair the faulty starting system, as
required.
8. The battery is physically
damaged.
8. Inspect the battery for loose terminal posts or a
cracked and leaking case. Replace the damaged
battery, as required.
TJ BATTERY SYSTEM 8F - 3
BATTERY SYSTEM (Continued)
BATTERY SYSTEM 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.
1. Refer to Battery System Specifications for the
proper specifications. Replace an incorrect
battery, as required.
2. The battery terminal
connections are loose or
corroded.
2. Refer to Battery Cable for the proper cable
diagnosis and testing procedures. Clean and
tighten the battery terminal connections, as
required.
3. The electrical system
ignition-off draw is excessive.
3. Refer to the IGNITION-OFF DRAW TEST
Standard Procedure for the proper test
procedures. Repair the faulty electrical system, as
required.
4. The battery is faulty. 4. Test the battery using the Micro 420 battery
tester. Refer to Standard Procedures for
additional test procedures. Replace the faulty
battery, as required.
5. The starting system is
faulty.
5. Determine if the starting system is performing
to specifications. Refer to Starting System for the
proper starting system diagnosis and testing
procedures. Repair the faulty starting system, as
required.
6. The charging system is
faulty.
6. Determine if the charging system is performing
to specifications. Refer to Charging System for
additional charging system diagnosis and testing
procedures. Repair the faulty charging system, as
required.
7. Electrical loads exceed the
output of the charging
system.
7. Inspect the vehicle for aftermarket electrical
equipment which might cause excessive electrical
loads.
8. Slow driving or prolonged
idling with high-amperage
draw systems in use.
8. Advise the vehicle operator, as required.
THE BATTERY WILL NOT
ACCEPT A CHARGE.
1. The battery is faulty. 1. Test the battery using the Micro 420 battery
tester. Charge or replace the faulty battery, as
required.
ABNORMAL BATTERY DISCHARGING
Any of the fol l owi ng condi ti ons can resul t i n abnor-
mal battery di schargi ng:
1. A faul ty or i ncorrect chargi ng system compo-
nent. Refer to Chargi ng System for chargi ng system
di agnosi s and testi ng procedures.
2. A faul ty or i ncorrect battery. Use Mi cro 420 bat-
tery tester and refer to Battery System for addi ti onal
battery di agnosi s and testi ng procedures.
3. A faul ty ci rcui t or component causi ng excessi ve
i gni ti on-off draw.
4. El ectri cal l oads that exceed the output of the
chargi ng system. Thi s can be due to equi pment
i nstal l ed after manufacture, or repeated short tri p
use.
5. A faul ty or i ncorrect starti ng system component.
Refer to Starti ng System for the proper starti ng sys-
tem di agnosi s and testi ng procedures.
6. Corroded or l oose battery posts and/or termi nal
cl amps.
7. Sl ow dri vi ng speeds (heavy traffi c condi ti ons) or
prol onged i dl i ng, wi th hi gh-amperage draw systems
i n use.
CLEANING
The fol l owi ng i nformati on detai l s the recommended
cl eani ng procedures for the battery and rel ated com-
8F - 4 BATTERY SYSTEM TJ
BATTERY SYSTEM (Continued)
ponents. I n addi ti on to the mai ntenance schedul es
found i n thi s servi ce manual and the owner’s man-
ual , i t i s recommended that these procedures be per-
formed any ti me the battery or rel ated components
must be removed for vehi cl e servi ce.
(1) Cl ean the battery cabl e termi nal cl amps of al l
corrosi on. Remove any corrosi on usi ng a wi re brush
or a post and termi nal cl eani ng tool , and a sodi um
bi carbonate (baki ng soda) and warm water cl eani ng
sol uti on (Fi g. 1).
(2) Cl ean the battery tray and battery hol d down
hardware of al l corrosi on. Remove any corrosi on
usi ng a wi re brush and a sodi um bi carbonate (baki ng
soda) and warm water cl eani ng sol uti on. Pai nt any
exposed bare metal .
(3) I f the removed battery i s to be rei nstal l ed,
cl ean the outsi de of the battery case and the top
cover wi th a sodi um bi carbonate (baki ng soda) and
warm water cl eani ng sol uti on usi ng a sti ff bri stl e
parts cl eani ng brush to remove any aci d fi l m (Fi g. 2).
Ri nse the battery wi th cl ean water. Ensure that the
cl eani ng sol uti on does not enter the battery cel l s
through the vent hol es. I f the battery i s bei ng
repl aced, refer to Battery System Speci fi cati ons for
the factory-i nstal l ed battery speci fi cati ons. Confi rm
that the repl acement battery i s the correct si ze and
has the correct rati ngs for the vehi cl e.
(4) I f the vehi cl e i s so equi pped, cl ean the battery
thermal guard wi th a sodi um bi carbonate (baki ng
soda) and warm water cl eani ng sol uti on usi ng a sti ff
bri stl e parts cl eani ng brush to remove any aci d fi l m.
(5) Cl ean any corrosi on from the battery termi nal
posts wi th a wi re brush or a post and termi nal
cl eaner, and a sodi um bi carbonate (baki ng soda) and
warm water cl eani ng sol uti on (Fi g. 3).
Fig. 1 Clean Battery Cable Terminal Clamp - Typical
1 - TERMINAL BRUSH
2 - BATTERY CABLE
Fig. 2 Battery Cleaning - Typical
1 - CLEANING BRUSH
2 - WARM WATER AND BAKING SODA SOLUTION
3 - BATTERY
Fig. 3 Clean Battery Terminal Post - Typical
1 - TERMINAL BRUSH
2 - BATTERY CABLE
3 - BATTERY
TJ BATTERY SYSTEM 8F - 5
BATTERY SYSTEM (Continued)
INSPECTION
The fol l owi ng i nformati on detai l s the recommended
i nspecti on procedures for the battery and rel ated
components. I n addi ti on to the mai ntenance sched-
ul es found i n thi s servi ce manual and the owner’s
manual , i t i s recommended that these procedures be
performed any ti me the battery or rel ated compo-
nents must be removed for vehi cl e servi ce.
(1) I nspect the battery cabl e termi nal cl amps for
damage. Repl ace any battery cabl e that has a dam-
aged or deformed termi nal cl amp.
(2) I nspect the battery tray and battery hol ddown
hardware for damage. Repl ace any damaged parts.
(3) Sl i de the thermal guard off of the battery case.
I nspect the battery case for cracks or other damage
that coul d resul t i n el ectrol yte l eaks. Al so, check the
battery termi nal posts for l ooseness. Batteri es wi th
damaged cases or l oose termi nal posts must be
repl aced.
(4) I nspect the battery thermal guard for tears,
cracks, deformati on or other damage. Repl ace any
battery thermal guard that has been damaged.
(5) I nspect the battery bui l t-i n test i ndi cator si ght
gl ass for an i ndi cati on of the battery condi ti on. I f the
battery i s di scharged, charge as requi red. Refer to
Standard Procedures for the proper battery bui l t-i n
i ndi cator test procedures. Al so refer to Standard Pro-
cedures for the proper battery chargi ng procedures.
SPECIFICATIONS
BATTERY SYSTEM SPECIFICATIONS
The battery Group Si ze number, the Col d Cranki ng
Amperage (CCA) rati ng, and the Reserve Capaci ty
(RC) rati ng or Ampere-Hours (AH) rati ng can be
found on the ori gi nal equi pment battery l abel . Be
certai n that a repl acement battery has the correct
Group Si ze number, as wel l as CCA, and RC or AH
rati ngs that equal or exceed the ori gi nal equi pment
speci fi cati on for the vehi cl e bei ng servi ced. Battery
si zes and rati ngs are di scussed i n more detai l bel ow.
• Group Size - The outsi de di mensi ons and ter-
mi nal pl acement of the battery conform to standards
establ i shed by the Battery Counci l I nternati onal
(BCI ). Each battery i s assi gned a BCI Group Si ze
number to hel p i denti fy a correctl y-si zed repl ace-
ment.
• Cold Cranking Amperage - The Col d Crank-
i ng Amperage (CCA) rati ng speci fi es how much cur-
rent (i n amperes) the battery can del i ver for thi rty
seconds at -18° C (0° F). Termi nal vol tage must not
fal l bel ow 7.2 vol ts duri ng or after the thi rty second
di scharge peri od. The CCA requi red i s general l y
hi gher as engi ne di spl acement i ncreases, dependi ng
al so upon the starter current draw requi rements.
• Reserve Capacity - The Reserve Capaci ty (RC)
rati ng speci fi es the ti me (i n mi nutes) i t takes for bat-
tery termi nal vol tage to fal l bel ow 10.5 vol ts, at a
di scharge rate of 25 amperes. RC i s determi ned wi th
the battery ful l y-charged at 26.7° C (80° F). Thi s rat-
i ng esti mates how l ong the battery mi ght l ast after a
chargi ng system fai l ure, under mi ni mum el ectri cal
l oad.
• Ampere-Hours - The Ampere-Hours (AH) rat-
i ng speci fi es the current (i n amperes) that a battery
can del i ver steadi l y for twenty hours, wi th the vol t-
age i n the battery not fal l i ng bel ow 10.5 vol ts. Thi s
rati ng i s al so someti mes i denti fi ed as the twenty-
hour di scharge rati ng.
Battery Classifications and Ratings
Part Number
BCI Group Size
Classification
Cold Cranking
Amperage
Reserve
Capacity
Ampere-Hours
Load Test
Amperage
04609365AC 34 600 120 Minutes 66 300
8F - 6 BATTERY SYSTEM TJ
BATTERY SYSTEM (Continued)
SPECIAL TOOLS
BATTERY SYSTEM SPECIAL TOOLS
BATTERY
DESCRIPTION
A l arge capaci ty, l ow-mai ntenance storage battery
(Fi g. 4) i s standard factory-i nstal l ed equi pment on
thi s model . Refer to Battery Speci fi cati ons for the
proper speci fi cati ons of the factory-i nstal l ed batteri es
avai l abl e on thi s model . Mal e post type termi nal s
made of a soft l ead materi al protrude from the top of
the mol ded pl asti c battery case to provi de the means
for connecti ng the battery to the vehi cl e el ectri cal
system. The battery posi ti ve termi nal post i s physi -
cal l y l arger i n di ameter than the negati ve termi nal
post to ensure proper battery connecti on. The l etters
POS and NEG are al so mol ded i nto the top of the
battery case adjacent to thei r respecti ve posi ti ve and
negati ve termi nal posts for i denti fi cati on confi rma-
ti on (Refer to 8 - ELECTRI CAL/BATTERY SYSTEM/
CABLES - DESCRI PTI ON).
The battery i s made up of si x i ndi vi dual cel l s that
are connected i n seri es. Each cel l contai ns posi ti vel y
charged pl ate groups that are connected wi th l ead
straps to the posi ti ve termi nal post, and negati vel y
charged pl ate groups that are connected wi th l ead
straps to the negati ve termi nal post. Each pl ate con-
si sts of a sti ff mesh framework or gri d coated wi th
l ead di oxi de (posi ti ve pl ate) or sponge l ead (negati ve
pl ate). I nsul ators or pl ate separators made of a non-
conducti ve materi al are i nserted between the posi ti ve
and negati ve pl ates to prevent them from contacti ng
or shorti ng agai nst one another. These di ssi mi l ar
metal pl ates are submerged i n a sul furi c aci d and
water sol uti on cal l ed an el ectrol yte.
The factory-i nstal l ed battery has a bui l t-i n test
i ndi cator (hydrometer). The col or vi si bl e i n the si ght
gl ass of the i ndi cator wi l l reveal the battery condi -
ti on. Refer to Standard Procedures for the proper
bui l t-i n i ndi cator test procedures. The factory-in-
stalled low-maintenance battery has removable
battery cell caps. Water can be added to thi s bat-
tery. The battery i s not seal ed and has vent hol es i n
the cel l caps. The chemi cal composi ti on of the metal
coated pl ates wi thi n the l ow-mai ntenance battery
reduces battery gassi ng and water l oss, at normal
charge and di scharge rates. Therefore, the battery
shoul d not requi re addi ti onal water i n normal ser-
vi ce. I f the el ectrol yte l evel i n thi s battery does
become l ow, water must be added. However, rapi d
l oss of el ectrol yte can be caused by an overchargi ng
condi ti on. Be certai n to di agnose the chargi ng system
after repl eni shi ng the water i n the battery for a l ow
el ectrol yte condi ti on and before returni ng the vehi cl e
to servi ce (Refer to 8 - ELECTRI CAL/CHARGI NG -
DI AGNOSI S AND TESTI NG).
MICRO 420 BATTERY TESTER
Fig. 4 Low-Maintenance Battery - Typical
1 - POSITIVE POST
2 - VENT
3 - CELL CAP
4 - VENT
5 - CELL CAP
6 - VENT
7 - NEGATIVE POST
8 - GREEN BALL
9 - ELECTROLYTE LEVEL
10 - PLATE GROUPS
11 - LOW-MAINTENANCE BATTERY
TJ BATTERY SYSTEM 8F - 7
BATTERY SYSTEM (Continued)
OPERATION
The battery i s desi gned to store el ectri cal energy i n
a chemi cal form. When an el ectri cal l oad i s appl i ed to
the termi nal s of the battery, an el ectrochemi cal reac-
ti on occurs. Thi s reacti on causes the battery to di s-
charge el ectri cal current from i ts termi nal s. As the
battery di scharges, a gradual chemi cal change takes
pl ace wi thi n each cel l . The sul furi c aci d i n the el ec-
trol yte combi nes wi th the pl ate materi al s, causi ng
both pl ates to sl owl y change to l ead sul fate. At the
same ti me, oxygen from the posi ti ve pl ate materi al
combi nes wi th hydrogen from the sul furi c aci d, caus-
i ng the el ectrol yte to become mai nl y water. The
chemi cal changes wi thi n the battery are caused by
the movement of excess or free el ectrons between the
posi ti ve and negati ve pl ate groups. Thi s movement of
el ectrons produces a fl ow of el ectri cal current
through the l oad devi ce attached to the battery ter-
mi nal s.
As the pl ate materi al s become more si mi l ar chem-
i cal l y, and the el ectrol yte becomes l ess aci d, the vol t-
age potenti al of each cel l i s reduced. However, by
chargi ng the battery wi th a vol tage hi gher than that
of the battery i tsel f, the battery di schargi ng process
i s reversed. Chargi ng the battery gradual l y changes
the sul fated l ead pl ates back i nto sponge l ead and
l ead di oxi de, and the water back i nto sul furi c aci d.
Thi s acti on restores the di fference i n the el ectron
charges deposi ted on the pl ates, and the vol tage
potenti al of the battery cel l s. For a battery to remai n
useful , i t must be abl e to produce hi gh-amperage cur-
rent over an extended peri od. A battery must al so be
abl e to accept a charge, so that i ts vol tage potenti al
may be restored.
The battery i s vented to rel ease excess hydrogen
gas that i s created when the battery i s bei ng charged
or di scharged. However, even wi th these vents,
hydrogen gas can col l ect i n or around the battery. I f
hydrogen gas i s exposed to fl ame or sparks, i t may
i gni te. I f the el ectrol yte l evel i s l ow, the battery may
arc i nternal l y and expl ode. I f the battery i s equi pped
wi th removabl e cel l caps, add di sti l l ed water when-
ever the el ectrol yte l evel i s bel ow the top of the
pl ates. I f the battery cel l caps cannot be removed, the
battery must be repl aced i f the el ectrol yte l evel
becomes l ow.
DIAGNOSIS AND TESTING - BATTERY
The battery must be compl etel y charged and the
termi nal s shoul d be properl y cl eaned and i nspected
before di agnosti c procedures are performed. Refer to
Battery System Cl eani ng for the proper cl eani ng pro-
cedures, and Battery System I nspecti on for the
proper battery i nspecti on procedures. Refer to Stan-
dard Procedures for the proper battery chargi ng pro-
cedures.
MICRO 420 BATTERY TESTER
The Mi cro 420 automoti ve battery tester i s
desi gned to hel p the deal ershi p techni ci ans di agnose
the cause of a defecti ve battery. Fol l ow the i nstruc-
ti on manual suppl i ed wi th the tester to properl y
di agnose a vehi cl e. I f the i nstructi on manual i s not
avai l abl e refer to the standard procedure i n thi s sec-
ti on, whi ch i ncl udes the di recti ons for usi ng the
Mi cro 420 battery tester.
WARNING: IF THE BATTERY SHOWS SIGNS OF
FREEZING, LEAKING OR LOOSE POSTS, DO NOT
TEST, ASSIST-BOOST, OR CHARGE. THE BATTERY
MAY ARC INTERNALLY AND EXPLODE. PERSONAL
INJURY AND/OR VEHICLE DAMAGE MAY RESULT.
WARNING: EXPLOSIVE HYDROGEN GAS FORMS IN
AND AROUND THE BATTERY. DO NOT SMOKE,
USE FLAME, OR CREATE SPARKS NEAR THE BAT-
TERY. PERSONAL INJURY AND/OR VEHICLE DAM-
AGE MAY RESULT.
WARNING: THE BATTERY CONTAINS SULFURIC
ACID, WHICH IS POISONOUS AND CAUSTIC. AVOID
CONTACT WITH THE SKIN, EYES, OR CLOTHING.
IN THE EVENT OF CONTACT, FLUSH WITH WATER
AND CALL A PHYSICIAN IMMEDIATELY. KEEP OUT
OF THE REACH OF CHILDREN.
A battery that wi l l not accept a charge i s faul ty,
and must be repl aced. Further testi ng i s not
requi red. A ful l y-charged battery must be l oad tested
to determi ne i ts cranki ng capaci ty. A battery that i s
ful l y-charged, but does not pass the l oad test, i s
faul ty and must be repl aced.
NOTE: Completely discharged batteries may take
several hours to accept a charge. Refer to Standard
Procedures for the proper battery charging proce-
dures.
STANDARD PROCEDURE
STANDARD PROCEDURE - BATTERY
CHARGING
Battery chargi ng i s the means by whi ch the bat-
tery can be restored to i ts ful l vol tage potenti al . A
battery i s ful l y-charged when:
• Al l of the battery cel l s are gassi ng freel y duri ng
battery chargi ng.
• A green col or i s vi si bl e i n the si ght gl ass of the
battery bui l t-i n test i ndi cator.
8F - 8 BATTERY SYSTEM TJ
BATTERY (Continued)
• Three hydrometer tests, taken at one-hour i nter-
val s, i ndi cate no i ncrease i n the temperature-cor-
rected speci fi c gravi ty of the battery el ectrol yte.
• Open-ci rcui t vol tage of the battery i s 12.4 vol ts
or above.
WARNING: NEVER EXCEED TWENTY AMPERES
WHEN CHARGING A COLD (-1° C [30° F] OR
LOWER) BATTERY. THE BATTERY MAY ARC INTER-
NALLY AND EXPLODE. PERSONAL INJURY AND/OR
VEHICLE DAMAGE MAY RESULT.
WARNING: IF THE BATTERY SHOWS SIGNS OF
FREEZING, LEAKING, LOOSE POSTS, DO NOT
TEST, ASSIST-BOOST, OR CHARGE. THE BATTERY
MAY ARC INTERNALLY AND EXPLODE. PERSONAL
INJURY AND/OR VEHICLE DAMAGE MAY RESULT.
WARNING: EXPLOSIVE HYDROGEN GAS FORMS IN
AND AROUND THE BATTERY. DO NOT SMOKE,
USE FLAME, OR CREATE SPARKS NEAR THE BAT-
TERY. PERSONAL INJURY AND/OR VEHICLE DAM-
AGE MAY RESULT.
WARNING: THE BATTERY CONTAINS SULFURIC
ACID, WHICH IS POISONOUS AND CAUSTIC. AVOID
CONTACT WITH THE SKIN, EYES, OR CLOTHING.
IN THE EVENT OF CONTACT, FLUSH WITH WATER
AND CALL A PHYSICIAN IMMEDIATELY. KEEP OUT
OF THE REACH OF CHILDREN.
WARNING: IF THE BATTERY IS EQUIPPED WITH
REMOVABLE CELL CAPS, BE CERTAIN THAT EACH
OF THE CELL CAPS IS IN PLACE AND TIGHT
BEFORE THE BATTERY IS RETURNED TO SER-
VICE. PERSONAL INJURY AND/OR VEHICLE DAM-
AGE MAY RESULT FROM LOOSE OR MISSING
CELL CAPS.
CAUTION: Always disconnect and isolate the bat-
tery negative cable before charging a battery. Do
not exceed sixteen volts while charging a battery.
Damage to the vehicle electrical system compo-
nents may result.
CAUTION: Battery electrolyte will bubble inside the
battery case during normal battery charging. Elec-
trolyte boiling or being discharged from the battery
vents indicates a battery overcharging condition.
Immediately reduce the charging rate or turn off the
charger to evaluate the battery condition. Damage
to the battery may result from overcharging.
CAUTION: The battery should not be hot to the
touch. If the battery feels hot to the touch, turn off
the charger and let the battery cool before continu-
ing the charging operation. Damage to the battery
may result.
After the battery has been charged to 12.4 vol ts or
greater, perform a l oad test to determi ne the battery
cranki ng capaci ty (Refer to 8 - ELECTRI CAL/BAT-
TERY SYSTEM/BATTERY - STANDARD PROCE-
DURE). I f the battery wi l l endure a l oad test, return
the battery to servi ce. I f the battery wi l l not endure a
l oad test, i t i s faul ty and must be repl aced.
Cl ean and i nspect the battery hol d downs, tray,
termi nal s, posts, and top before compl eti ng battery
servi ce (Refer to 8 - ELECTRI CAL/BATTERY SYS-
TEM - CLEANI NG), and (Refer to 8 - ELECTRI CAL/
BATTERY SYSTEM - I NSPECTI ON).
CHARGING A COMPLETELY DISCHARGED
BATTERY
The fol l owi ng procedure shoul d be used to recharge
a compl etel y di scharged battery. Unl ess thi s proce-
dure i s properl y fol l owed, a good battery may be
needl essl y repl aced.
(1) Measure the vol tage at the battery posts wi th a
vol tmeter, accurate to 1/10 (0.10) vol t (Fi g. 5). I f the
readi ng i s bel ow ten vol ts, the battery chargi ng cur-
rent wi l l be l ow. I t coul d take some ti me before the
battery accepts a current greater than a few mi l l i am-
peres. Such l ow current may not be detectabl e on the
ammeters bui l t i nto many battery chargers.
(2) Di sconnect and i sol ate the battery negati ve
cabl e. Connect the battery charger l eads. Some bat-
tery chargers are equi pped wi th pol ari ty-sensi ng ci r-
cui try. Thi s ci rcui try protects the battery charger and
the battery from bei ng damaged i f they are i mprop-
erl y connected. I f the battery state-of-charge i s too
l ow for the pol ari ty-sensi ng ci rcui try to detect, the
battery charger wi l l not operate. Thi s makes i t
Fig. 5 Voltmeter - Typical
TJ BATTERY SYSTEM 8F - 9
BATTERY (Continued)
appear that the battery wi l l not accept chargi ng cur-
rent. See the i nstructi ons provi ded by the manufac-
turer of the battery charger for detai l s on how to
bypass the pol ari ty-sensi ng ci rcui try.
(3) Battery chargers vary i n the amount of vol tage
and current they provi de. The amount of ti me
requi red for a battery to accept measurabl e chargi ng
current at vari ous vol tages i s shown i n the Charge
Rate Tabl e. I f the chargi ng current i s sti l l not mea-
surabl e at the end of the chargi ng ti me, the battery
i s faul ty and must be repl aced. I f the chargi ng cur-
rent i s measurabl e duri ng the chargi ng ti me, the bat-
tery may be good and the chargi ng shoul d be
compl eted i n the normal manner.
CHARGE RATE TABLE
Voltage Hours
16.0 volts maximum up to 4 hours
14.0 to 15.9 volts up to 8 hours
13.9 volts or less up to 16 hours
CHARGING TIME REQUIRED
The ti me requi red to charge a battery wi l l vary,
dependi ng upon the fol l owi ng factors:
• Battery Capacity - A compl etel y di scharged
heavy-duty battery requi res twi ce the chargi ng ti me
of a smal l capaci ty battery.
• Temperature - A l onger ti me wi l l be needed to
charge a battery at -18° C (0° F) than at 27° C (80°
F). When a fast battery charger i s connected to a col d
battery, the current accepted by the battery wi l l be
very l ow at fi rst. As the battery warms, i t wi l l accept
a hi gher chargi ng current rate (amperage).
• Charger Capacity - A battery charger that
suppl i es onl y fi ve amperes wi l l requi re a l onger
chargi ng ti me. A battery charger that suppl i es
twenty amperes or more wi l l requi re a shorter charg-
i ng ti me.
• State-Of-Charge - A compl etel y di scharged bat-
tery requi res more chargi ng ti me than a parti al l y
di scharged battery. El ectrol yte i s nearl y pure water
i n a compl etel y di scharged battery. At fi rst, the
chargi ng current (amperage) wi l l be l ow. As the bat-
tery charges, the speci fi c gravi ty of the el ectrol yte
wi l l gradual l y ri se.
The Battery Chargi ng Ti me Tabl e gi ves an i ndi ca-
ti on of the ti me requi red to charge a typi cal battery
at room temperature based upon the battery state-of-
charge and the charger capaci ty.
BATTERY CHARGING TIME TABLE
Charging
Amperage
5 Amps
10
Amps
20 Amps
Open Circuit
Voltage
Hours Charging @ 21°C (70°
F)
12.25 to 12.49 6 hours 3 hours 1.5
hours
12.00 to 12.24 10 hours 5 hours 2.5
hours
10.00 to 11.99 14 hours 7 hours 3.5
hours
Below 10.00 18 hours 9 hours 4.5
hours
STANDARD PROCEDURE - BUILT-IN
INDICATOR TEST
An i ndi cator (hydrometer) bui l t i nto the top of the
battery case provi des vi sual i nformati on for battery
testi ng (Fi g. 6). Li ke a hydrometer, the bui l t-i n i ndi -
cator measures the speci fi c gravi ty of the battery
el ectrol yte. The speci fi c gravi ty of the el ectrol yte
reveal s the battery state-of-charge; however, i t wi l l
not reveal the cranki ng capaci ty of the battery. A l oad
test must be performed to determi ne the battery
cranki ng capaci ty. Refer to Standard Procedures for
the proper battery l oad test procedures.
Before testi ng, vi sual l y i nspect the battery for any
damage (a cracked case or cover, l oose posts, etc.)
that woul d cause the battery to be faul ty. I n order to
obtai n correct i ndi cati ons from the bui l t-i n i ndi cator,
i t i s i mportant that the battery be l evel and have a
cl ean si ght gl ass. Addi ti onal l i ght may be requi red to
vi ew the i ndi cator. Do not use open flame as a
source of additional light.
Fig. 6 Built-In Indicator
1 - SIGHT GLASS
2 - BATTERY TOP
3 - GREEN BALL
4 - PLASTIC ROD
8F - 10 BATTERY SYSTEM TJ
BATTERY (Continued)
To read the bui l t-i n i ndi cator, l ook i nto the si ght
gl ass and note the col or of the i ndi cati on (Fi g. 7). The
battery condi ti on that each col or i ndi cates i s
descri bed i n the fol l owi ng l i st:
• Green - I ndi cates 75% to 100% battery state-of-
charge. The battery i s adequatel y charged for further
testi ng or return to servi ce. I f the starter wi l l not
crank for a mi ni mum of fi fteen seconds wi th a ful l y-
charged battery, the battery must be l oad tested.
Refer to Standard Procedures for the proper battery
l oad test procedures.
• Black or Dark - I ndi cates 0% to 75% battery
state-of-charge. The battery i s i nadequatel y charged
and must be charged unti l a green i ndi cati on i s vi si -
bl e i n the si ght gl ass (12.4 vol ts or more), before the
battery i s tested further or returned to servi ce. Refer
to Standard Procedures for the proper battery charg-
i ng procedures. Al so refer to Di agnosi s and Testi ng
for more i nformati on on the possi bl e causes of the
di scharged battery condi ti on.
• Clear or Bright - I ndi cates a l ow battery el ec-
trol yte l evel . The el ectrol yte l evel i n the battery i s
bel ow the bui l t-i n i ndi cator. A mai ntenance-free bat-
tery wi th non-removabl e cel l caps must be repl aced i f
the el ectrol yte l evel i s l ow. Water must be added to a
l ow-mai ntenance battery wi th removabl e cel l caps
before i t i s charged. Refer to Standard Procedures for
the proper battery fi l l i ng procedures. A l ow el ectro-
l yte l evel may be caused by an overchargi ng condi -
ti on. Refer to Chargi ng System for the proper
chargi ng system di agnosi s and testi ng procedures.
STANDARD PROCEDURE - OPEN-CIRCUIT
VOLTAGE TEST
A battery open-ci rcui t vol tage (no l oad) test wi l l
show the approxi mate state-of-charge of a battery.
Thi s test can be used i n pl ace of the hydrometer test
when a hydrometer i s not avai l abl e, or for mai nte-
nance-free batteri es wi th non-removabl e cel l caps.
Before proceedi ng wi th thi s test, compl etel y charge
the battery (Refer to 8 - ELECTRI CAL/BATTERY
SYSTEM/BATTERY - STANDARD PROCEDURE).
(1) Before measuri ng the open-ci rcui t vol tage, the
surface charge must be removed from the battery.
Turn on the headl amps for fi fteen seconds, then
al l ow up to fi ve mi nutes for the battery vol tage to
stabi l i ze.
(2) Di sconnect and i sol ate both battery cabl es, neg-
ati ve cabl e fi rst.
(3) Usi ng a vol tmeter connected to the battery
posts (see the i nstructi ons provi ded by the manufac-
turer of the vol tmeter), measure the open-ci rcui t vol t-
age (Fi g. 8).
See the Open-Ci rcui t Vol tage Tabl e. Thi s vol tage
readi ng wi l l i ndi cate the battery state-of-charge, but
wi l l not reveal i ts cranki ng capaci ty. I f a battery has
an open-ci rcui t vol tage readi ng of 12.4 vol ts or
greater, i t may be l oad tested to reveal i ts cranki ng
capaci ty (Refer to 8 - ELECTRI CAL/BATTERY SYS-
TEM/BATTERY - STANDARD PROCEDURE).
OPEN CIRCUIT VOLTAGE TABLE
Open Circuit Voltage Charge Percentage
11.7 volts or less 0%
12.0 volts 25%
12.2 volts 50%
12.4 volts 75%
12.6 volts or more 100%
STANDARD PROCEDURE - IGNITION-OFF
DRAW TEST
The term I gni ti on-Off Draw (I OD) i denti fi es a nor-
mal condi ti on where power i s bei ng drai ned from the
battery wi th the i gni ti on swi tch i n the Off posi ti on. A
normal vehi cl e el ectri cal system wi l l draw from fi ve
to thi rty-fi ve mi l l i amperes (0.005 to 0.035 ampere)
wi th the i gni ti on swi tch i n the Off posi ti on, and al l
non-i gni ti on control l ed ci rcui ts i n proper worki ng
order. Up to thi rty-fi ve mi l l i amperes are needed to
enabl e the memory functi ons for the Powertrai n Con-
Fig. 7 Built-In Indicator Sight Glass Chart
Fig. 8 Testing Open-Circuit Voltage - Typical
TJ BATTERY SYSTEM 8F - 11
BATTERY (Continued)
trol Modul e (PCM), di gi tal cl ock, el ectroni cal l y tuned
radi o, and other modul es whi ch may vary wi th the
vehi cl e equi pment.
A vehi cl e that has not been operated for approxi -
matel y twenty days, may di scharge the battery to an
i nadequate l evel . When a vehi cl e wi l l not be used for
twenty days or more (stored), remove the I OD fuse
from the Power Di stri buti on Center (PDC). Thi s wi l l
reduce battery di schargi ng.
Excessi ve I OD can be caused by:
• El ectri cal i tems l eft on.
• Faul ty or i mproperl y adjusted swi tches.
• Faul ty or shorted el ectroni c modul es and compo-
nents.
• An i nternal l y shorted generator.
• I ntermi ttent shorts i n the wi ri ng.
I f the I OD i s over thi rty-fi ve mi l l i amperes, the
probl em must be found and corrected before repl ac-
i ng a battery. I n most cases, the battery can be
charged and returned to servi ce after the excessi ve
I OD condi ti on has been corrected.
(1) Veri fy that al l el ectri cal accessori es are off.
Turn off al l l amps, remove the i gni ti on key, and cl ose
al l doors. I f the vehi cl e i s equi pped wi th an i l l umi -
nated entry system or an el ectroni cal l y tuned radi o,
al l ow the el ectroni c ti mer functi on of these systems
to automati cal l y shut off (ti me out). Thi s may take
up to three mi nutes.
(2) Determi ne that the underhood l amp i s operat-
i ng properl y, then di sconnect the l amp wi re harness
connector or remove the l amp bul b.
(3) Di sconnect the battery negati ve cabl e.
(4) Set an el ectroni c di gi tal mul ti -meter to i ts
hi ghest amperage scal e. Connect the mul ti -meter
between the di sconnected battery negati ve cabl e ter-
mi nal cl amp and the battery negati ve termi nal post.
Make sure that the doors remai n cl osed so that the
i l l umi nated entry system i s not acti vated. The mul ti -
meter amperage readi ng may remai n hi gh for up to
three mi nutes, or may not gi ve any readi ng at al l
whi l e set i n the hi ghest amperage scal e, dependi ng
upon the el ectri cal equi pment i n the vehi cl e. The
mul ti -meter l eads must be securel y cl amped to the
battery negati ve cabl e termi nal cl amp and the bat-
tery negati ve termi nal post. I f conti nui ty between the
battery negati ve termi nal post and the negati ve cabl e
termi nal cl amp i s l ost duri ng any part of the I OD
test, the el ectroni c ti mer functi on wi l l be acti vated
and al l of the tests wi l l have to be repeated.
(5) After about three mi nutes, the hi gh-amperage
I OD readi ng on the mul ti -meter shoul d become very
l ow or nonexi stent, dependi ng upon the el ectri cal
equi pment i n the vehi cl e. I f the amperage readi ng
remai ns hi gh, remove and repl ace each fuse or ci rcui t
breaker i n the Power Di stri buti on Center (PDC) and
then i n the Juncti on Bl ock (JB), one at a ti me unti l
the amperage readi ng becomes very l ow, or nonexi st-
ent. Refer to the appropri ate wi ri ng i nformati on i n
thi s servi ce manual for compl ete PDC and JB fuse,
ci rcui t breaker, and ci rcui t i denti fi cati on. Thi s wi l l
i sol ate each ci rcui t and i denti fy the ci rcui t that i s the
source of the hi gh-amperage I OD. I f the amperage
readi ng remai ns hi gh after removi ng and repl aci ng
each fuse and ci rcui t breaker, di sconnect the wi re
harness from the generator. I f the amperage readi ng
now becomes very l ow or nonexi stent, refer to Charg-
i ng System for the proper chargi ng system di agnosi s
and testi ng procedures. After the hi gh-amperage I OD
has been corrected, swi tch the mul ti -meter to pro-
gressi vel y l ower amperage scal es and, i f necessary,
repeat the fuse and ci rcui t breaker remove-and-re-
pl ace process to i denti fy and correct al l sources of
excessi ve I OD. I t i s now safe to sel ect the l owest mi l -
l i ampere scal e of the mul ti -meter to check the l ow-
amperage I OD.
CAUTION: Do not open any doors, or turn on any
electrical accessories with the lowest milliampere
scale selected, or the multi-meter may be damaged.
(6) Observe the mul ti -meter readi ng. The l ow-am-
perage I OD shoul d not exceed thi rty-fi ve mi l l i am-
peres (0.035 ampere). I f the current draw exceeds
thi rty-fi ve mi l l i amperes, i sol ate each ci rcui t usi ng the
fuse and ci rcui t breaker remove-and-repl ace process
i n Step 5. The mul ti -meter readi ng wi l l drop to
wi thi n the acceptabl e l i mi t when the source of the
excessi ve current draw i s di sconnected. Repai r thi s
ci rcui t as requi red; whether a wi ri ng short, i ncorrect
swi tch adjustment, or a component fai l ure i s at faul t.
STANDARD PROCEDURE - USING MICRO 420
BATTERY TESTER
Al ways use the Mi cro 420 I nstructi on Manual that
was suppl i ed wi th the tester as a reference. I f the
I nstructi on Manual i s not avai l abl e the fol l owi ng pro-
cedure can be used:
WARNING: ALWAYS WEAR APPROPRIATE EYE
PROTECTION AND USE EXTREME CAUTION WHEN
WORKING WITH BATTERIES.
BATTERY TESTING
(1) I f testi ng the battery OUT-OF-VEHI CLE, cl ean
the battery termi nal s wi th a wi re brush before test-
i ng. I f the battery i s equi pped wi th si de post termi -
nal s, i nstal l and ti ghten the suppl i ed l ead termi nal
stud adapters. Do not use steel bol ts. Fai l ure to prop-
erl y i nstal l the stud adapters, or usi ng stud adapters
that are di rty or worn-out may resul t i n fal se test
readi ngs.
8F - 12 BATTERY SYSTEM TJ
BATTERY (Continued)
(2) I f testi ng the battery I N-THE-VEHI CLE, make
certai n al l of the vehi cl e accessory l oads are OFF,
i ncl udi ng the i gni ti on. The preferred test position
is at the battery terminal. I f the battery i s not
accessi bl e, you may test usi ng both the posi ti ve and
negati ve jumper posts. Sel ect TESTI NG AT JUMPER
POST when connecti ng to that l ocati on.
(3) Connect the tester (Fi g. 9) to the battery or
jumper posts, the red cl amp to posi ti ve (+) and the
bl ack cl amp to negati ve (–).
NOTE: Multiple batteries connected in parallel must
have the ground cable disconnected to perform a
battery test. Failure to disconnect may result in
false battery test readings.
(4) Usi ng the ARROW key sel ect in or out of vehi -
cl e testi ng and press ENTER to make a sel ecti on.
(5) I f not sel ected, choose the Col d Cranki ng Amp
(CCA) battery rati ng. Or sel ect the appropri ate bat-
tery rati ng for your area (see menu). The tester wi l l
then run i ts sel f programmed test of the battery and
di spl ay the resul ts. Refer to the test resul t tabl e
noted bel ow.
CAUTION: If REPLACE BATTERY is the result of the
test, this may mean a poor connection between the
vehicle’s cables and battery exists. After discon-
necting the vehicle’s battery cables from the bat-
tery, retest the battery using the OUT-OF-VEHICLE
test before replacing.
(6) Whi l e vi ewi ng the battery test resul t, press the
CODE button and the tester wi l l prompt you for the
l ast 4 di gi ts of the VI N. Use the UP/DOWN arrow
buttons to scrol l to the correct character; then press
ENTER to sel ect and move to the next di gi t. Then
press the ENTER button to vi ew the SERVI CE
CODE. Pressi ng the CODE button a second ti me wi l l
return you to the test resul ts.
BATTERY TEST RESULTS
GOOD BATTERY Return to service
GOOD - RECHARGE Fully charge battery and
return to service
CHARGE & RETEST Fully charge battery and
retest battery
REPLACE BATTERY Replace the battery and
retest complete system
BAD-CELL REPLACE Replace the battery and
retest complete system
NOTE: The SERVICE CODE is required on every
warranty claim submitted for battery replacement.
REMOVAL
(1) Turn the i gni ti on swi tch to the Off posi ti on. Be
certai n that al l el ectri cal accessori es are turned off.
(2) Loosen the battery negati ve cabl e termi nal
cl amp pi nch-bol t hex nut.
(3) Di sconnect the battery negati ve cabl e termi nal
cl amp from the battery negati ve termi nal post. I f
necessary, use a battery termi nal pul l er to remove
the termi nal cl amp from the battery post (Fi g. 10).
(4) Loosen the battery posi ti ve cabl e termi nal
cl amp pi nch-bol t hex nut.
(5) Di sconnect the battery posi ti ve cabl e termi nal
cl amp from the battery posi ti ve termi nal post. I f nec-
essary, use a battery termi nal pul l er to remove the
termi nal cl amp from the battery post.
Fig. 9 Micro 420 Battery Tester
Fig. 10 Remove Battery Cable Terminal Clamp -
Typical
1 - BATTERY
2 - BATTERY TERMINAL PULLER
TJ BATTERY SYSTEM 8F - 13
BATTERY (Continued)
(6) Remove the battery hol ddowns from the bat-
tery. Refer to Battery Hol ddown for the proper bat-
tery hol ddown removal procedures.
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.
(7) Remove the battery and the battery thermal
guard from the battery tray as a uni t.
(8) Remove the battery thermal guard from the
battery case. Refer to Thermal Guard for the proper
battery thermal guard removal procedures.
INSTALLATION
(1) Cl ean and i nspect al l of the battery system
components. Refer to Battery System Cl eani ng for
the proper cl eani ng procedures, and refer to Battery
System I nspecti on for the proper i nspecti on proce-
dures.
(2) Rei nstal l the battery thermal guard onto the
battery case. Refer to Thermal Guard for the proper
battery thermal guard i nstal l ati on procedures.
(3) Posi ti on the battery and the battery thermal
guard onto the battery tray as a uni t. Ensure that
the battery posi ti ve and negati ve termi nal posts are
correctl y posi ti oned. The battery cabl e termi nal
cl amps must reach the correct battery termi nal post
wi thout stretchi ng the cabl es (Fi g. 11).
(4) Rei nstal l the battery hol ddowns onto the bat-
tery. Refer to Battery Hol ddown for the proper i nstal -
l ati on procedure.
CAUTION: Be certain that the battery cable terminal
clamps are connected to the correct battery termi-
nal posts. Reversed battery polarity may damage
electrical components of the vehicle.
(5) Cl ean the battery cabl e termi nal cl amps and
the battery termi nal posts. Refer to Battery System
Cl eani ng for cl eani ng procedure.
(6) Reconnect the battery posi ti ve cabl e termi nal
cl amp to the battery posi ti ve termi nal post. Ti ghten
the termi nal cl amp pi nch-bol t hex nut to 8.4 N·m (75
i n. l bs.).
(7) Reconnect the battery negati ve cabl e termi nal
cl amp to the battery negati ve termi nal post. Ti ghten
the termi nal cl amp pi nch-bol t hex nut to 8.4 N·m (75
i n. l bs.).
(8) Appl y a thi n coati ng of petrol eum jel l y or chas-
si s grease to the exposed surfaces of the battery cabl e
termi nal cl amps and the battery termi nal posts.
BATTERY HOLDDOWN
DESCRIPTION
The battery hol d down hardware (Fi g. 12) i ncl udes
two J-bol ts, a hol d down bracket and two hex nuts
wi th coned washers. The battery hol d down bracket
consi sts of a stamped steel bracket that i s then pl as-
ti c-coated for corrosi on protecti on.
Fig. 11 Battery Cables - Typical
1 - RADIATOR CROSSMEMBER
2 - WHEELHOUSE INNER PANEL
3 - NEGATIVE CABLE
4 - POSITIVE CABLE
5 - BATTERY
Fig. 12 Battery Hold Downs
1 - J-BOLT (2)
2 - NUT (2)
3 - BRACKET
4 - BATTERY
8F - 14 BATTERY SYSTEM TJ
BATTERY (Continued)
The hol d down J-bol ts are i nstal l ed a hol e i n the
front and rear fl anges of the battery tray from the
top, wi th the threaded ends of the bol ts extendi ng
upward. The hooked end of each J-bol t i s then
engaged i n a second hol e i n the front and rear
fl anges of the battery tray from the bottom. The bat-
tery hol d down bracket i s i nstal l ed across the top of
the battery case and over the two upri ght threaded
ends of the J-bol ts. A hex nut wi th coned washer i s
then i nstal l ed and ti ghtened onto each of the J-bol ts
to securel y hol d down the battery i n the battery tray.
When i nstal l i ng a battery i nto the battery tray, be
certai n that the hol d down hardware i s properl y
i nstal l ed and that the fasteners are ti ghtened to the
proper speci fi cati ons. I mproper hol d down fastener
ti ghtness, whether too l oose or too ti ght, can resul t i n
damage to the battery, the vehi cl e or both. (Refer to 8
- ELECTRI CAL/BATTERY SYSTEM/BATTERY
HOLDDOWN - I NSTALLATI ON) the proper hol d
down fastener ti ghtness speci fi cati ons.
OPERATION
The battery hol ddown secures the battery i n the
battery tray. Thi s hol ddown i s desi gned to prevent
battery movement duri ng the most extreme vehi cl e
operati on condi ti ons. Peri odi c removal and l ubri ca-
ti on of the battery hol ddown hardware i s recom-
mended to prevent hardware sei zure at a l ater date.
CAUTION: Never operate a vehicle without a battery
holddown device properly installed. Damage to the
vehicle, components and battery could result.
REMOVAL
Al l of the battery hol d down hardware can be ser-
vi ced wi thout removal of the battery or the battery
tray.
(1) Turn the i gni ti on swi tch to the Off posi ti on. Be
certai n that al l el ectri cal accessori es are turned off.
(2) Loosen the battery negati ve cabl e termi nal
cl amp pi nch-bol t hex nut.
(3) Di sconnect the battery negati ve cabl e termi nal
cl amp from the battery negati ve termi nal post. I f
necessary, use a battery termi nal pul l er to remove
the termi nal cl amp from the battery post.
(4) Remove the nut wi th washer from the threaded
end of each of the two J-bol ts (Fi g. 13).
(5) Remove the battery hol d down bracket from
the threaded ends of the two J-bol ts and the top of
the battery case.
(6) Di sengage the hooked end of each J-bol t from
the hol es i n the front or rear fl ange of the battery
tray and remove the two J-bol ts.
INSTALLATION
Al l of the battery hol d down hardware can be ser-
vi ced wi thout removal of the battery or the battery
tray.
(1) Cl ean and i nspect the battery hol d down hard-
ware. (Refer to 8 - ELECTRI CAL/BATTERY SYS-
TEM - CLEANI NG).
(2) Engage the hooked end of each J-bol t i nto the
hol es i n the front or rear fl ange of the battery tray
and posi ti on the two J-bol ts.
(3) Posi ti on the battery hol d down bracket onto the
threaded ends of the two J-bol ts and across the top of
the battery case.
(4) I nstal l and ti ghten the nut wi th washer onto
the threaded end of each of the two J-bol ts. Ti ghten
the nuts to 4.7 N·m (42 i n. l bs.).
(5) Reconnect the battery negati ve cabl e termi nal
cl amp to the battery negati ve termi nal post. Ti ghten
the termi nal cl amp pi nch-bol t hex nut to 8.4 N·m (75
i n. l bs.).
Fig. 13 Battery Hold Downs Remove/Install
1 - J-BOLT (2)
2 - NUT (2)
3 - BRACKET
4 - BATTERY
TJ BATTERY SYSTEM 8F - 15
BATTERY HOLDDOWN (Continued)
BATTERY CABLES
DESCRIPTION
The battery cabl es are l arge gauge, stranded cop-
per wi res sheathed wi thi n a heavy pl asti c or syn-
theti c rubber i nsul ati ng jacket. The wi re used i n the
battery cabl es combi nes excel l ent fl exi bi l i ty and rel i -
abi l i ty wi th hi gh el ectri cal current carryi ng capaci ty.
The battery cabl es feature a cl ampi ng type femal e
battery termi nal made of soft l ead that i s di e cast
onto one end of the battery cabl e wi re. A square
headed pi nch-bol t and hex nut are i nstal l ed at the
open end of the femal e battery termi nal cl amp. Large
eyel et type termi nal s are cri mped onto the opposi te
end of the battery cabl e wi re and then sol der-di pped.
The battery posi ti ve cabl e wi res have a red i nsul at-
i ng jacket to provi de vi sual i denti fi cati on and feature
a l arger femal e battery termi nal cl amp to al l ow con-
necti on to the l arger battery posi ti ve termi nal post.
The battery negati ve cabl e wi res have a bl ack i nsu-
l ati ng jacket and a smal l er femal e battery termi nal
cl amp.
The battery cabl es cannot be repai red and, i f dam-
aged or faul ty they must be repl aced. Both the bat-
tery posi ti ve and negati ve cabl es are avai l abl e for
servi ce repl acement onl y as a uni t wi th the battery
wi re harness, whi ch may i ncl ude porti ons of the wi r-
i ng ci rcui ts for the generator and other components
on some model s. Refer to the appropri ate wi ri ng
i nformati on i n thi s servi ce manual for the l ocati on of
the proper battery cabl e wi re harness di agrams. The
wi ri ng i nformati on al so i ncl udes proper wi re and con-
nector repai r procedures, further detai l s on wi re har-
ness routi ng and retenti on, as wel l as pi n-out and
l ocati on vi ews for the vari ous wi re harness connec-
tors, spl i ces and grounds.
OPERATION
The battery cabl es connect the battery termi nal
posts to the vehi cl e el ectri cal system. These cabl es
al so provi de a path back to the battery for el ectri cal
current generated by the chargi ng system for restor-
i ng the vol tage potenti al of the battery. The femal e
battery termi nal cl amps on the ends of the battery
cabl e wi res provi de a strong and rel i abl e connecti on
of the battery cabl e to the battery termi nal posts.
The termi nal pi nch bol ts al l ow the femal e termi nal
cl amps to be ti ghtened around the mal e termi nal
posts on the top of the battery. The eyel et termi nal s
secured to the opposi te ends of the battery cabl e
wi res from the femal e battery termi nal cl amps pro-
vi de secure and rel i abl e connecti on of the battery
cabl es to the vehi cl e el ectri cal system.
The battery posi ti ve cabl e termi nal cl amp i s di e
cast onto the ends of two wi res. One wi re has an eye-
l et termi nal that connects the battery posi ti ve cabl e
to the B(+) termi nal stud of the Power Di stri buti on
Center (PDC), and the other wi re has an eyel et ter-
mi nal that connects the battery posi ti ve cabl e to the
B(+) termi nal stud of the engi ne starter motor sol e-
noi d. The battery negati ve cabl e termi nal cl amp i s
al so di e cast onto the ends of two wi res. One wi re
has an eyel et termi nal that connects the battery neg-
ati ve cabl e to the vehi cl e powertrai n through a stud
on the ri ght si de of the engi ne cyl i nder bl ock. The
other wi re has an eyel et termi nal that connects the
battery negati ve cabl e to the vehi cl e body through a
ground screw on the ri ght front fender i nner shi el d,
near the battery.
DIAGNOSIS AND TESTING - BATTERY CABLES
A vol tage drop test wi l l determi ne i f there i s exces-
si ve resi stance i n the battery cabl e termi nal connec-
ti ons or the battery cabl e. I f excessi ve resi stance i s
found i n the battery cabl e connecti ons, the connec-
ti on poi nt shoul d be di sassembl ed, cl eaned of al l cor-
rosi on or forei gn materi al , then reassembl ed.
Fol l owi ng reassembl y, check the vol tage drop for the
battery cabl e connecti on and the battery cabl e agai n
to confi rm repai r.
When performi ng the vol tage drop test, i t i s i mpor-
tant to remember that the vol tage drop i s gi vi ng an
i ndi cati on of the resi stance between the two poi nts at
whi ch the vol tmeter probes are attached. EXAM-
PLE: When testi ng the resi stance of the battery pos-
i ti ve cabl e, touch the vol tmeter l eads to the battery
posi ti ve cabl e termi nal cl amp and to the battery pos-
i ti ve cabl e eyel et termi nal at the starter sol enoi d
B(+) termi nal stud. I f you probe the battery posi ti ve
termi nal post and the battery posi ti ve cabl e eyel et
termi nal at the starter sol enoi d B(+) termi nal stud,
you are readi ng the combi ned vol tage drop i n the
battery posi ti ve cabl e termi nal cl amp-to-termi nal
post connecti on and the battery posi ti ve cabl e.
VOLTAGE DROP TEST
The fol l owi ng operati on wi l l requi re a vol tmeter
accurate to 1/10 (0.10) vol t. Before performi ng thi s
test, be certai n that the fol l owi ng procedures are
accompl i shed:
• The battery i s ful l y-charged and l oad tested.
Refer to Standard Procedures for the proper battery
chargi ng and l oad test procedures.
• Ful l y engage the parki ng brake.
• I f the vehi cl e i s equi pped wi th an automati c
transmi ssi on, pl ace the gearshi ft sel ector l ever i n the
Park posi ti on. I f the vehi cl e i s equi pped wi th a man-
ual transmi ssi on, pl ace the gearshi ft sel ector l ever i n
the Neutral posi ti on and bl ock the cl utch pedal i n the
ful l y depressed posi ti on.
• Veri fy that al l l amps and accessori es are turned
off.
8F - 16 BATTERY SYSTEM TJ
• To prevent the engi ne from starti ng, remove the
Automati c Shut Down (ASD) rel ay. The ASD rel ay i s
l ocated i n the Power Di stri buti on Center (PDC), i n
the engi ne compartment. See the fuse and rel ay l ay-
out l abel affi xed to the undersi de of the PDC cover
for ASD rel ay i denti fi cati on and l ocati on.
(1) Connect the posi ti ve l ead of the vol tmeter to
the battery negati ve termi nal post. Connect the neg-
ati ve l ead of the vol tmeter to the battery negati ve
cabl e termi nal cl amp (Fi g. 14). Rotate and hol d the
i gni ti on swi tch i n the Start posi ti on. Observe the
vol tmeter. I f vol tage i s detected, correct the poor con-
necti on between the battery negati ve cabl e termi nal
cl amp and the battery negati ve termi nal post.
(2) Connect the posi ti ve l ead of the vol tmeter to
the battery posi ti ve termi nal post. Connect the nega-
ti ve l ead of the vol tmeter to the battery posi ti ve cabl e
termi nal cl amp (Fi g. 15). Rotate and hol d the i gni ti on
swi tch i n the Start posi ti on. Observe the vol tmeter. I f
vol tage i s detected, correct the poor connecti on
between the battery posi ti ve cabl e termi nal cl amp
and the battery posi ti ve termi nal post.
(3) Connect the vol tmeter to measure between the
battery posi ti ve cabl e termi nal cl amp and the starter
sol enoi d B(+) termi nal stud (Fi g. 16). Rotate and hol d
the i gni ti on swi tch i n the Start posi ti on. Observe the
vol tmeter. I f the readi ng i s above 0.2 vol t, cl ean and
ti ghten the battery posi ti ve cabl e eyel et termi nal con-
necti on at the starter sol enoi d B(+) termi nal stud.
Repeat the test. I f the readi ng i s sti l l above 0.2 vol t,
repl ace the faul ty battery posi ti ve cabl e.
(4) Connect the vol tmeter to measure between the
battery negati ve cabl e termi nal cl amp and a good
cl ean ground on the engi ne bl ock (Fi g. 17). Rotate
and hol d the i gni ti on swi tch i n the Start posi ti on.
Observe the vol tmeter. I f the readi ng i s above 0.2
vol t, cl ean and ti ghten the battery negati ve cabl e
eyel et termi nal connecti on to the engi ne bl ock.
Repeat the test. I f the readi ng i s sti l l above 0.2 vol t,
repl ace the faul ty battery negati ve cabl e.
Fig. 14 Test Battery Negative Connection
Resistance - Typical
1 - VOLTMETER
2 - BATTERY
Fig. 15 Test Battery Positive Connection Resistance
- Typical
1 - VOLTMETER
2 - BATTERY
Fig. 16 Test Battery Positive Cable Resistance -
Typical
1 - BATTERY
2 - VOLTMETER
3 - STARTER MOTOR
TJ BATTERY SYSTEM 8F - 17
BATTERY CABLES (Continued)
REMOVAL
Both the battery negati ve cabl e and the battery
posi ti ve cabl e are servi ced i n the battery wi re har-
ness. I f ei ther battery cabl e i s damaged or faul ty, the
battery wi re harness uni t must be repl aced.
(1) Turn the i gni ti on swi tch to the Off posi ti on. Be
certai n that al l el ectri cal accessori es are turned off.
(2) Loosen the battery negati ve cabl e termi nal
cl amp pi nch-bol t hex nut.
(3) Di sconnect the battery negati ve cabl e termi nal
cl amp from the battery negati ve termi nal post. I f
necessary, use a battery termi nal pul l er to remove
the termi nal cl amp from the battery post.
(4) Loosen the battery posi ti ve cabl e termi nal
cl amp pi nch-bol t hex nut.
(5) Di sconnect the battery posi ti ve cabl e termi nal
cl amp from the battery posi ti ve termi nal post. I f nec-
essary, use a battery termi nal pul l er to remove the
termi nal cl amp from the battery post.
(6) Unl atch and remove the B(+) termi nal stud
cover from the rear of the Power Di stri buti on Center
(PDC).
(7) Remove the two nuts that secure the battery
posi ti ve cabl e and the generator output cabl e eyel et
termi nal to the two B(+) termi nal studs on the PDC.
(8) Remove the battery posi ti ve cabl e and the gen-
erator output eyel et termi nal from the two B(+) ter-
mi nal studs on the PDC.
(9) Remove the screw that secures the battery neg-
ati ve cabl e eyel et termi nal to the dash panel near the
battery.
(10) Unl atch and remove the cover from the gener-
ator output termi nal stud housi ng on the back of the
generator.
(11) Remove the nut that secures the generator
output cabl e eyel et termi nal to the generator output
termi nal stud.
(12) Remove the generator output cabl e eyel et ter-
mi nal from the generator output termi nal stud.
(13) Remove the nut that secures the battery neg-
ati ve cabl e ground eyel et termi nal to the stud on the
ri ght si de of the engi ne bl ock.
(14) Remove the battery negati ve cabl e ground
eyel et termi nal from the engi ne bl ock stud.
(15) Remove the nut that secures the battery pos-
i ti ve cabl e eyel et termi nal to the B(+) termi nal stud
on the starter sol enoi d.
(16) Remove the battery posi ti ve cabl e eyel et ter-
mi nal from the B(+) termi nal stud on the starter
sol enoi d.
(17) Remove the battery wi re harness from the
engi ne compartment.
INSTALLATION
Both the battery negati ve cabl e and the battery
posi ti ve cabl e are servi ced i n the battery wi re har-
ness. I f ei ther battery cabl e i s damaged or faul ty, the
battery wi re harness uni t must be repl aced.
(1) Cl ean and i nspect the battery cabl e termi nal
cl amps and the battery termi nal posts (Refer to 8 -
ELECTRI CAL/BATTERY SYSTEM - CLEANI NG),
and (Refer to 8 - ELECTRI CAL/BATTERY SYSTEM -
I NSPECTI ON).
(2) Posi ti on the battery wi re harness i nto the
engi ne compartment.
(3) I nstal l the battery posi ti ve cabl e eyel et termi nal
onto the B(+) termi nal stud on the starter sol enoi d.
(4) I nstal l and ti ghten the nut that secures the
battery posi ti ve cabl e eyel et termi nal to the B(+) ter-
mi nal stud on the starter sol enoi d. Ti ghten the nut to
10 N·m (90 i n. l bs.).
(5) I nstal l the battery negati ve cabl e ground eyel et
termi nal onto the stud on the ri ght si de of the engi ne
bl ock.
Fig. 17 Test Ground Circuit Resistance - Typical
1 - VOLTMETER
2 - BATTERY
3 - ENGINE GROUND
8F - 18 BATTERY SYSTEM TJ
BATTERY CABLES (Continued)
(6) I nstal l and ti ghten the nut that secures the
battery negati ve cabl e ground eyel et termi nal to the
stud on the ri ght si de of the engi ne bl ock. Ti ghten
the nut to 16.9 N·m (150 i n. l bs.).
(7) I nstal l the generator output cabl e eyel et termi -
nal onto the generator output termi nal stud.
(8) I nstal l and ti ghten the nut that secures the
generator output cabl e eyel et termi nal to the genera-
tor output termi nal stud. Ti ghten the nut to 8.4 N·m
(75 i n. l bs.).
(9) Posi ti on the cover for the generator output ter-
mi nal stud housi ng onto the back of the generator
and snap i t i nto pl ace.
(10) I nstal l and ti ghten the screw that secures the
battery negati ve cabl e eyel et termi nal to the dash
panel near the battery. Ti ghten the screw to 48.7
N·m (36 ft. l bs.).
(11) I nstal l the battery posi ti ve cabl e and the gen-
erator output cabl e eyel et termi nal onto the PDC
B(+) termi nal studs.
(12) I nstal l and ti ghten the two nuts that secure
the battery posi ti ve cabl e and the generator output
cabl e eyel et termi nal to the PDC B(+) termi nal studs.
Ti ghten the nuts to 11.3 N·m (100 i n. l bs.).
(13) Engage the tabs on the l ower edge of the B(+)
termi nal stud cover i n the sl ots on the rear of the
PDC housi ng, then engage the l atch on the top of the
cover wi th the l atch tabs on the PDC housi ng.
(14) Reconnect the battery posi ti ve cabl e termi nal
cl amp to the battery posi ti ve termi nal post. Ti ghten
the termi nal cl amp pi nch-bol t hex nut to 8.4 N·m (75
i n. l bs.).
(15) Reconnect the battery negati ve cabl e termi nal
cl amp to the battery negati ve termi nal post. Ti ghten
the termi nal cl amp pi nch-bol t hex nut to 8.4 N·m (75
i n. l bs.).
(16) Appl y a thi n coati ng of petrol eum jel l y or
chassi s grease to the exposed surfaces of the battery
cabl e termi nal cl amps and the battery termi nal
posts.
BATTERY TRAY
DESCRIPTION
The battery i s mounted i n a stamped steel tray
(Fi g. 18) l ocated i n the passenger si de rear corner of
the engi ne compartment. The battery tray i s secured
by four hex screws wi th washers to the rei nforcement
l ocated between the engi ne compartment si de of the
dash panel and the rear of the front fender wheel -
house i nner panel .
A hol e i n the bottom of the battery tray i s fi tted
wi th a battery temperature sensor (Refer to 8 -
ELECTRI CAL/CHARGI NG/BATTERY TEMPERA-
TURE SENSOR - DESCRI PTI ON).
OPERATION
The battery tray provi des a secure mounti ng l oca-
ti on and supports the battery. On some vehi cl es, the
battery tray al so provi des the anchor poi nt/s for the
battery hol ddown hardware. The battery tray and
the battery hol ddown hardware combi ne to secure
and stabi l i ze the battery i n the engi ne compartment,
whi ch prevents battery movement duri ng vehi cl e
operati on. Unrestrai ned battery movement duri ng
vehi cl e operati on coul d resul t i n damage to the vehi -
cl e, the battery, or both.
Fig. 18 Battery Tray
1 - BATTERY TEMPERATURE SENSOR
2 - REINFORCEMENT
3 - BATTERY TRAY
4 - POWER DISTRIBUTION CENTER
TJ BATTERY SYSTEM 8F - 19
BATTERY CABLES (Continued)
REMOVAL
(1) Remove the battery from the battery tray
(Refer to 8 - ELECTRI CAL/BATTERY SYSTEM/BAT-
TERY - REMOVAL).
(2) Remove the battery temperature sensor from
the battery tray (Refer to 8 - ELECTRI CAL/CHARG-
I NG/BATTERY TEMPERATURE SENSOR -
REMOVAL).
(3) Remove the four screws wi th washers that
secure the battery tray to the rei nforcement l ocated
between the dash panel and the rear of the front
wheel house i nner panel i n the engi ne compartment
(Fi g. 19).
(4) Remove the battery tray from the rei nforce-
ment i n the engi ne compartment.
INSTALLATION
(1) Cl ean and i nspect the battery tray (Refer to 8 -
ELECTRI CAL/BATTERY SYSTEM - CLEANI NG),
and (Refer to 8 - ELECTRI CAL/BATTERY SYSTEM -
I NSPECTI ON).
(2) Posi ti on the battery tray onto the rei nforce-
ment i n the engi ne compartment.
(3) I nstal l and ti ghten the four screws wi th wash-
ers that secure the battery tray to the rei nforcement
l ocated between the dash panel and the rear of the
front wheel house i nner panel i n the engi ne compart-
ment. Ti ghten the screws to 22.6 N·m (200 i n. l bs.).
(4) I nstal l the battery temperature sensor onto the
battery tray (Refer to 8 - ELECTRI CAL/CHARGI NG/
BATTERY TEMPERATURE SENSOR - I NSTALLA-
TI ON).
(5) I nstal l the battery onto the battery tray (Refer
to 8 - ELECTRI CAL/BATTERY SYSTEM/BATTERY -
I NSTALLATI ON).
Fig. 19 Battery Tray Remove/Install
1 - BATTERY TRAY
2 - SCREW (4)
3 - REINFORCEMENT
4 - BATTERY TEMPERATURE SENSOR MOUNTING HOLE
8F - 20 BATTERY SYSTEM TJ
BATTERY TRAY (Continued)
CHARGING
TABLE OF CONTENTS
page page
CHARGING
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 21
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
DIAGNOSIS AND TESTING - CHARGING
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
SPECIFICATIONS
GENERATOR RATINGS . . . . . . . . . . . . . . . . . 22
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . 23
BATTERY TEMPERATURE SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 23
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 24
GENERATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 24
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 24
GENERATOR DECOUPLER PULLEY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 26
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
DIAGNOSIS AND TESTING - GENERATOR
DECOUPLER . . . . . . . . . . . . . . . . . . . . . . . . . 26
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 29
VOLTAGE REGULATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 30
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
CHARGING
DESCRIPTION
The chargi ng system consi sts of:
• Generator
• Generator Decoupl er Pul l ey (i f equi pped)
• El ectroni c Vol tage Regul ator (EVR) ci rcui try
wi thi n the Powertrai n Control Modul e (PCM)
• I gni ti on swi tch
• Battery (refer to 8, Battery for i nformati on)
• Battery temperature sensor
• Generator Lamp (i f equi pped)
• Check Gauges Lamp (i f equi pped)
• Vol tmeter (refer to 8, I nstrument Cl uster for
i nformati on)
• Wi ri ng harness and connecti ons (refer to 8, Wi r-
i ng for i nformati on)
OPERATION
The chargi ng system i s turned on and off wi th the
i gni ti on swi tch. The system i s on when the engi ne i s
runni ng and the ASD rel ay i s energi zed. When the
ASD rel ay i s on, vol tage i s suppl i ed to the ASD rel ay
sense ci rcui t at the PCM. Thi s vol tage i s connected
through the PCM and suppl i ed to one of the genera-
tor fi el d termi nal s (Gen. Source +) at the back of the
generator.
The amount of DC current produced by the gener-
ator i s control l ed by the EVR (fi el d control ) ci rcui try
contai ned wi thi n the PCM. Thi s ci rcui try i s con-
nected i n seri es wi th the second rotor fi el d termi nal
and ground.
A battery temperature sensor, l ocated i n the bat-
tery tray housi ng, i s used to sense battery tempera-
ture. Thi s temperature data, al ong wi th data from
moni tored l i ne vol tage, i s used by the PCM to vary
the battery chargi ng rate. Thi s i s done by cycl i ng the
ground path to control the strength of the rotor mag-
neti c fi el d. The PCM then compensates and regul ates
generator current output accordi ngl y.
Al l vehi cl es are equi pped wi th On-Board Di agnos-
ti cs (OBD). Al l OBD-sensed systems, i ncl udi ng EVR
(fi el d control ) ci rcui try, are moni tored by the PCM.
Each moni tored ci rcui t i s assi gned a Di agnosti c Trou-
bl e Code (DTC). The PCM wi l l store a DTC i n el ec-
troni c memory for certai n fai l ures i t detects. Refer to
Di agnosti c Troubl e Codes i n; Powertrai n Control
Modul e; El ectroni c Control Modul es for more DTC
i nformati on.
The Check Gauges Lamp (i f equi pped) moni tors:
charging system voltage, engi ne cool ant tempera-
ture and engi ne oi l pressure. I f an extreme condi ti on
i s i ndi cated, the l amp wi l l be i l l umi nated. Thi s i s
done as remi nder to check the three gauges. The si g-
nal to acti vate the l amp i s sent vi a the CCD bus ci r-
cui ts. The l amp i s l ocated on the i nstrument panel .
Refer to 8, I nstrument Cl uster for addi ti onal i nfor-
mati on.
TJ CHARGING 8F - 21
DIAGNOSIS AND TESTING - CHARGING
SYSTEM
The fol l owi ng procedures may be used to di agnose
the chargi ng system i f:
• the check gauges l amp (i f equi pped) i s i l l umi -
nated wi th the engi ne runni ng
• the vol tmeter (i f equi pped) does not regi ster
properl y
• an undercharged or overcharged battery condi -
ti on occurs.
Remember that an undercharged battery i s often
caused by:
• accessori es bei ng l eft on wi th the engi ne not
runni ng
• a faul ty or i mproperl y adjusted swi tch that
al l ows a l amp to stay on. Refer to I gni ti on-Off Draw
Test i n 8, Battery for more i nformati on.
INSPECTION
The Powertrai n Control Modul e (PCM) moni tors
cri ti cal i nput and output ci rcui ts of the chargi ng sys-
tem, maki ng sure they are operati onal . A Di agnosti c
Troubl e Code (DTC) i s assi gned to each i nput and
output ci rcui t moni tored by the On-Board Di agnosti c
(OBD) system. Some chargi ng system ci rcui ts are
checked conti nuousl y, and some are checked onl y
under certai n condi ti ons.
Refer to Di agnosti c Troubl e Codes i n; Powertrai n
Control Modul e; El ectroni c Control Modul es for more
DTC i nformati on. Thi s wi l l i ncl ude a compl ete l i st of
DTC’s i ncl udi ng DTC’s for the chargi ng system.
To perform a compl ete test of the chargi ng system,
refer to the appropri ate Powertrai n Di agnosti c Proce-
dures servi ce manual and the DRB௡ scan tool . Per-
form the fol l owi ng i nspecti ons before attachi ng the
scan tool .
(1) I nspect the battery condi ti on. Refer to 8, Bat-
tery for procedures.
(2) I nspect condi ti on of battery cabl e termi nal s,
battery posts, connecti ons at engi ne bl ock, starter
sol enoi d and rel ay. They shoul d be cl ean and ti ght.
Repai r as requi red.
(3) I nspect al l fuses i n both the fusebl ock and
Power Di stri buti on Center (PDC) for ti ghtness i n
receptacl es. They shoul d be properl y i nstal l ed and
ti ght. Repai r or repl ace as requi red.
(4) I nspect generator mounti ng bol ts for ti ghtness.
Repl ace or ti ghten bol ts i f requi red. Refer to the Gen-
erator Removal /I nstal l ati on secti on of thi s group for
torque speci fi cati ons.
(5) I nspect generator dri ve bel t condi ti on and ten-
si on. Ti ghten or repl ace bel t as requi red. Refer to
Bel t Tensi on Speci fi cati ons i n 7, Cool i ng System.
(6) I nspect automati c bel t tensi oner (i f equi pped).
Refer to 7, Cool i ng System for i nformati on.
(7) I nspect generator el ectri cal connecti ons at gen-
erator fi el d, battery output, and ground termi nal (i f
equi pped). Al so check generator ground wi re connec-
ti on at engi ne (i f equi pped). They shoul d al l be cl ean
and ti ght. Repai r as requi red.
SPECIFICATIONS
GENERATOR RATINGS
TYPE PART NUMBER RATED SAE AMPS ENGINES MINIMUM TEST AMPS
DENSO 56044530AB 124 2.4L 88
DENSO 56044532AB 136 2.4 96
DENSO 56041685AA 117 4.0L 88
DENSO 56041565AA 81 4.0L 57
DENSO 56041822AA 124 4.0L 90
8F - 22 CHARGING TJ
CHARGING (Continued)
TORQUE
DESCRIPTION N-m Ft. Lbs. In. Lbs.
Generator Mounting Bolts
(2.4L)
57 42 -
Generator Mounting Bolt
(4.0L)
55 41 -
Generator Pivot Bolt/Nut
(4.0L)
55 41 -
Generator B+ Cable Nut 13 - 115
SPECIAL TOOLS
BATTERY TEMPERATURE
SENSOR
DESCRIPTION
The Battery Temperature Sensor (BTS) i s attached
to the battery tray l ocated under the battery.
OPERATION
The BTS i s used to determi ne the battery temper-
ature and control battery chargi ng rate. Thi s temper-
ature data, al ong wi th data from moni tored l i ne
vol tage, i s used by the PCM to vary the battery
chargi ng rate. System vol tage wi l l be hi gher at col der
temperatures and i s gradual l y reduced at warmer
temperatures.
The PCM sends 5 vol ts to the sensor and i s
grounded through the sensor return l i ne. As temper-
ature i ncreases, resi stance i n the sensor decreases
and the detecti on vol tage at the PCM i ncreases.
The BTS i s al so used for OBD I I di agnosti cs. Cer-
tai n faul ts and OBD I I moni tors are ei ther enabl ed
or di sabl ed, dependi ng upon BTS i nput (for exampl e,
di sabl e purge and enabl e Leak Detecti on Pump
(LDP) and O2 sensor heater tests). Most OBD I I
moni tors are di sabl ed bel ow 20 degrees F.
REMOVAL
The battery temperature sensor i s l ocated under
the vehi cl e battery (Fi g. 1) and i s attached to a
mounti ng hol e on battery tray.
GENERATOR DECOUPLER TOOL #8433
GENERATOR DECOUPLER TOOL #8823
Fig. 1 Battery Temperature Sensor Remove/Install
1 - BATTERY TEMPERATURE SENSOR
2 - BATTERY TRAY
TJ CHARGING 8F - 23
CHARGING (Continued)
(1) Remove battery. Refer to 8, Battery for proce-
dures.
(2) Di sconnect sensor pi gtai l harness from engi ne
wi re harness.
(3) Pry sensor strai ght up from battery tray
mounti ng hol e.
INSTALLATION
The battery temperature sensor i s l ocated under
the vehi cl e battery and i s attached to a mounti ng
hol e on battery tray.
(1) Feed pi gtai l harness through hol e i n top of bat-
tery tray and press sensor i nto top of battery tray.
(2) Connect pi gtai l harness.
(3) I nstal l battery. Refer to 8, Battery for proce-
dures.
GENERATOR
DESCRIPTION
The generator i s bel t-dri ven by the engi ne usi ng a
serpenti ne type dri ve bel t. I t i s servi ced onl y as a
compl ete assembl y. I f the generator fai l s for any rea-
son, the enti re assembl y must be repl aced.
OPERATION
As the energi zed rotor begi ns to rotate wi thi n the
generator, the spi nni ng magneti c fi el d i nduces a cur-
rent i nto the wi ndi ngs of the stator coi l . Once the
generator begi ns produci ng suffi ci ent current, i t al so
provi des the current needed to energi ze the rotor.
The Y type stator wi ndi ng connecti ons del i ver the
i nduced AC current to 3 posi ti ve and 3 negati ve
di odes for recti fi cati on. From the di odes, recti fi ed DC
current i s del i vered to the vehi cl e el ectri cal system
through the generator battery termi nal .
Al though the generators appear the same exter-
nal l y, di fferent generators wi th di fferent output rat-
i ngs are used on thi s vehi cl e. Be certai n that the
repl acement generator has the same output rati ng
and part number as the ori gi nal uni t. Refer to Gen-
erator Rati ngs i n the Speci fi cati ons secti on at the
back of thi s group for amperage rati ngs and part
numbers.
Noi se emi tti ng from the generator may be caused
by: worn, l oose or defecti ve beari ngs; a l oose or defec-
ti ve dri ve pul l ey; i ncorrect, worn, damaged or mi sad-
justed fan dri ve bel t; l oose mounti ng bol ts; a
mi sal i gned dri ve pul l ey or a defecti ve stator or di ode.
REMOVAL
WARNING: DISCONNECT NEGATIVE CABLE FROM
BATTERY BEFORE REMOVING BATTERY OUTPUT
WIRE (B+ WIRE) FROM GENERATOR. FAILURE TO
DO SO CAN RESULT IN INJURY OR DAMAGE TO
ELECTRICAL SYSTEM.
(1) Di sconnect negati ve battery cabl e at battery.
(2) Remove generator dri ve bel t. Refer to 7, Cool -
i ng System for procedure.
(3) Remove generator pi vot and mounti ng bol ts/nut
(Fi g. 2) , or (Fi g. 3). Posi ti on generator for access to
wi re connectors.
(4) I f equi pped, unsnap pl asti c cover from B+ ter-
mi nal .
(5) Remove B+ cabl e output termi nal mounti ng
nut at rear of generator (Fi g. 4), (Fi g. 5), or (Fi g. 6).
Di sconnect termi nal from generator.
(6) Di sconnect fi el d wi re connector at rear of gen-
erator by pushi ng on connector tab.
(7) Remove generator from vehi cl e.
INSTALLATION
(1) Posi ti on generator to engi ne and snap fi el d
wi re connector i nto rear of generator.
(2) I nstal l B+ termi nal to generator mounti ng
stud. Ti ghten mounti ng nut. Refer to Torque Speci fi -
cati ons.
(3) I f equi pped, snap pl asti c cover to B+ termi nal .
(4) I nstal l generator mounti ng fasteners and
ti ghten. Refer to Torque Speci fi cati ons.
CAUTION: Never force a belt over a pulley rim
using a screwdriver. The synthetic fiber of the belt
can be damaged.
Fig. 2 GENERATOR REMOVE/INSTALL - 4.0L
1 - GENERATOR
2 - UPPER BOLT
3 - LOWER BOLT
8F - 24 CHARGING TJ
BATTERY TEMPERATURE SENSOR (Continued)
CAUTION: When installing a serpentine accessory
drive belt, the belt MUST be routed correctly. The
water pump will be rotating in the wrong direction if
the belt is installed incorrectly, causing the engine
to overheat. Refer to belt routing label in engine
compartment, or refer to Belt Schematics in 7, Cool-
ing System.
(5) I nstal l generator dri ve bel t. Refer to 7, Cool i ng
System for procedure.
(6) I nstal l negati ve battery cabl e to battery.
Fig. 3 GENERATOR MOUNTING- 2.4L
1 - UPPER MOUNTING BOLT
2 - GENERTOR
3 - LOWER MOUNTING BOLT
Fig. 4 GENERATOR CONNECTORS (TYPICAL
DENSO)
1 - FIELD WIRES
2 - B+ (OUTPUT TERMINAL)
3 - FIELD WIRE CONNECTOR
Fig. 5 GENERATOR CONNECTORS - 4.0L
1 - FIELD WIRE CONNECTOR
2 - B+ CABLE
3 - GENERATOR
4 - B+ CABLE MOUNTING NUT
5 - CABLE PROTECTOR
Fig. 6 GENERATOR ELECTRICAL CONNECTORS -
2.4L - TYPICAL
1 - PROTECTIVE CAP
2 - B+ NUT
3 - B+ TERMINAL
4 - FIELD ELECTRICAL CONNECTOR
TJ CHARGING 8F - 25
GENERATOR (Continued)
GENERATOR DECOUPLER
PULLEY
DESCRIPTION
The generator decoupler is used only with
certain engines. The decoupl er i s used i n pl ace of
the standard generator dri ve pul l ey (Fi g. 7).
OPERATION
The generator decoupler is used only with
certain engines. The decoupl er (Fi g. 7) i s a one-way
cl utch desi gned to hel p reduce bel t tensi on fl uctua-
ti on, vi brati on, reduce fati gue l oads, i mprove bel t l i fe,
reduce hubl oads on components, and reduce noi se.
Dry operati on i s used (no grease or l ubri cants). The
decoupl er i s not temperature sensi ti ve and al so has a
l ow sensi ti vi ty to el ectri cal l oad. The decoupl er i s a
non-servi ceabl e i tem and i s to be repl aced as an
assembl y.
DIAGNOSIS AND TESTING - GENERATOR DECOUPLER
CONDITION POSSIBLE CAUSES CORRECTION
Does not drive generator
(generator not charging)
Internal failure Replace decoupler
Noise coming from
decoupler
Internal failure Replace decoupler
REMOVAL
The generator decoupler is used only with
certain engines.
Two di fferent type generator decoupl er pul l eys are
used. One can be i denti fi ed by the use of machi ned
spl i nes (Fi g. 8). The other can be i denti fi ed by a hex
openi ng (Fi g. 9) and wi l l not use spl i nes.
Di fferent speci al tool s are requi red to servi ce each
di fferent decoupl er. Refer to fol l owi ng procedure.
INA Decoupler
(1) Di sconnect negati ve battery cabl e.
(2) Remove generator and accessory dri ve bel t.
Refer to Generator Removal .
(3) Posi ti on Speci al Tool #8823 (VM.1048) i nto
decoupl er (Fi g. 10).
(4) Determi ne i f end of generator shaft i s hex
shaped (Fi g. 11) or i s spl i ned (Fi g. 12). I f hex i s used,
i nsert a 10MM deep socket i nto tool #8823 (VM.1048)
(Fi g. 13). I f spl i ned, i nsert a 5/16” 6-poi nt hex dri ver,
or a 10MM 12-poi nt tri pl e square dri ver i nto tool
#8823 (VM.1048) (Fi g. 14).
Fig. 7 GENERATOR DECOUPLER PULLEY
Fig. 8 GENERATOR DECOUPLER PULLEY (INA)
1 - GENERATOR
2 - DECOUPLER (INA)
3 - MACHINED SPLINES
8F - 26 CHARGING TJ
(5) The generator shaft uses conventi onal ri ght-
hand threads to attach decoupl er. To break decoupl er
l oose from generator threads, rotate end of tool cl ock-
wi se (Fi g. 13) or, (Fi g. 14).
(6) After breaki ng l oose wi th tool , unthread decou-
pl er by hand from generator.
Fig. 9 GENERATOR DECOUPLER PULLEY (LITENS)
1 - DECOUPLER (LITENS)
2 - HEX OPENING
Fig. 10 #8823 TOOL AND INA DECOUPLER
1 - INA DECOUPLER
2 - TOOL #8823 (VM.1048)
Fig. 11 END OF GENERATOR SHAFT (HEX)
1 - GENERATOR SHAFT
2 - HEX
Fig. 12 END OF GENERATOR SHAFT (SPLINED)
1 - GENERATOR SHAFT
2 - SPLINES
TJ CHARGING 8F - 27
GENERATOR DECOUPLER PULLEY (Continued)
Litens Decoupler
(1) Di sconnect negati ve battery cabl e.
(2) Remove generator and accessory dri ve bel t.
Refer to Generator Removal .
(3) Posi ti on Speci al Tool #8433 (Fi g. 15) i nto
decoupl er. Al i gn to hex end of generator shaft.
(4) The generator shaft uses conventi onal ri ght-
hand threads to attach decoupl er. To break decoupl er
l oose from generator threads, rotate end of tool cl ock-
wi se (Fi g. 16).
(5) After breaki ng l oose wi th tool , unthread decou-
pl er by hand from generator.
Fig. 13 DECOUPLER REMOVAL (INA-HEX)
1 - DEEP 10 MM SOCKET
2 - TOOL #8823 (VM.1048)
Fig. 14 DECOUPLER REMOVAL (INA-SPLINED)
1 - DRIVER
2 - TOOL #8823 (VM.1048)
3 - 17 MM WRENCH
Fig. 15 # 8433 TOOL AND LITENS DECOUPLER
Fig. 16 DECOUPLER REMOVAL (LITENS)
8F - 28 CHARGING TJ
GENERATOR DECOUPLER PULLEY (Continued)
INSTALLATION
INA Decoupler
(1) Thread decoupl er pul l ey onto generator shaft
by hand (ri ght-hand threads).
(2) Posi ti on Speci al Tool #8823 (VM.1048) i nto
decoupl er (Fi g. 10).
(3) Determi ne i f end of generator shaft i s hex
shaped (Fi g. 11) or i s spl i ned (Fi g. 12). I f hex i s used,
i nsert a 10MM deep socket i nto tool #8823 (VM.1048)
(Fi g. 17). I f spl i ned, i nsert a 5/16” 6-poi nt hex dri ver,
or a 10MM 12-poi nt tri pl e square dri ver i nto tool
#8823 (VM.1048) (Fi g. 18).
(4) Do not use an adjustable, ratcheting “click
type” torque wrench. Most “click type”
wrenches will only allow torque to be applied
in a clockwise rotation. Use a dial-type or
beam-type wrench. Ti ghten i n counter-cl ockwi se
rotati on (Fi g. 17) or, (Fi g. 18). Refer to torque speci -
fi cati ons.
(5) I nstal l accessory dri ve bel t, and generator.
Refer to Generator I nstal l ati on.
(6) Connect negati ve battery cabl e.
Litens Decoupler
(1) Thread decoupl er pul l ey onto generator shaft
by hand (ri ght-hand threads).
(2) Posi ti on Speci al Tool 8433 (Fi g. 15) i nto decou-
pl er. Al i gn tool to hex end of generator shaft.
(3) Do not use an adjustable, ratcheting “click
type” torque wrench. Most “click type”
wrenches will only allow torque to be applied
in a clockwise rotation. Use a dial-type or
beam-type wrench. Ti ghten i n counter-cl ockwi se
rotati on (Fi g. 19). Refer to torque speci fi cati ons.
(4) I nstal l accessory dri ve bel t, and generator.
Refer to Generator I nstal l ati on.
(5) Connect negati ve battery cabl e.
Fig. 17 DECOUPLER INSTALLATION (INA-HEX)
1 - 10MM DEEP SOCKET
2 - TOOL # 8823 (VM.1048)
Fig. 18 DECOUPLER INSTALLATION (INA SPLINED)
1 - DRIVER
2 - TOOL # 8823 (VM.1048)
Fig. 19 DECOUPLER INSTALLATION (Litens)
TJ CHARGING 8F - 29
GENERATOR DECOUPLER PULLEY (Continued)
VOLTAGE REGULATOR
DESCRIPTION
The El ectroni c Vol tage Regul ator (EVR) i s not a
separate component. I t i s actual l y a vol tage regul at-
i ng ci rcui t l ocated wi thi n the Powertrai n Control
Modul e (PCM). The EVR i s not servi ced separatel y. I f
repl acement i s necessary, the PCM must be repl aced.
OPERATION
The amount of DC current produced by the gener-
ator i s control l ed by EVR ci rcui try contai ned wi thi n
the PCM. Thi s ci rcui try i s connected i n seri es wi th
the generators second rotor fi el d termi nal and i ts
ground.
Vol tage i s regul ated by cycl i ng the ground path to
control the strength of the rotor magneti c fi el d. The
EVR ci rcui try moni tors system l i ne vol tage (B+) and
battery temperature (refer to Battery Temperature
Sensor for more i nformati on). I t then determi nes a
target chargi ng vol tage. I f sensed battery vol tage i s
0.5 vol ts or l ower than the target vol tage, the PCM
grounds the fi el d wi ndi ng unti l sensed battery vol t-
age i s 0.5 vol ts above target vol tage. A ci rcui t i n the
PCM cycl es the ground si de of the generator fi el d up
to 100 ti mes per second (100Hz), but has the capabi l -
i ty to ground the fi el d control wi re 100% of the ti me
(ful l fi el d) to achi eve the target vol tage. I f the charg-
i ng rate cannot be moni tored (l i mp-i n), a duty cycl e
of 25% i s used by the PCM i n order to have some
generator output. Al so refer to Chargi ng System
Operati on for addi ti onal i nformati on.
8F - 30 CHARGING TJ
STARTING
TABLE OF CONTENTS
page page
STARTING
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 31
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
DIAGNOSIS AND TESTING - STARTING
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
INSPECTION - STARTING SYSTEM . . . . . . . . . 36
SPECIFICATIONS
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
STARTER MOTOR
DIAGNOSIS AND TESTING - STARTER
MOTOR/SOLENOID . . . . . . . . . . . . . . . . . . . . 37
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 40
STARTER MOTOR RELAY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 40
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
DIAGNOSIS AND TESTING - STARTER RELAY . 40
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 41
STARTING
DESCRIPTION
The starti ng system consi sts of:
• Starter rel ay
• Starter motor (i ncl udi ng an i ntegral starter sol e-
noi d)
Other components to be consi dered as part of start-
i ng system are:
• Battery
• Battery cabl es
• I gni ti on swi tch and key l ock cyl i nder
• Cl utch pedal posi ti on swi tch (manual transmi s-
si on)
• Park/neutral posi ti on swi tch (automati c trans-
mi ssi on)
• Wi re harnesses and connecti ons.
The Battery, Starti ng, and Chargi ng systems oper-
ate i n conjuncti on wi th one another, and must be
tested as a compl ete system. For correct operati on of
starti ng/chargi ng systems, al l components used i n
these 3 systems must perform wi thi n speci fi cati ons.
When attempti ng to di agnose any of these systems, i t
i s i mportant that you keep thei r i nterdependency i n
mi nd.
The di agnosti c procedures used i n each of these
groups i ncl ude the most basi c conventi onal di agnosti c
methods, to the more sophi sti cated On-Board Di ag-
nosti cs (OBD) bui l t i nto the Powertrai n Control Mod-
ul e (PCM). Use of an i nducti on-type mi l l i ampere
ammeter, vol t/ohmmeter, battery charger, carbon pi l e
rheostat (l oad tester), and 12-vol t test l amp may be
requi red.
Certai n starti ng system components are moni tored
by the PCM and may produce a Di agnosti c Troubl e
Code (DTC).
OPERATION
The starti ng system components form two separate
ci rcui ts. A hi gh-amperage feed ci rcui t that feeds the
starter motor between 150 and 350 amperes (700
amperes - di esel engi ne), and a l ow-amperage control
ci rcui t that operates on l ess than 20 amperes. The
hi gh-amperage feed ci rcui t components i ncl ude the
battery, the battery cabl es, the contact di sc porti on of
the starter sol enoi d, and the starter motor. The l ow-
amperage control ci rcui t components i ncl ude the i gni -
ti on swi tch, the cl utch pedal posi ti on swi tch (manual
transmi ssi on), the park/neutral posi ti on swi tch (auto-
mati c transmi ssi on), the starter rel ay, the el ectro-
magneti c wi ndi ngs of the starter sol enoi d, and the
connecti ng wi re harness components.
I f the vehi cl e i s equi pped wi th a manual transmi s-
si on, i t has a cl utch pedal posi ti on swi tch i nstal l ed i n
seri es between the i gni ti on swi tch and the coi l bat-
tery termi nal of the starter rel ay. Thi s normal l y open
swi tch prevents the starter rel ay from bei ng ener-
gi zed when the i gni ti on swi tch i s turned to the
momentary Start posi ti on, unl ess the cl utch pedal i s
depressed. Thi s feature prevents starter motor oper-
ati on whi l e the cl utch di sc and the fl ywheel are
engaged. The starter rel ay coi l ground termi nal i s
al ways grounded on vehi cl es wi th a manual trans-
mi ssi on.
I f the vehi cl e i s equi pped wi th an automati c trans-
mi ssi on, battery vol tage i s suppl i ed through the l ow-
amperage control ci rcui t to the coi l battery termi nal
of the starter rel ay when the i gni ti on swi tch i s
turned to the momentary Start posi ti on. The park/
TJ STARTING 8F - 31
neutral posi ti on swi tch i s i nstal l ed i n seri es between
the starter rel ay coi l ground termi nal and ground.
Thi s normal l y open swi tch prevents the starter rel ay
from bei ng energi zed and the starter motor from
operati ng unl ess the automati c transmi ssi on gear
sel ector i s i n the Neutral or Park posi ti ons.
When the starter rel ay coi l i s energi zed, the nor-
mal l y open rel ay contacts cl ose. The rel ay contacts
connect the rel ay common feed termi nal to the rel ay
normal l y open termi nal . The cl osed rel ay contacts
energi ze the starter sol enoi d coi l wi ndi ngs.
The energi zed sol enoi d pul l -i n coi l pul l s i n the sol e-
noi d pl unger. The sol enoi d pl unger pul l s the shi ft
l ever i n the starter motor. Thi s engages the starter
overrunni ng cl utch and pi ni on gear wi th the starter
ri ng gear on the manual transmi ssi on fl ywheel or on
the automati c transmi ssi on torque converter or
torque converter dri ve pl ate.
As the sol enoi d pl unger reaches the end of i ts
travel , the sol enoi d contact di sc compl etes the hi gh-
amperage starter feed ci rcui t and energi zes the sol e-
noi d pl unger hol d-i n coi l . Current now fl ows between
the sol enoi d battery termi nal and the starter motor,
energi zi ng the starter.
Once the engi ne starts, the overrunni ng cl utch pro-
tects the starter motor from damage by al l owi ng the
starter pi ni on gear to spi n faster than the pi ni on
shaft. When the dri ver rel eases the i gni ti on swi tch to
the On posi ti on, the starter rel ay coi l i s de-energi zed.
Thi s causes the rel ay contacts to open. When the
rel ay contacts open, the starter sol enoi d pl unger
hol d-i n coi l i s de-energi zed.
When the sol enoi d pl unger hol d-i n coi l i s de-ener-
gi zed, the sol enoi d pl unger return spri ng returns the
pl unger to i ts rel axed posi ti on. Thi s causes the con-
tact di sc to open the starter feed ci rcui t, and the shi ft
l ever to di sengage the overrunni ng cl utch and pi ni on
gear from the starter ri ng gear.
DIAGNOSIS AND TESTING - STARTING
SYSTEM
The battery, starti ng system and chargi ng system
i n the vehi cl e operate wi th one another, and must be
tested as a compl ete system. I n order for the engi ne
to start and the battery to charge properl y, al l of the
components that are used i n these systems must per-
form wi thi n speci fi cati ons. The servi ce i nformati on
for these systems has been separated wi thi n thi s ser-
vi ce manual to make i t easi er to l ocate the speci fi c
i nformati on you are seeki ng. However, when
attempti ng to di agnose any of these systems, i t i s
i mportant that you keep thei r i nterdependency i n
mi nd.
The di agnosti c procedures used for the battery,
starti ng system and chargi ng system i ncl ude the
most basi c conventi onal di agnosti c methods, to the
more sophi sti cated On-Board Di agnosti cs (OBD) bui l t
i nto the Powertrai n Control Modul e (PCM). Use of an
i nducti on-type mi l l i ampere ammeter, a vol t/ohmme-
ter, a battery charger, a carbon pi l e rheostat (l oad
tester) and a 12-vol t test l amp may be requi red. Al l
OBD-sensed systems are moni tored by the PCM.
Each moni tored ci rcui t i s assi gned a Di agnosti c Trou-
bl e Code (DTC). The PCM wi l l store a DTC i n el ec-
troni c memory for any fai l ure i t detects. Refer to
Charging System, On-Board Diagnostic Test for
on-board di agnosti c test procedures.
Starting System Diagnosis
Condition Possible Cause Correction
Starter fails to operate. 1. Battery discharged or
faulty.
1. Refer to 8, Battery. Replace faulty battery as required.
2. Starting circuit wiring
faulty.
2. Refer to Wiring. Test and repair faulty starter feed
and/or control circuits, as required.
3. Starter relay faulty. 3. Refer to Starter Relay. Replace faulty starter relay as
required.
4. Ignition switch faulty. 4. Refer to Ignition Switch and Key Lock Cylinder.
Replace faulty ignition switch as required.
5. Clutch pedal position
switch faulty.
5. Refer to Clutch Pedal Position Switch. Replace faulty
clutch hydraulic linkage unit as required.
6. Park/Neutral position
switch faulty or
misadjusted.
6. Refer to Park/Neutral Position Switch. Replace faulty
park/neutral position switch as required.
7. Starter solenoid faulty. 7. Refer to Starter Motors. Replace faulty starter motor as
required.
8F - 32 STARTING TJ
STARTING (Continued)
Starting System Diagnosis
Condition Possible Cause Correction
8. Starter motor faulty. 8. Refer to Starter Motor. Replace faulty starter motor as
required.
Starter engages, fails to
turn engine.
1. Battery discharged or
faulty.
1. Refer to Battery. Replace faulty battery as required.
2. Starting circuit wiring
faulty.
2. Refer to Wiring. Test and repair faulty starter feed
and/or control circuits as required.
3. Starter motor faulty. 3. Refer to Starter Motor. Replace faulty starter motor as
required.
4. Engine seized. 4. Refer to 9, Engine Diagnosis. Repair or replace faulty
engine as required.
Starter engages, spins
out before engine starts.
1. Starter ring gear faulty. 1. Refer to Starter Motor. Remove starter motor to inspect
starter ring gear. Replace faulty starter ring gear as
required.
2. Starter motor faulty. 2. Refer to Starter Motor. Replace faulty starter motor as
required.
Starter does not
disengage.
1. Starter motor
improperly installed.
1. Refer to Starter Motor. Tighten starter motor mounting
hardware to correct tightness specifications as required.
2. Starter relay faulty. 2. Refer to Starter Relay. Replace faulty starter relay as
required.
3. Ignition switch faulty. 3. Refer to Ignition Switch and Key Lock Cylinder.
Replace faulty ignition switch as required.
4. Starter motor faulty. 4. Refer to Starter Motor. Replace faulty starter motor as
required.
TESTING
Before testi ng the starti ng system perform a vi sual
i nspecti on of the starti ng system components and
connecti ons.
COLD CRANKING TEST
Refer to Starting System i n the i ndex of thi s ser-
vi ce manual for the l ocati on of compl ete starti ng sys-
tem wi ri ng di agrams. Before performi ng thi s test, be
certai n that the fol l owi ng procedures are accom-
pl i shed:
• The battery i s ful l y-charged and l oad tested.
Refer to Battery Charging for battery chargi ng pro-
cedures. Refer to Battery for battery di agnosi s and
testi ng procedures, i ncl udi ng battery l oad test proce-
dures.
• Ful l y engage the parki ng brake.
• I f the vehi cl e i s equi pped wi th an automati c
transmi ssi on, pl ace the gearshi ft sel ector l ever i n the
Park posi ti on. I f the vehi cl e i s equi pped wi th a man-
ual transmi ssi on, pl ace the gearshi ft sel ector l ever i n
the Neutral posi ti on and bl ock the cl utch pedal i n the
ful l y depressed posi ti on.
• Veri fy that al l l amps and accessori es are turned
off.
• To prevent the engi ne from starti ng, remove the
Automati c ShutDown (ASD) rel ay. The ASD rel ay i s
l ocated i n the Power Di stri buti on Center (PDC), i n
the engi ne compartment. See the fuse and rel ay l ay-
out l abel affi xed to the undersi de of the PDC cover
for ASD rel ay i denti fi cati on and l ocati on.
(1) Connect a sui tabl e vol t-ampere tester to the
battery termi nal s (Fi g. 1). See the i nstructi ons pro-
vi ded by the manufacturer of the vol t-ampere tester
bei ng used.
(2) Rotate and hol d the i gni ti on swi tch i n the Start
posi ti on. Note the cranki ng vol tage and current
(amperage) draw readi ngs shown on the vol t-ampere
tester.
(a) I f the vol tage reads bel ow 9.6 vol ts, refer to
Starter Motor for starter motor di agnosi s and
testi ng procedures. I f the starter motor tests OK,
refer to Engine Diagnosis engi ne di agnosi s and
testi ng procedures. I f the starter motor i s not OK,
repl ace faul ty starter motor.
(b) I f the vol tage reads above 9.6 vol ts and the
current (amperage) draw reads bel ow speci fi ca-
ti ons, refer to the Feed Circuit Testi n thi s sec-
ti on.
TJ STARTING 8F - 33
STARTING (Continued)
(c) I f the vol tage reads 12.5 vol ts or greater and
the starter motor does not turn, refer to the Con-
trol Circuit Test i n thi s secti on.
(d) I f the vol tage reads 12.5 vol ts or greater and
the starter motor turns very sl owl y, refer to the
Feed Circuit Test i n thi s secti on.
NOTE: A cold engine will increase the starter cur-
rent (amperage) draw reading, and reduce the bat-
tery voltage reading.
FEED CIRCUIT TEST
The starter feed ci rcui t test (vol tage drop method)
wi l l determi ne i f there i s excessi ve resi stance i n the
hi gh-amperage starter feed ci rcui t.
When performi ng the vol tage drop test, i t i s i mpor-
tant to remember that the vol tage drop i s gi vi ng an
i ndi cati on of the resi stance between the two poi nts at
whi ch the vol tmeter probes are attached.
EXAMPLE:When testi ng the resi stance of the bat-
tery posi ti ve cabl e, touch the vol tmeter l eads to the
battery posi ti ve cabl e termi nal cl amp and to the bat-
tery posi ti ve cabl e eyel et termi nal at the starter sol e-
noi d B(+) termi nal stud. I f you probe the battery
posi ti ve termi nal post and the battery posi ti ve cabl e
eyel et termi nal at the starter sol enoi d B(+) termi nal
stud, you are readi ng the combi ned vol tage drop i n
the battery posi ti ve cabl e termi nal cl amp-to-termi nal
post connecti on and the battery posi ti ve cabl e.
The fol l owi ng operati on wi l l requi re a vol tmeter
accurate to 1/10 (0.10) vol t. Before performi ng thi s
test, be certai n that the fol l owi ng procedures are
accompl i shed:
• The battery i s ful l y-charged and l oad tested.
Refer to Battery Charging for battery chargi ng pro-
cedures. Refer to Battery for battery di agnosi s and
testi ng procedures, i ncl udi ng battery l oad test proce-
dures.
• Ful l y engage the parki ng brake.
• I f the vehi cl e i s equi pped wi th an automati c
transmi ssi on, pl ace the gearshi ft sel ector l ever i n the
Park posi ti on. I f the vehi cl e i s equi pped wi th a man-
ual transmi ssi on, pl ace the gearshi ft sel ector l ever i n
the Neutral posi ti on and bl ock the cl utch pedal i n the
ful l y depressed posi ti on.
• Veri fy that al l l amps and accessori es are turned
off.
• To prevent the engi ne from starti ng, remove the
Automati c ShutDown (ASD) rel ay. The ASD rel ay i s
l ocated i n the Power Di stri buti on Center (PDC), i n
the engi ne compartment. See the fuse and rel ay l ay-
out l abel affi xed to the undersi de of the PDC cover
for ASD rel ay i denti fi cati on and l ocati on.
(1) Connect the posi ti ve l ead of the vol tmeter to
the battery negati ve termi nal post. Connect the neg-
ati ve l ead of the vol tmeter to the battery negati ve
cabl e termi nal cl amp (Fi g. 2). Rotate and hol d the
i gni ti on swi tch i n the Start posi ti on. Observe the
vol tmeter. I f vol tage i s detected, correct the poor con-
tact between the battery negati ve cabl e termi nal
cl amp and the battery negati ve termi nal post.
(2) Connect the posi ti ve l ead of the vol tmeter to
the battery posi ti ve termi nal post. Connect the nega-
ti ve l ead of the vol tmeter to the battery posi ti ve cabl e
termi nal cl amp (Fi g. 3). Rotate and hol d the i gni ti on
swi tch i n the Start posi ti on. Observe the vol tmeter. I f
vol tage i s detected, correct the poor connecti on
between the battery posi ti ve cabl e termi nal cl amp
and the battery posi ti ve termi nal post.
Fig. 1 Volts-Amps Tester Connections - Typical
1 - POSITIVE CLAMP
2 - NEGATIVE CLAMP
3 - INDUCTION AMMETER CLAMP
Fig. 2 Test Battery Negative Connection Resistance
- Typical
1 - VOLTMETER
2 - BATTERY
8F - 34 STARTING TJ
STARTING (Continued)
(3) Connect the vol tmeter to measure between the
battery posi ti ve cabl e termi nal cl amp and the starter
sol enoi d B(+) termi nal stud (Fi g. 4). Rotate and hol d
the i gni ti on swi tch i n the Start posi ti on. Observe the
vol tmeter. I f the readi ng i s above 0.2 vol t, cl ean and
ti ghten the battery posi ti ve cabl e eyel et termi nal con-
necti on at the starter sol enoi d B(+) termi nal stud.
Repeat the test. I f the readi ng i s sti l l above 0.2 vol t,
repl ace the faul ty battery posi ti ve cabl e.
(4) Connect the vol tmeter to measure between the
battery negati ve cabl e termi nal cl amp and a good
cl ean ground on the engi ne bl ock (Fi g. 5). Rotate and
hol d the i gni ti on swi tch i n the Start posi ti on.
Observe the vol tmeter. I f the readi ng i s above 0.2
vol t, cl ean and ti ghten the battery negati ve cabl e
eyel et termi nal connecti on to the engi ne bl ock.
Repeat the test. I f the readi ng i s sti l l above 0.2 vol t,
repl ace the faul ty battery negati ve cabl e.
(5) Connect the posi ti ve l ead of the vol tmeter to
the starter housi ng. Connect the negati ve l ead of the
vol tmeter to the battery negati ve termi nal post (Fi g.
6). Rotate and hol d the i gni ti on swi tch i n the Start
posi ti on. Observe the vol tmeter. I f the readi ng i s
above 0.2 vol t, correct the poor starter to engi ne
bl ock ground contact.
I f the resi stance tests detect no feed ci rcui t prob-
l ems, refer to Starter Motor.
Fig. 3 Test Battery Positive Connection Resistance -
Typical
1 - VOLTMETER
2 - BATTERY
Fig. 4 Test Battery Positive Cable Resistance -
Typical
1 - BATTERY
2 - VOLTMETER
3 - STARTER MOTOR
Fig. 5 Test Ground Circuit Resistance - Typical
1 - VOLTMETER
2 - BATTERY
3 - ENGINE GROUND
Fig. 6 Test Starter Ground - Typical
1 - STARTER MOTOR
2 - BATTERY
3 - VOLTMETER
TJ STARTING 8F - 35
STARTING (Continued)
CONTROL CIRCUIT TEST
The starter control ci rcui t components shoul d be
tested i n the order i n whi ch they are l i sted, as fol -
l ows:
Starter Relay
• Refer to Starter Relay.
Starter Solenoid
• Refer to Starter Motor.
Ignition Switch
• Refer to Ignition Switch and Key Lock Cyl-
inder for i gni ti on swi tch di agnosi s and testi ng proce-
dures.
Clutch Pedal Position Switch
• I f the vehi cl e i s equi pped wi th a manual trans-
mi ssi on, refer to Clutch Pedal Position Switch for
cl utch pedal posi ti on swi tch di agnosi s and testi ng
procedures.
Park/Neutral Position Switch
• I f the vehi cl e i s equi pped wi th an automati c
transmi ssi on, refer to Park/Neutral Position
Switch for park/neutral posi ti on swi tch di agnosi s
and testi ng procedures.
INSPECTION - STARTING SYSTEM
The fol l owi ng starti ng system components shoul d
be careful l y i nspected whenever any starti ng system
probl em i s encountered.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR AIRBAG SYSTEM
CAPACITOR TO DISCHARGE BEFORE PERFORM-
ING FURTHER DIAGNOSIS OR SERVICE. THIS IS
THE ONLY SURE WAY TO DISABLE AIRBAG SYS-
TEM. FAILURE TO TAKE PROPER PRECAUTIONS
COULD RESULT IN ACCIDENTAL AIRBAG DEPLOY-
MENT AND POSSIBLE PERSONAL INJURY.
Battery
• Vi sual l y i nspect battery for i ndi cati ons of physi -
cal damage and l oose or corroded cabl e connecti ons.
Determi ne state-of-charge and cranki ng capaci ty of
battery. Charge or repl ace battery, i f requi red. Refer
to Battery for battery cl eani ng and i nspecti on proce-
dures.
Ignition Switch
• Vi sual l y i nspect i gni ti on swi tch for i ndi cati ons of
physi cal damage and l oose or corroded wi re harness
connecti ons. Cl ean corroded connecti ons as requi red.
Refer to Wiring Diagrams. Refer to Ignition
Switch and Key Lock Cylinder for i gni ti on swi tch
servi ce procedures.
Clutch Pedal Position Switch
• I f vehi cl e i s equi pped wi th a manual transmi s-
si on, vi sual l y i nspect cl utch pedal posi ti on swi tch for
i ndi cati ons of physi cal damage and l oose or corroded
wi re harness connecti ons. Cl ean corroded connecti ons
as requi red. Refer to Clutch Hydraulic Linkage for
cl utch pedal posi ti on swi tch servi ce procedures.
Park/Neutral Position Switch
• I f vehi cl e i s equi pped wi th an automati c trans-
mi ssi on, vi sual l y i nspect park/neutral posi ti on swi tch
for i ndi cati ons of physi cal damage and l oose or cor-
roded wi re harness connecti ons. Cl ean corroded con-
necti ons as requi red. Refer to Park/Neutral
Position Switch for park/neutral posi ti on swi tch
servi ce procedures.
Starter Relay
• Vi sual l y i nspect starter rel ay for i ndi cati ons of
physi cal damage and l oose or corroded wi re harness
connecti ons. Cl ean corroded connecti ons as requi red.
Refer to Starter Relay for starter rel ay servi ce pro-
cedures.
Starter Motor
• Vi sual l y i nspect starter motor for i ndi cati ons of
physi cal damage and l oose or corroded wi re harness
connecti ons. Cl ean corroded connecti ons as requi red.
I f probl em bei ng di agnosed i nvol ves i mproper starter
engagement, di sengagement or noi se compl ai nts,
starter motor shoul d be removed. Wi th starter motor
removed, i nspect starter pi ni on and ri ng gears for
damaged or mi ssi ng teeth. Repl ace faul ty compo-
nents as requi red. Refer to Starter Motor for
removal /i nstal l ati on procedures.
Starter Solenoid
• Vi sual l y i nspect starter sol enoi d for i ndi cati ons
of physi cal damage and l oose or corroded wi re har-
ness connecti ons. Cl ean corroded connecti ons as
requi red. Refer to Starter Motor for starter sol enoi d
servi ce procedures.
Wiring
• Vi sual l y i nspect starti ng system wi re harnesses
for i ndi cati ons of physi cal damage. Repai r or repl ace
any faul ty wi ri ng, as requi red. Refer to Wiring Dia-
grams for repai r or connector and termi nal servi ce
procedures.
8F - 36 STARTING TJ
STARTING (Continued)
SPECIFICATIONS
STARTER
Starter Motor and Solenoid
Manufacturer Mitsubishi
Engine Application 2.4L, 4.0L
Power Rating
2.4L - 1.4 Kilowatt (1.9 Horsepower)
4.0L - 1.4 Kilowatt (1.9 Horsepower)
Voltage 12 Volts
** Number of Permanent Magnets 6
Number of Brushes 4
Drive Type Planetary Gear Reduction
Free Running Test Voltage 11.2 Volts
Free Running Test Maximum Amperage Draw 90 Amperes
Free Running Test Minimum Speed
2.4L - 24400 rpm
4.0L - 2500 rpm
Solenoid Closing Maximum Voltage Required 7.8 Volts
*Cranking Amperage Draw Test
2.4L - 160 Amperes
4.0L - 160 Amperes
* Test at operating temperature. Cold engine, tight (new) engine, or heavy oil will increase starter amperage draw.
** The starter is equipped with permanent magnets. Never strike the starter case to attempt to loosen a sticking/
stuck armature as permanent magnets may crack or break.
TORQUE
DESCRIPTION N-m Ft. Lbs. In. Lbs.
Starter Solenoid B+
Terminal Nut
11.3 - 100
Starter Mounting Bolts
(2.4L)
54 40 -
Starter Heat Shield
Mounting Bolts
6 - 55
Starter Mounting Bolt
(forward facing 4.0L)
41 30 -
Starter Mounting Bolt
(rearward facing 4.0L)
48 35 -
STARTER MOTOR
DIAGNOSIS AND TESTING - STARTER
MOTOR/SOLENOID
Correct starter motor operati on can be confi rmed
by performi ng the fol l owi ng free runni ng bench test.
Thi s test can onl y be performed wi th starter motor
removed from vehi cl e. Refer to starter motor speci fi -
cati ons.
CAUTION: Permanent magnets are used in the
starter. Permanent magnet starters are highly sensi-
tive to hammering, shocks, external pressure and
reverse polarity. This starter motor must never be
clamped in a vise by starter field frame. The starter
should only be clamped by mounting flange. Do not
reverse battery cable connections to starter motor
when testing. The permanent magnets may be dam-
aged and starter rendered unserviceable if it is sub-
jected to any of these conditions.
TJ STARTING 8F - 37
STARTING (Continued)
STARTER MOTOR TESTING
(1) Remove starter motor from vehi cl e. Refer to
Starter Motor Removal / I nstal l ati on.
(2) Mount starter motor securel y i n a soft-jawed
bench vi se. The vi se jaws shoul d be cl amped on
mounti ng fl ange of starter motor. Never cl amp on
starter motor by fi el d frame.
(3) Connect a sui tabl e vol t-ampere tester and12-
vol t battery to starter motor i n seri es, and set amme-
ter to 100 ampere scal e. See i nstructi ons provi ded by
manufacturer of vol t-ampere tester bei ng used.
(4) I nstal l a jumper wi re from sol enoi d termi nal to
sol enoi d B(+) termi nal stud. The starter motor shoul d
operate. I f starter motor fai l s to operate, repl ace
faul ty starter motor.
(5) Adjust carbon pi l e l oad of tester to obtai n free
runni ng test vol tage. Refer to starter motor free run-
ni ng test vol tage speci fi cati ons.
(6) Note readi ng on ammeter and compare readi ng
to free runni ng test maxi mum amperage draw. Refer
to starter motor free runni ng test maxi mum amper-
age draw speci fi cati ons.
(7) I f ammeter readi ng exceeds maxi mum amper-
age draw speci fi cati on, repl ace faul ty starter motor.
STARTER SOLENOID TESTING
Thi s test can onl y be performed wi th starter motor
removed from vehi cl e.
(1) Remove starter motor from vehi cl e. Refer to
Starter Motor for removal /i nstal l ati on.
(2) Di sconnect wi re from sol enoi d fi el d coi l termi -
nal .
(3) Check for conti nui ty between sol enoi d termi nal
and sol enoi d fi el d coi l termi nal wi th a conti nui ty
tester (Fi g. 7). There shoul d be conti nui ty. I f OK, go
to Step 4. I f not OK, repl ace faul ty starter motor.
(4) Check for conti nui ty between sol enoi d termi nal
and sol enoi d case (Fi g. 8). There shoul d be conti nui ty.
I f not OK, repl ace faul ty starter motor.
REMOVAL
2. 4L
(1) Di sconnect and i sol ate negati ve battery cabl e.
(2) Rai se and support vehi cl e.
(3) Whi l e supporti ng starter motor, remove two
bol ts securi ng starter motor to transmi ssi on (Fi g. 9).
(4) Lower starter motor far enough to access and
remove nut securi ng battery cabl e to starter sol enoi d
B(+) termi nal stud (Fi g. 10). Al ways support starter
motor duri ng thi s process. Do not l et starter motor
hang from wi re harness.
(5) Remove battery cabl e at starter.
(6) Di sconnect sol enoi d termi nal wi re harness con-
nector from starter sol enoi d.
(7) Remove starter motor.
Fig. 7 CONTINUITY TEST BETWEEN SOLENOID
TERMINAL AND FIELD COIL TERMINAL
1 - SOLENOID
2 - SOLENOID TERMINAL
3 - OHMMETER
4 - FIELD COIL TERMINAL
Fig. 8 CONTINUITY TEST BETWEEN SOLENOID
TERMINAL AND SOLENOID CASE - TYPICAL
1 - SOLENOID
2 - SOLENOID TERMINAL
3 - OHMMETER
Fig. 9 STARTER - 2.4L
1 - STARTER
2 - MOUNTING BOLTS (2)
8F - 38 STARTING TJ
STARTER MOTOR (Continued)
4. 0L
(1) Di sconnect and i sol ate negati ve battery cabl e.
(2) Rai se and support vehi cl e.
(3) 4.0L With Manual Transmission: Remove
l ower bol t (forward faci ng) securi ng starter motor to
transmi ssi on housi ng (Fi g. 11).
(4) 4.0L With Manual Transmission: Whi l e sup-
porti ng starter motor, remove upper bol t (rearward
faci ng) securi ng starter motor to transmi ssi on hous-
i ng.
(5) 4.0L With 42 RLE Automatic Transmission:
Remove 2 starter mounti ng bol ts (Fi g. 12).
(6) Lower starter motor from front of transmi ssi on
housi ng far enough to access and remove nut secur-
i ng battery to starter sol enoi d. Al ways support
starter motor duri ng thi s process. Do not l et starter
motor hang from wi re harness.
(7) Remove battery cabl e at starter sol enoi d.
(8) Di sconnect sol enoi d termi nal wi re harness con-
nector from starter sol enoi d.
(9) Remove starter motor from transmi ssi on hous-
i ng.
Fig. 10 STARTER ELECTRICAL CONNECTORS (2.4L
SHOWN)
1 - BATERY CABLE NUT
2 - BATTERY CABLE
3 - SOLENOID CONNECTOR
4 - HEAT SHIELD (IF USED)
Fig. 11 STARTER - 4.0L - MAN. TRANS.
1 - BOLT
2 - STARTER MOTOR
3 - BOLT
Fig. 12 STARTER - 4.0L - 42RLE AUTO. TRANS.
1 - BOLT
2 - STARTER MOTOR
TJ STARTING 8F - 39
STARTER MOTOR (Continued)
INSTALLATION
2. 4L
(1) Connect sol enoi d termi nal wi re harness connec-
tor to starter sol enoi d. Al ways support starter motor
duri ng thi s process. Do not l et starter motor hang
from wi re harness.
(2) I nstal l battery cabl e eyel et onto starter sol e-
noi d stud. Refer to Torque Speci fi cati ons.
(3) Posi ti on starter motor to transmi ssi on. I nstal l
and ti ghten 2 bol ts. Refer to Torque Speci fi cati ons.
(4) Lower vehi cl e.
(5) Connect negati ve battery cabl e.
4. 0L
(1) Connect sol enoi d termi nal wi re harness connec-
tor to starter sol enoi d. Al ways support starter motor
duri ng thi s process. Do not l et starter motor hang
from wi re harness.
(2) I nstal l battery cabl e eyel et onto starter sol e-
noi d stud. Refer to Torque Speci fi cati ons.
(3) Posi ti on starter motor to transmi ssi on housi ng.
Loosel y i nstal l two mounti ng bol ts.
(4) Ti ghten upper (rearward faci ng) mounti ng bol t
to 47.5 N·m (35 ft. l bs.).
(5) Ti ghten l ower (forward faci ng) mounti ng bol t to
40.7 N·m (30 ft. l bs.).
(6) Lower vehi cl e.
(7) Connect negati ve battery cabl e.
STARTER MOTOR RELAY
DESCRIPTION
The starter rel ay (Fi g. 13) i s an el ectromechani cal
devi ce that swi tches battery current to the pul l -i n
coi l of the starter sol enoi d when the i gni ti on swi tch
i s turned to the Start posi ti on. The starter rel ay i s
l ocated i n the Power Di stri buti on Center (PDC), i n
the engi ne compartment. See the fuse and rel ay l ay-
out l abel affi xed to the i nsi de surface of the PDC
cover for starter rel ay i denti fi cati on and l ocati on.
The starter rel ay i s a I nternati onal Standards
Organi zati on (I SO) mi cro-rel ay. Rel ays conformi ng to
the I SO speci fi cati ons have common physi cal di men-
si ons, current capaci ti es, termi nal patterns, and ter-
mi nal functi ons. The I SO mi cro-rel ay termi nal
functi ons are the same as a conventi onal I SO rel ay.
However, the I SO mi cro-rel ay termi nal pattern (or
footpri nt) i s di fferent, the current capaci ty i s l ower,
and the physi cal di mensi ons are smal l er than those
of the conventi onal I SO rel ay.
The starter rel ay cannot be repai red or adjusted
and, i f faul ty or damaged, i t must be repl aced.
OPERATION
The I SO rel ay consi sts of an el ectromagneti c coi l , a
resi stor or di ode, and three (two fi xed and one movabl e)
el ectri cal contacts. The movabl e (common feed) rel ay
contact i s hel d agai nst one of the fi xed contacts (nor-
mal l y cl osed) by spri ng pressure. When the el ectromag-
neti c coi l i s energi zed, i t draws the movabl e contact
away from the normal l y cl osed fi xed contact, and hol ds
i t agai nst the other (normal l y open) fi xed contact.
When the el ectromagneti c coi l i s de-energi zed,
spri ng pressure returns the movabl e contact to the
normal l y cl osed posi ti on. The resi stor or di ode i s con-
nected i n paral l el wi th the el ectromagneti c coi l i n the
rel ay, and hel ps to di ssi pate vol tage spi kes that are
produced when the coi l i s de-energi zed.
DIAGNOSIS AND TESTING - STARTER RELAY
The starter rel ay (Fi g. 14) i s l ocated i n the Power
Di stri buti on Center (PDC), i n engi ne compartment.
Refer to fuse and rel ay l ayout l abel affi xed to under-
si de of PDC cover starter rel ay i denti fi cati on and
l ocati on.
RELAY TEST
(1) Remove starter rel ay from PDC. Refer to
Starter Relay.
(2) A rel ay i n de-energi zed posi ti on shoul d have
conti nui ty between termi nal s 87A and 30, and no
conti nui ty between termi nal s 87 and 30. I f OK, go to
Step 3. I f not OK, repl ace faul ty rel ay.
(3) Resi stance between termi nal s 85 and 86 (el ec-
tromagnet) shoul d be 75 ± 5 ohms. I f OK, go to Step
4. I f not OK, repl ace faul ty rel ay.
(4) Connect a battery to termi nal s 85 and 86.
There shoul d now be conti nui ty between termi nal s
30 and 87, and no conti nui ty between termi nal s 87A
and 30. I f OK, perform Rel ay Ci rcui t Test that fol -
l ows. I f not OK, repl ace faul ty rel ay.
Fig. 13 Starter Relay
30 - COMMON FEED
85 - COIL GROUND
86 - COIL BATTERY
87 - NORMALLY OPEN
87A - NORMALLY CLOSED
8F - 40 STARTING TJ
STARTER MOTOR (Continued)
RELAY CIRCUIT TEST
(1) The rel ay common feed termi nal cavi ty (30) i s
connected to battery vol tage and shoul d be hot at al l
ti mes. I f OK, go to Step 2. I f not OK, repai r open ci r-
cui t to fused B(+) fuse i n PDC as requi red.
(2) The rel ay normal l y cl osed termi nal (87A) i s
connected to termi nal 30 i n de-energi zed posi ti on,
but i s not used for thi s appl i cati on. Go to Step 3.
(3) The rel ay normal l y open termi nal (87) i s con-
nected to the common feed termi nal (30) i n energi zed
posi ti on. Thi s termi nal suppl i es battery vol tage to
starter sol enoi d fi el d coi l . There shoul d be conti nui ty
between cavi ty for rel ay termi nal 87 and starter sol e-
noi d termi nal at al l ti mes. I f OK, go to Step 4. I f not
OK, repai r open engi ne starter motor rel ay output
ci rcui t to starter sol enoi d as requi red.
(4) The coi l battery termi nal (86) i s connected to
el ectromagnet i n rel ay. I t i s energi zed when i gni ti on
swi tch i s hel d i n Start posi ti on. On vehi cl es wi th a
manual transmi ssi on, the cl utch pedal must be
bl ocked i n ful l y depressed posi ti on for thi s test.
Check for battery vol tage at cavi ty for rel ay termi nal
86 wi th i gni ti on swi tch i n Start posi ti on, and no vol t-
age when i gni ti on swi tch i s rel eased to On posi ti on.
I f OK, go to Step 5. I f not OK wi th a manual trans-
mi ssi on, di sconnect cl utch pedal posi ti on swi tch wi re
harness connector and i nstal l a jumper wi re between
two cavi ti es i n body hal f of connector and check for
battery vol tage agai n at cavi ty for rel ay termi nal 86.
I f now OK, repl ace faul ty cl utch pedal posi ti on
swi tch. I f sti l l not OK wi th a manual transmi ssi on or
i f not OK wi th an automati c transmi ssi on, check for
open or shorted fused i gni ti on swi tch output (start)
ci rcui t to i gni ti on swi tch and repai r, as requi red. I f
fused i gni ti on swi tch output (start) ci rcui t i s OK,
refer to Ignition Switch and Key Lock Cylinder.
(5) The coi l ground termi nal (85) i s connected to
el ectromagnet i n rel ay. On vehi cl es wi th a manual
transmi ssi on, i t i s grounded at al l ti mes. On vehi cl es
wi th an automati c transmi ssi on, i t i s grounded
through park/neutral posi ti on swi tch onl y when gear-
shi ft sel ector l ever i s i n Park or Neutral posi ti ons.
Check for conti nui ty to ground at cavi ty for rel ay ter-
mi nal 85. I f not OK wi th a manual transmi ssi on,
repai r open park/neutral posi ti on swi tch sense ci rcui t
to ground as requi red. I f not OK wi th an automati c
transmi ssi on, check for an open or shorted park/neu-
tral posi ti on swi tch sense ci rcui t to park/neutral posi -
ti on swi tch and repai r, as requi red. I f park/neutral
posi ti on swi tch sense ci rcui t checks OK, refer to
Park/Neutral Position Switch.
REMOVAL
(1) Di sconnect and i sol ate battery negati ve cabl e.
(2) Unl atch and open cover on Power Di stri buti on
Center (PDC) (Fi g. 15).
(3) See fuse and rel ay l ayout l abel affi xed to
undersi de of PDC cover for starter rel ay i denti fi ca-
ti on and l ocati on.
(4) Remove starter rel ay from PDC.
INSTALLATION
(1) See fuse and rel ay l ayout l abel affi xed to under-
si de of PDC cover for proper starter rel ay l ocati on.
(2) Posi ti on starter rel ay i n proper receptacl e i n
PDC.
(3) Al i gn starter rel ay termi nal s wi th termi nal
cavi ti es i n PDC receptacl e.
(4) Push down fi rml y on starter rel ay unti l termi nal s
are ful l y seated i n termi nal cavi ti es i n PDC receptacl e.
(5) Cl ose and l atch PDC cover.
(6) Connect negati ve battery cabl e.
Fig. 14 Starter Relay
30 - COMMON FEED
85 - COIL GROUND
86 - COIL BATTERY
87 - NORMALLY OPEN
87A - NORMALLY CLOSED
Fig. 15 Power Distribution Center
1 - POWER DISTRIBUTION CENTER (PDC)
2 - LATCHES
3 - COVER
4 - RIGHT FRONT FENDER
TJ STARTING 8F - 41
STARTER MOTOR RELAY (Continued)
HEATED SYSTEMS
TABLE OF CONTENTS
page page
HEATED GLASS . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 HEATED MIRRORS . . . . . . . . . . . . . . . . . . . . . . . . . 7
HEATED GLASS
TABLE OF CONTENTS
page page
HEATED GLASS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DIAGNOSIS AND TESTING
REAR WINDOW DEFOGGER SYSTEM . . . . . . 2
REAR WINDOW DEFOGGER RELAY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 3
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 4
REAR WINDOW DEFOGGER SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 4
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DIAGNOSIS AND TESTING
REAR WINDOW DEFOGGER SWITCH . . . . . . 4
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 5
REAR WINDOW DEFOGGER GRID
STANDARD PROCEDURE
GRID LINE AND TERMINAL REPAIR
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 6
HEATED GLASS
DESCRIPTION
CAUTION: Grid lines can be damaged or scraped
off with sharp instruments. Care should be taken in
cleaning glass or removing foreign materials,
decals or stickers. Normal glass cleaning solvents
or hot water used with rags or toweling is recom-
mended.
The rear wi ndow defogger system, al so known as
el ectri c backl i ght (EBL), consi sts of two verti cal bus
bars l i nked by a seri es of gri d l i nes fi red onto the
i nsi de surface of the rear wi ndow (Fi g. 1).
The EBL system i s turned On or Off by a control
swi tch mounted i nto the accessory swi tch bezel i n the
i nstrument panel and the ti mer and l ogi c ci rcui try i n
the i nstrument cl uster assembl y (Refer to 8 - ELEC-
TRI CAL/HEATED GLASS/REAR WI NDOW DEFOG-
GER SWI TCH - DESCRI PTI ON).
Ci rcui t protecti on i s provi ded by a 40 amp fuse
l ocated i n the fuse bl ock for the heated gri d ci rcui t,
and by a 10 amp fuse l ocated i n the fuse bl ock for
the control ci rcui t.
OPERATION
The el ectri c backl i ght (EBL) system i s control l ed
by a momentary swi tch l ocated i n the accessory
swi tch bezel on the i nstrument panel (Fi g. 2). When
the defogger swi tch for the EBL system i s pressed to
the On posi ti on, current i s di rected to the rear defog-
ger gri d l i nes and the heated power mi rrors (i f
equi pped). The heated gri d l i nes heat the gl ass to
hel p cl ear the rear wi ndow and si de mi rror surfaces
of fog or frost.
An amber i ndi cator l amp i n the defogger swi tch
wi l l i l l umi nate to i ndi cate when the EBL system i s
turned on. The i nstrument cl uster contai ns the EBL
system control ci rcui try.
NOTE: The EBL system turns off automatically after
approximately ten minutes of initial operation. Each
following activation cycle of the EBL system will
last approximately five minutes.
TJ HEATED SYSTEMS 8G - 1
The EBL system wi l l be automati cal l y turned off
after a programmed ti me i nterval of about ten mi n-
utes. After the i ni ti al ti me i nterval has expi red, i f the
defogger swi tch i s turned on agai n duri ng the same
i gni ti on cycl e, the defogger system wi l l automati cal l y
turn off after about fi ve mi nutes.
The EBL system wi l l automati cal l y shut off i f the
i gni ti on swi tch i s turned to the Off posi ti on, or i t can
be turned off manual l y by depressi ng the defogger
swi tch a second ti me.
The rear wi ndow defogger ti mer and l ogi c ci rcui try
cannot be adjusted or repai red and, i f faul ty or dam-
aged, the i nstrument cl uster assembl y must be
repl aced.
DIAGNOSIS AND TESTING
REAR WINDOW DEFOGGER SYSTEM
NOTE: Illumination of the defogger switch indicator
lamp means that there is electrical current available
at the output of the rear window defogger logic cir-
cuitry, but does not confirm that the electrical cur-
rent is reaching the rear glass heating grid lines.
NOTE: For circuit descriptions and diagrams of the
rear window defogger system, refer to 8W - WIRING
DIAGRAM INFORMATION.
Operati on of the el ectri cal backl i ght (EBL) system
can be confi rmed by the fol l owi ng:
(1) Use a scan tool and check for di agnosti c troubl e
codes (DTCs) rel ated to the A/C-heater control and
the i nstrument cl uster. I f no DTCs are found, go to
Step 2. I f any DTCs are found, repai r as requi red,
then proceed to Step 2
(2) Turn the i gni ti on swi tch to the On posi ti on.
(3) Set the defogger swi tch i n the On posi ti on. The
rear wi ndow defogger operati on can be checked by
feel i ng the rear wi ndow or outsi de rear vi ew mi rror
gl ass. A di sti nct di fference i n temperature between
the gri d l i nes and the adjacent cl ear gl ass or the mi r-
ror gl ass can be detected wi thi n three to four mi n-
utes of operati on. I f the i ndi cator l i ght i s not
i l l umi nated, check the 10 amp i ndi cator fuse and the
40 amp defogger gri d power feed fuse l ocated i n the
fuse bl ock.
(4) I f a temperature di fference i s not detected, use
a 12-vol t DC vol tmeter and contact the rear gl ass
heati ng gri d termi nal A wi th the negati ve l ead, and
termi nal B wi th the posi ti ve l ead (Fi g. 3). The vol t-
meter shoul d read battery vol tage. I f the vol tmeter
does not read battery vol tage, check the fol l owi ng:
• Confi rm that the i gni ti on swi tch i s i n the On
posi ti on.
• Check the 10 amp EBL control ci rcui t fuse
l ocated i n the fuse bl ock.
• Make sure that the EBL feed wi re and ground
wi re are connected to the termi nal s. Confi rm that the
ground wi re has conti nui ty to ground.
• Check the EBL rel ay l ocated i n the power di stri -
buti on center (PDC) i n the engi ne compartment. The
rel ay must be ti ght i n i t’s receptacl e and al l el ectri cal
connecti ons must be secure (Refer to 8 - ELECTRI -
CAL/HEATED GLASS/REAR WI NDOW DEFOGGER
RELAY - REMOVAL).
Fig. 1 Rear Window Defogger
1 - REAR DEFOGGER GRID
2 - REAR WINDOW
Fig. 2 03 ACCESSORY SWITCH BEZEL
1 - BEZEL SCREWS (4)
2 - BEZEL
3 - WIRE HARNESS
4 - ELECTRICAL CONNECTORS (7)
8G - 2 HEATED GLASS TJ
HEATED GLASS (Continued)
(5) When the above steps have been compl eted and
the system i s sti l l i noperati ve, one or more of the fol -
l owi ng i s faul ty:
• Rear wi ndow defogger swi tch i n the i nstrument
panel .
• Rear wi ndow defogger rel ay control ci rcui ty i n
the i nstrument cl uster.
• Rear wi ndow defogger gri d l i nes (al l gri d l i nes
woul d have to be broken, or the power feed or ground
wi re di sconnected, for the enti re heated gri d to be
i noperati ve).
REAR WINDOW DEFOGGER
RELAY
DESCRIPTION
The rear wi ndow defogger (EBL) rel ay (Fi g. 4) i s a
I nternati onal Standards Organi zati on (I SO)-type
rel ay. Rel ays conformi ng to the I SO speci fi cati ons
have common physi cal di mensi ons, current capaci -
ti es, termi nal functi ons and patterns. The EBL rel ay
i s a el ectromechani cal devi ce. When the EBL ti mer
and l ogi c ci rcui try i n the i nstrument cl uster grounds
the rel ay coi l , the rear wi ndow defogger rel ay
swi tches battery current through a 40 amp fuse
l ocated i n the fuse bl ock to the rear wi ndow defogger
gri d and to the l i ght-emi tti ng di ode (LED) i ndi cator
of the rear wi ndow defogger swi tch and al so to the
heati ng el ements of the outsi de mi rrors (when
equi pped).
The rear wi ndow defogger (EBL) rel ay i s l ocated i n
the power di stri buti on center (PDC) i n the engi ne
compartment. See the fuse and rel ay l ayout map on
the i nner surface of the cover of the PDC for rear
wi ndow defogger rel ay i denti fi cati on and l ocati on.
The rear wi ndow defogger (EBL) rel ay cannot be
adjusted or repai red and, i f damaged or faul ty, i t
must be repl aced.
OPERATION
The I SO-standard rear wi ndow defogger (EBL)
rel ay consi sts of an el ectromagneti c coi l , a resi stor or
di ode, and three (two fi xed and one movabl e) el ectri -
cal contacts. The movabl e (common feed) rel ay con-
tact i s hel d agai nst one of the fi xed contacts
(normal l y cl osed) by spri ng pressure. When the el ec-
tromagneti c coi l i s energi zed, i t draws the movabl e
contact away from the normal l y cl osed fi xed contact,
and hol ds i t agai nst the other (normal l y open) fi xed
contact.
When the el ectromagneti c coi l i s de-energi zed,
spri ng pressure returns the movabl e contact to the
normal l y cl osed posi ti on. The resi stor i s connected i n
paral l el wi th the el ectromagneti c coi l i n the rel ay,
and hel ps to di ssi pate vol tage spi kes that are pro-
duced when the coi l i s de-energi zed.
Refer to the appropri ate wi ri ng i nformati on for
di agnosi s and testi ng of the EBL rel ay and for com-
pl ete EBL system wi ri ng di agrams.
REMOVAL
(1) Di sconnect and i sol ate the negati ve battery
cabl e.
(2) Open the cover of the power di stri buti on center
(PDC) l ocated i n the engi ne compartment (Fi g. 5).
NOTE: Refer to the fuse and relay map on the inner
surface of the PDC cover for EBL relay identifica-
tion and location.
Fig. 3 Rear Window Glass Grid Test
1 - POINT A
2 - POINT B
3 - FEED WIRE
4 - MID-POINT C (TYPICAL)
5 - HEATED REAR WINDOW DEFOGGER GRID
6 - GROUND WIRE
Fig. 4 Rear Window Defogger (EBL) Relay
30 - COMMON FEED
85 - COIL GROUND
86 - COIL BATTERY
87 - NORMALLY OPEN
87A - NORMALLY CLOSED
TJ HEATED GLASS 8G - 3
HEATED GLASS (Continued)
(3) Remove the EBL rel ay from the PDC.
INSTALLATION
NOTE: Refer to the fuse and relay map on the inner
surface of the power distribution center (PDC)
cover for EBL relay identification and location.
(1) Posi ti on the EBL rel ay to the proper receptacl e
of the PDC.
(2) Al i gn the EBL rel ay termi nal s wi th the termi -
nal cavi ti es i n the PDC and push down fi rml y on the
rel ay unti l the termi nal s are ful l y seated.
(3) Cl ose the cover of the PDC.
(4) Reconnect the negati ve battery cabl e.
REAR WINDOW DEFOGGER
SWITCH
DESCRIPTION
The swi tch for the EBL system i s l ocated i n the
i nstrument panel accessory swi tch bezel , whi ch i s
mounted near the bottom of the i nstrument panel
center bezel (Fi g. 6).
When the rear wi ndow defogger swi tch i s turned to
the ON posi ti on, current i s di rected to the rear defog-
ger gri d l i nes and the heated power mi rrors (i f
equi pped). The heated gri d l i nes heat the gl ass to
hel p cl ear the surface of fog or frost.
OPERATION
Depressi ng the rear wi ndow defogger swi tch sends
a request si gnal to the i nstrument cl uster rear wi n-
dow defogger ti mer and l ogi c ci rcui try whi ch
responds by energi zi ng or de-energi zi ng the EBL
rel ay. The EBL rel ay control s the current to fl ow to
the gri ds of the rear wi ndow defogger and the heated
power si de vi ew mi rrors, when equi pped.
NOTE: After the initial time interval has expired, if
the defogger switch is turned on again during the
same ignition cycle, the EBL system will automati-
cally turn off after about five minutes.
The EBL rel ay wi l l be on for approxi matel y 10
mi nutes or unti l the control swi tch or i gni ti on i s
turned off. An LED i ndi cator wi l l i l l umi nate when
the EBL system i s on.
The EBL system wi l l be on for approxi matel y ten
mi nutes or unti l the control swi tch or the i gni ti on
swi tch i s turned off.
The rear wi ndow defogger swi tch and i ndi cator
l amp cannot be repai red and, i f faul ty or damaged,
the defogger swi tch must be repl aced.
DIAGNOSIS AND TESTING
REAR WINDOW DEFOGGER SWITCH
WARNING: On vehicles equipped with airbags, dis-
able the airbag system before attempting any steer-
ing wheel, steering column, or instrument panel
component diagnosis or service. Disconnect and
isolate the battery negative (ground) cable, then
wait two minutes for the airbag system capacitor to
discharge before performing further diagnosis or
service. Failure to take the proper precautions
could result in accidental airbag deployment and
possible personal injury or death.
Fig. 5 Power Distribution Center (PDC)
1 - POWER DISTRIBUTION CENTER (PDC)
2 - LATCHES
3 - COVER
4 - RIGHT FRONT FENDER
Fig. 6 03 ACCESSORY SWITCH BEZEL
1 - BEZEL SCREWS (4)
2 - BEZEL
3 - WIRE HARNESS
4 - ELECTRICAL CONNECTORS (7)
8G - 4 HEATED GLASS TJ
REAR WINDOW DEFOGGER RELAY (Continued)
NOTE: For circuit descriptions and diagrams, refer
to Rear Window Defogger in Group 8W - Wiring Dia-
grams.
(1) Di sconnect and i sol ate the negati ve battery
cabl e. Remove the accessory swi tch bezel from the
i nstrument panel and di sconnect the wi re harness
connector from the defogger swi tch.
(2) Check for conti nui ty between the ground ci r-
cui t cavi ty of the defogger swi tch wi re harness con-
nector and a good ground. There shoul d be
conti nui ty. I f OK, go to Step 3. I f not OK, repai r the
open ci rcui t as requi red.
(3) Check for conti nui ty between the ground ci r-
cui t termi nal and the rear wi ndow defogger swi tch
sense ci rcui t termi nal on the back of the defogger
swi tch housi ng (Fi g. 7). There shoul d be momentary
conti nui ty as the defogger swi tch i s pressed, and
then no conti nui ty. I f OK, test the i nstrument cl uster
(Refer to 8 - ELECTRI CAL/I NSTRUMENT CLUS-
TER - DI AGNOSI S AND TESTI NG). I f not OK,
repl ace the faul ty rear wi ndow defogger swi tch (Refer
to 8 - ELECTRI CAL/HEATED GLASS/REAR WI N-
DOW DEFOGGER SWI TCH - REMOVAL).
REMOVAL
WARNING: On vehicles equipped with airbags, dis-
able the airbag system before attempting any steer-
ing wheel, steering column, or instrument panel
component diagnosis or service. Disconnect and
isolate the battery negative (ground) cable, then
wait two minutes for the airbag system capacitor to
discharge before performing further diagnosis or
service. Failure to take the proper precautions
could result in accidental airbag deployment and
possible personal injury or death.
(1) Di sconnect and i sol ate the negati ve battery
cabl e.
(2) Remove the center bezel from the i nstrument
panel (Refer to 23 - BODY/I NSTRUMENT PANEL/
CLUSTER BEZEL - REMOVAL).
(3) Remove the four screws that secure the acces-
sory swi tch bezel to the i nstrument panel (Fi g. 8).
(4) Pul l the accessory swi tch bezel out from the
i nstrument panel far enough to access the wi re har-
ness connectors.
(5) Di sconnect the wi re harness connectors from
the rear of the accessory swi tches and the ci gar l i ght-
er/power outl et.
(6) Remove the accessory swi tch bezel from the
i nstrument panel .
(7) Usi ng a smal l thi n-bl aded screwdri ver, gentl y
pry the snap cl i ps at the top and at the bottom of the
rear wi ndow defogger swi tch receptacl e on the back
of the accessory swi tch bezel and pul l the swi tch out
of the bezel .
INSTALLATION
(1) I nstal l the rear wi ndow defogger swi tch i nto
the back of the accessory swi tch bezel by pushi ng the
swi tch fi rml y i nto the bezel .
(2) Connect the wi re harness connectors to the
rear of the accessory swi tches and the ci gar l i ghter/
power outl et.
Fig. 7 Rear Window Defogger Switch Continuity
SWITCH POSITION CONTINUITY BETWEEN
OFF LAMPS
ON MOMENTARY 1 AND 2
ILLUMINATION LAMP 1 AND 4
INDICATOR LAMP 1 AND 3
Fig. 8 Accessory Switch Bezel
1 - BEZEL SCREWS (4)
2 - BEZEL
3 - WIRE HARNESS
4 - ELECTRICAL CONNECTORS (7)
TJ HEATED GLASS 8G - 5
REAR WINDOW DEFOGGER SWITCH (Continued)
(3) I nstal l the accessory swi tch bezel to the i nstru-
ment panel .
(4) I nstal l the four screws that secure the acces-
sory swi tch bezel to the i nstrument panel . Ti ghten
the screws to 2.2 N·m (20 i n. l bs.).
(5) I nstal l the center bezel to the i nstrument panel
(Refer to 23 - BODY/I NSTRUMENT PANEL/CLUS-
TER BEZEL - I NSTALLATI ON).
(6) Reconnect the negati ve battery cabl e.
REAR WINDOW DEFOGGER
GRID
STANDARD PROCEDURE
GRID LINE AND TERMINAL REPAIR
PROCEDURE
WARNING: Materials contained in the Repair Kit
(Part Number 04549275) may cause skin or eye irri-
tation. The kit contains epoxy resin and amine type
hardener, which are harmful if swallowed. Avoid
contact with the skin and eyes. For skin contact,
wash the affected areas with soap and water. For
contact with the eyes, flush with plenty of water. Do
not take internally. If taken internally, induce vomit-
ing and call a physician immediately. Use with ade-
quate ventilation. Do not use near fire or flame.
Contains flammable solvents. Keep out of the reach
of children. Failure to follow the warnings could
result in possible personal injury or death.
Repai r of the rear gl ass heati ng gri d l i nes, bus
bars or termi nal s can be accompl i shed usi ng the
Mopar௡ Rear Wi ndow Defogger Repai r Ki t (Part
Number 04549275) or equi val ent.
(1) Mask the repai r area wi th maski ng tape so
that the conducti ve epoxy can be appl i ed neatl y (Fi g.
9). Extend the epoxy appl i cati on onto the gri d l i ne or
the bus bar on each si de of the break.
(2) Fol l ow the i nstructi ons i n the repai r ki t for
prepari ng the damaged area.
(3) Remove the package separator cl amp and mi x
the two conducti ve epoxy components thoroughl y
wi thi n the packagi ng. Fol d the package i n hal f and
cut the center corner to di spense the epoxy.
(4) For gri d l i ne repai rs, mask the area to be
repai red wi th maski ng tape or use a templ ate.
(5) Appl y the epoxy through the sl i t i n the mask-
i ng tape or templ ate. Overl ap both ends of the break
by at l east 19 mi l l i meters (0.75 i nch).
(6) For a termi nal repl acement, mask the adjacent
areas so the epoxy can be extended onto the adjacent
gri d l i ne as wel l as the bus bar. Appl y a thi n l ayer of
epoxy to the area where the termi nal was fastened
and onto the adjacent gri d l i ne.
(7) Appl y a thi n l ayer of conducti ve epoxy to the
termi nal and pl ace i t i n the proper l ocati on on the
bus bar. To prevent the termi nal from movi ng whi l e
the epoxy i s curi ng, i t must be wedged or cl amped.
(8) Careful l y remove the maski ng tape or tem-
pl ate.
CAUTION: Do not allow the glass surface to exceed
204°C (400°F) when using a heat gun, or the glass
may fracture.
(9) Al l ow the epoxy to cure 24 hours at room tem-
perature, or careful l y use a heat gun for fi fteen mi n-
utes. When usi ng a heat gun, hol d i t approxi matel y
25.4 centi meters (10 i nches) from the repai r and do
not al l ow the gl ass surface to exceed 204° C (400° F).
NOTE: Do not attach the wire harness connectors
to the terminals until the curing process is com-
plete.
(10) After the conducti ve epoxy i s properl y cured,
remove the wedge or cl amp from the termi nal .
(11) Connect the wi re harness l eads to the gri d
termi nal s and veri fy EBL operati on.
Fig. 9 Grid Line Repair
1 - BREAK
2 - GRID LINE
3 - MASKING TAPE
8G - 6 HEATED GLASS TJ
REAR WINDOW DEFOGGER SWITCH (Continued)
HEATED MIRRORS
TABLE OF CONTENTS
page page
HEATED MIRRORS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
HEATED MIRRORS
DESCRIPTION
The opti onal heated mi rror system i s control l ed by
the momentary rear wi ndow defogger swi tch i n the
accessory swi tch bezel (Fi g. 1). An amber i ndi cator
l amp i n the swi tch wi l l i l l umi nate to i ndi cate when
the rear wi ndow defogger (EBL) system i s turned on.
The heated mi rror system onl y operates i n concert
wi th the EBL system, and wi l l be automati cal l y shut
off after a programmed ti me i nterval of about ten
mi nutes. After the i ni ti al ti me i nterval has expi red, i f
the defogger swi tch i s pressed agai n duri ng the same
i gni ti on cycl e, the heated mi rror system wi l l auto-
mati cal l y shut off after about fi ve mi nutes.
The heated mi rror system wi l l automati cal l y shut
off i f the i gni ti on swi tch i s turned to the Off posi ti on,
or i t can be shut off manual l y by pressi ng the rear
wi ndow defogger swi tch a second ti me.
OPERATION
When the rear wi ndow defogger swi tch i s pressed,
the rear wi ndow defogger (EBL) system becomes acti -
vated and an el ectri c heater gri d l ocated behi nd the
gl ass of each of the outsi de rear vi ew mi rrors i s ener-
gi zed. When energi zed, each of these heater gri ds
produce heat to hel p cl ear the outsi de rear vi ew mi r-
rors of i ce, snow, or fog.
I f the outsi de mi rror heati ng gri ds are both i noper-
ati ve, refer to DI AGNOSI S AND TESTI NG - REAR
WI NDOW DEFOGGER SYSTEM i n hi s group. I f
onl y one of the outsi de mi rror heati ng gri ds i s i nop-
erati ve, refer to 8 - ELECTRI CAL/POWER MI R-
RORS - DI AGNOSI S AND TESTI NG.
The heati ng gri d behi nd each outsi de mi rror gl ass
cannot be repai red and, i f faul ty or damaged, the
enti re power mi rror assembl y must be repl aced.
Fig. 1 03 ACCESSORY SWITCH BEZEL
1 - BEZEL SCREWS (4)
2 - BEZEL
3 - WIRE HARNESS
4 - ELECTRICAL CONNECTORS (7)
TJ HEATED MIRRORS 8G - 7
HORN
TABLE OF CONTENTS
page page
HORN SYSTEM
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
HORN
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DIAGNOSIS AND TESTING - HORN . . . . . . . . . . 1
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 2
HORN SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 2
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DIAGNOSIS AND TESTING - HORN SWITCH . . . 2
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 3
HORN SYSTEM
DESCRIPTION
The horn system features one l ow-note horn uni t.
The horn system uses a non-swi tched source of bat-
tery current so that the system wi l l remai n func-
ti onal , regardl ess of the i gni ti on swi tch posi ti on. The
horn system i ncl udes the fol l owi ng components:
• Cl ockspri ng
• Horn
• Horn rel ay
• Horn swi tch
OPERATION
The horn system i s acti vated by a horn swi tch con-
ceal ed beneath the dri ver si de ai rbag modul e tri m
cover i n the center of the steeri ng wheel . Depressi ng
the center of the dri ver si de ai rbag modul e tri m cover
cl oses the horn swi tch. Cl osi ng the horn swi tch acti -
vates the horn rel ay. The acti vated horn rel ay then
swi tches the battery current needed to energi ze the
horns.
HORN
DESCRIPTION
The horn i s secured wi th a bracket to the l eft front
i nner fender shi el d just ahead of the l eft front wheel
house i n the engi ne compartment.
The horn cannot be repai red or adjusted and, i f
faul ty or damaged, i t must be repl aced.
OPERATION
Wi thi n the two hal ves of the mol ded pl asti c horn
housi ng are a fl exi bl e di aphragm, a pl unger, an el ec-
tromagneti c coi l and a set of contact poi nts. The di a-
phragm i s secured i n suspensi on around i ts
peri meter by the mati ng surfaces of the horn hous-
i ng. The pl unger i s secured to the center of the di a-
phragm and extends i nto the center of the
el ectromagnet. The contact poi nts control the current
fl ow through the el ectromagnet.
When the horn i s energi zed, el ectri cal current
fl ows through the cl osed contact poi nts to the el ectro-
magnet. The resul ti ng el ectromagneti c fi el d draws
the pl unger and di aphragm toward i t unti l that
movement mechani cal l y opens the contact poi nts.
When the contact poi nts open, the el ectromagneti c
fi el d col l apses al l owi ng the pl unger and di aphragm to
return to thei r rel axed posi ti ons and cl osi ng the con-
tact poi nts agai n. Thi s cycl e conti nues repeati ng at a
very rapi d rate produci ng the vi brati on and move-
ment of ai r that creates the sound that i s di rected
through the horn outl et.
DIAGNOSIS AND TESTING - HORN
For compl ete ci rcui t di agrams, refer to the appro-
pri ate wi ri ng i nformati on.
(1) Di sconnect the wi re harness connectors from
the horn connector receptacl es. Measure the resi s-
tance between the ground ci rcui t cavi ty of the horns
wi re harness connectors and a good ground. There
shoul d be conti nui ty. I f OK, go to Step 2. I f not OK,
repai r the open ground ci rcui t to ground as requi red.
(2) Check for battery vol tage at the horn rel ay out-
put ci rcui t cavi ty of the horns wi re harness connec-
tors. There shoul d be zero vol ts. I f OK, go to Step 3.
I f not OK, repai r the shorted horn rel ay output ci r-
cui t or repl ace the faul ty horn rel ay as requi red.
(3) Depress the horn swi tch. There shoul d now be
battery vol tage at the horn rel ay output ci rcui t cavi ty
of the horns wi re harness connectors. I f OK, repl ace
the faul ty horns. I f not OK, repai r the open horn
rel ay output ci rcui t to the horn rel ay as requi red.
TJ HORN 8H - 1
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Di sconnect the wi re harness connector from the
horn (Fi g. 1).
(3) Remove the screw that secures the horn and
mounti ng bracket to the l eft front i nner fender
shi el d.
(4) Remove the horn and mounti ng bracket from
the l eft front i nner fender shi el d.
INSTALLATION
(1) Posi ti on the horn and mounti ng bracket onto
the l eft front i nner fender shi el d.
(2) I nstal l the mounti ng screw. Ti ghten the screw
to 8.5 N·m (75 i n. l bs.).
(3) Reconnect the wi re harness connector.
(4) Connect the battery negati ve cabl e.
HORN SWITCH
DESCRIPTION
A center-bl ow, normal l y open, resi sti ve membrane-
type horn swi tch i s secured i n a pl asti c tray that i s
i nserted i n a pocket sewn on the front of the dri ver
si de ai rbag retai ner strap. The horn swi tch i s con-
ceal ed behi nd the dri ver si de ai rbag modul e tri m
cover.
The steeri ng wheel and steeri ng col umn must be
properl y grounded i n order for the horn swi tch to
functi on properl y. The horn swi tch and pl asti c tray
are servi ced as a uni t. I f the horn swi tch i s damaged
or faul ty, or i f the dri ver si de ai rbag i s depl oyed, the
horn swi tch and tray must be repl aced as a uni t.
OPERATION
When the center area of the dri ver si de ai rbag tri m
cover i s depressed, the el ectri cal l y conducti ve gri ds
on the faci ng surfaces of the horn swi tch membranes
contact each other, cl osi ng the swi tch ci rcui t. The
compl eted horn swi tch ci rcui t provi des a ground for
the control coi l si de of the horn rel ay, whi ch acti vates
the rel ay. When the horn swi tch i s rel eased, the
resi sti ve tensi on of the convex membrane separates
the two el ectri cal l y conducti ve gri ds and opens the
swi tch ci rcui t.
DIAGNOSIS AND TESTING - HORN SWITCH
For compl ete ci rcui t di agrams, refer to the appro-
pri ate wi ri ng i nformati on.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO ELECTRICAL, RESTRAINTS
BEFORE ATTEMPTING ANY STEERING WHEEL,
STEERING COLUMN, OR INSTRUMENT PANEL
COMPONENT DIAGNOSIS OR SERVICE. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
(1) Di sconnect and i sol ate the battery negati ve
cabl e. Remove the steeri ng col umn openi ng cover
from the i nstrument panel .
(2) Check for conti nui ty between the metal steer-
i ng col umn jacket and a good ground. There shoul d
be conti nui ty. I f OK, go to Step 3. I f not OK, refer to
Steeri ng, Col umn for proper i nstal l ati on of the steer-
i ng col umn.
(3) Remove the dri ver si de ai rbag modul e from the
steeri ng wheel . Di sconnect the horn swi tch wi re har-
ness connectors from the dri ver si de ai rbag modul e.
(4) Remove the horn rel ay from the Power Di stri -
buti on Center (PDC). Check for conti nui ty between
the steeri ng col umn hal f of the horn swi tch feed wi re
harness connector and a good ground. There shoul d
be no conti nui ty. I f OK, go to Step 5. I f not OK,
repai r the shorted horn rel ay control ci rcui t to the
horn rel ay i n the PDC as requi red.
(5) Check for conti nui ty between the steeri ng col -
umn hal f of the horn swi tch feed wi re harness con-
nector and the horn rel ay control ci rcui t cavi ty for
the horn rel ay i n the PDC. There shoul d be conti nu-
i ty. I f OK, go to Step 6. I f not OK, repai r the open
horn rel ay control ci rcui t to the horn rel ay i n the
PDC as requi red.
(6) Check for conti nui ty between the horn swi tch
feed wi re and the horn swi tch ground wi re on the
dri ver si de ai rbag modul e. There shoul d be no conti -
nui ty. I f OK, go to Step 7. I f not OK, repl ace the
faul ty horn swi tch.
Fig. 1 HORN
8H - 2 HORN TJ
HORN (Continued)
(7) Depress the center of the dri ver si de ai rbag
modul e tri m cover and check for conti nui ty between
the horn swi tch feed wi re and the horn swi tch
ground wi re on the dri ver si de ai rbag modul e. There
shoul d now be conti nui ty. I f not OK, repl ace the
faul ty horn swi tch.
REMOVAL
WARNING:
• ON VEHICLES EQUIPPED WITH AIRBAGS,
REFER TO ELECTRICAL, RESTRAINTS BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCI-
DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
• THE HORN SWITCH IS INTEGRAL TO THE
DRIVER SIDE AIRBAG MODULE. SERVICE OF THIS
COMPONENT SHOULD BE PERFORMED ONLY BY
CHRYSLER-TRAINED AND AUTHORIZED DEALER
SERVICE TECHNICIANS. FAILURE TO TAKE THE
PROPER PRECAUTIONS OR TO FOLLOW THE
PROPER PROCEDURES COULD RESULT IN ACCI-
DENTAL, INCOMPLETE, OR IMPROPER AIRBAG
DEPLOYMENT AND POSSIBLE OCCUPANT INJU-
RIES.
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the tri m cover from the dri ver si de ai r-
bag. (Refer to 8 - ELECTRI CAL/RESTRAI NTS/
DRI VER AI RBAG - REMOVAL).
(3) Remove the horn swi tch and tray as a uni t
from the pouch on the retai ni ng strap of the dri ver
si de ai rbag modul e (Fi g. 2).
INSTALLATION
WARNING:
• ON VEHICLES EQUIPPED WITH AIRBAGS,
REFER TO ELECTRICAL, RESTRAINTS BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCI-
DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
• THE HORN SWITCH IS INTEGRAL TO THE
DRIVER SIDE AIRBAG MODULE. SERVICE OF THIS
COMPONENT SHOULD BE PERFORMED ONLY BY
CHRYSLER-TRAINED AND AUTHORIZED DEALER
SERVICE TECHNICIANS. FAILURE TO TAKE THE
PROPER PRECAUTIONS OR TO FOLLOW THE
PROPER PROCEDURES COULD RESULT IN ACCI-
DENTAL, INCOMPLETE, OR IMPROPER AIRBAG
DEPLOYMENT AND POSSIBLE OCCUPANT INJU-
RIES.
(1) I nstal l the horn swi tch and tray as a uni t i nto
the pouch on the retai ni ng strap of the dri ver si de
ai rbag modul e. Be certai n that the tray i s faci ng the
ai rbag modul e, that the horn swi tch i s faci ng the
tri m cover, that the horn swi tch feed wi re i s on the
l eft, and that the horn swi tch ground wi re i s on the
ri ght.
(2) I nstal l the tri m cover onto the dri ver si de ai r-
bag. (Refer to 8 - ELECTRI CAL/RESTRAI NTS/
DRI VER AI RBAG - I NSTALLATI ON) for the
procedure.
(3) Reconnect the battery negati ve cabl e.
Fig. 2 HORN SWITCH
1 - HORN SWITCH GROUND WIRE EYELET
2 - HORN SWITCH
3 - AIRBAG RETAINING STRAP
4 - POUCH
5 - DRIVER SIDE AIRBAG MODULE (TRIM COVER REMOVED)
6 - TRAY
7 - HORN SWITCH FEED WIRE CONNECTOR
TJ HORN 8H - 3
HORN SWITCH (Continued)
IGNITION CONTROL
TABLE OF CONTENTS
page page
IGNITION CONTROL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SPECIFICATIONS
SPECIFICATIONS - IGNITION TIMING . . . . . . . 2
ENGINE FIRING ORDER - 2.4L 4-CYLINDER . 2
ENGINE FIRING ORDER - 4.0L 6-CYLINDER
ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
IGNITION COIL RESISTANCE - 2.4L . . . . . . . . 2
IGNITION COIL RESISTANCE - 4.0L ENGINE . 3
SPARK PLUGS . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIFICATIONS - SPARK PLUG CABLE
RESISTANCE . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIFICATIONS - TORQUE - IGNITION
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
AUTO SHUT DOWN RELAY
DESCRIPTION - PCM OUTPUT . . . . . . . . . . . . . 4
OPERATION
OPERATION - ASD SENSE - PCM INPUT . . . . 4
OPERATION - PCM OUTPUT . . . . . . . . . . . . . 4
DIAGNOSIS AND TESTING - ASD AND FUEL
PUMP RELAYS . . . . . . . . . . . . . . . . . . . . . . . . 4
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CAMSHAFT POSITION SENSOR - 2.4L
DESCRIPTION - 2.4L . . . . . . . . . . . . . . . . . . . . . 5
OPERATION - 2.4L . . . . . . . . . . . . . . . . . . . . . . . 5
REMOVAL - 2.4L . . . . . . . . . . . . . . . . . . . . . . . . . 6
INSTALLATION - 2.4L . . . . . . . . . . . . . . . . . . . . . 6
CAMSHAFT POSITION SENSOR - 4.0L
DESCRIPTION - 4.0L . . . . . . . . . . . . . . . . . . . . . 7
OPERATION - 4.0L . . . . . . . . . . . . . . . . . . . . . . . 7
REMOVAL - 4.0L . . . . . . . . . . . . . . . . . . . . . . . . . 8
INSTALLATION - 4.0L . . . . . . . . . . . . . . . . . . . . . 9
COIL RAIL - 4.0L
DESCRIPTION - 4.0L . . . . . . . . . . . . . . . . . . . . 10
OPERATION - 4.0L . . . . . . . . . . . . . . . . . . . . . . 11
REMOVAL - 4.0L . . . . . . . . . . . . . . . . . . . . . . . . 11
INSTALLATION - 4.0L . . . . . . . . . . . . . . . . . . . . 11
IGNITION COIL - 2.4L
DESCRIPTION - 2.4L . . . . . . . . . . . . . . . . . . . . 12
OPERATION - 2.4L . . . . . . . . . . . . . . . . . . . . . . 12
REMOVAL - 2.4L . . . . . . . . . . . . . . . . . . . . . . . . 13
INSTALLATION - 2.4L . . . . . . . . . . . . . . . . . . . . 13
SPARK PLUG
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 13
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
DIAGNOSIS AND TESTING - SPARK PLUG
CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . 13
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
CLEANING
CLEANING SPARK PLUGS . . . . . . . . . . . . . . 16
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 16
SPARK PLUG CABLE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 17
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . 17
REMOVAL - 2.4L . . . . . . . . . . . . . . . . . . . . . . . . 18
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 18
IGNITION CONTROL
DESCRIPTION
The i gni ti on systems used on both the 2.4L 4–cyl -
i nder and 4.0L 6–cyl i nder engi nes are a di stri butor-
l ess type.
The i gni ti on system consi sts of:
• Spark Pl ugs
• Spark Pl ug Cabl es (secondary wi res)
• I gni ti on Coi l (s)
• Powertrai n Control Modul e (PCM)
• Crankshaft Posi ti on Sensor
• Camshaft Posi ti on Sensor
• The MAP, TPS, I AC and ECT al so have an effect
on the control of the i gni ti on system.
OPERATION
2. 4L
A common i gni ti on coi l di vi ded i nto 2 hal ves i s
used. Secondary, hi gh-tensi on spark pl ug cabl es are
al so used. One hal f of the coi l fi res two spark pl ugs
si mul taneousl y (one pl ug i s the cyl i nder under com-
pressi on, and the other pl ug i s the cyl i nder on the
exhaust stroke). Coi l hal f number one fi res cyl i nders
1 and 4. Coi l hal f number two fi res cyl i nders 2 and 3.
The PCM determi nes whi ch of the coi l s to charge and
fi re at the correct ti me.
The Auto Shutdown (ASD) rel ay provi des battery
vol tage to the i gni ti on coi l . The PCM provi des a
ground contact (ci rcui t) for energi zi ng the coi l . When
the PCM breaks the contact, the energy i n the coi l
TJ IGNITION CONTROL 8I - 1
pri mary transfers to the secondary causi ng a spark.
The PCM wi l l de-energi ze the ASD rel ay i f i t does
not recei ve i nputs from ei ther the crankshaft or cam-
shaft posi ti on sensors.
A di stri butor i s not used wi th the 2.4L engi ne.
4. 0L
The 4.0L 6-cyl i nder engi ne uses a one-pi ece coi l
rai l contai ni ng three i ndependent coi l s. Al though cyl -
i nder fi ri ng order i s the same as 4.0L engi nes of pre-
vi ous years, spark pl ug fi ri ng i s not. The 3 coi l s dual -
fi re the spark pl ugs on cyl i nders 1-6, 2-5 and/or 3-4.
When one cyl i nder i s bei ng fi red (on compressi on
stroke), the spark to the opposi te cyl i nder i s bei ng
wasted (on exhaust stroke). The one-pi ece coi l bol ts
di rectl y to the cyl i nder head. Rubber boots seal the
secondary termi nal ends of the coi l s to the top of al l
6 spark pl ugs. One el ectri cal connector (l ocated at
the rear end of the coi l rai l ) i s used for al l three coi l s.
Because of coi l desi gn, spark pl ug cabl es (second-
ary cabl es) are not used. A distributor is not used
wi th the 4.0L engi ne.
The i gni ti on system i s control l ed by the Powertrai n
Control Modul e (PCM).
SPECIFICATIONS
SPECIFICATIONS - IGNITION TIMING
Ignition timing is not adjustable on any
engine.
ENGINE FIRING ORDER - 2. 4L 4-CYLINDER
1 - 3 - 4 - 2
ENGINE FIRING ORDER - 4. 0L 6-CYLINDER
ENGINE
IGNITION COIL RESISTANCE - 2. 4L
Engine Coil Manufacture
Primary Resistance at
21°C-27°C (70°F-80°F)
Secondary Resistance at
21°C-27°C (70°F-80°F)
2.4L Toyodenso or Diamond 0.51 to 0.61 Ohms 11,500 to 13,500 Ohms
IGNITION COIL - 2.4L
FIRING ORDER - 4.0L
8I - 2 IGNITION CONTROL TJ
IGNITION CONTROL (Continued)
IGNITION COIL RESISTANCE - 4. 0L ENGINE
PRIMARY RESISTANCE 21-27°C (70-80°F)
0.71 - 0.88 Ohms
SPARK PLUGS
ENGINE PLUG TYPE ELECTRODE GAP
2.4L 4-Cylinder RE14MCC5 (Champion #) 1.24 to 1.37 mm (0.048 to 0.053 in.)
4.0L 6-Cylinder ZFR5N (NGK #) 1.00 mm (0.040 in.)
SPECIFICATIONS - SPARK PLUG CABLE
RESISTANCE
MINIMUM MAXIMUM
250 Ohms Per Inch 1000 Ohms Per Inch
3000 Ohms Per Foot 12,000 Ohms Per Foot
SPECIFICATIONS - TORQUE - IGNITION SYSTEM
DESCRIPTION N·m Ft. Lbs. In. Lbs.
Camshaft Position Sensor
Mounting Bolts – 4.0L
2
-
15
Camshaft Position Sensor
– 2.4L
12
-
106
Ignition Coil Rail Mounting
Bolts – 4.0L
29 - 250
Ignition Coil Mounting
Bolts – 2.4L
11 - 105
Oil Pump Drive Hold-down
Bolt – 4.0L
23 17 -
** Spark Plugs - 2.4L
4-Cylinder
15 11 -
Spark Plugs - 4.0L
6-cylinder
30 22 -
** Torque critical tapered
design. Do not exceed 15
ft. lbs. torque.
TJ IGNITION CONTROL 8I - 3
IGNITION CONTROL (Continued)
AUTO SHUT DOWN RELAY
DESCRIPTION - PCM OUTPUT
The 5–pi n, 12–vol t, Automati c Shutdown (ASD)
rel ay i s l ocated i n the Power Di stri buti on Center
(PDC). Refer to l abel on PDC cover for rel ay l ocati on.
OPERATION
OPERATION - ASD SENSE - PCM INPUT
A 12 vol t si gnal at thi s i nput i ndi cates to the PCM
that the ASD has been acti vated. The rel ay i s used to
connect the oxygen sensor heater el ement, i gni ti on
coi l and fuel i njectors to 12 vol t + power suppl y.
Thi s i nput i s used onl y to sense that the ASD rel ay
i s energi zed. I f the Powertrai n Control Modul e
(PCM) does not see 12 vol ts at thi s i nput when the
ASD shoul d be acti vated, i t wi l l set a Di agnosti c
Troubl e Code (DTC).
OPERATION - PCM OUTPUT
The ASD rel ay suppl i es battery vol tage (12+ vol ts)
to the fuel i njectors and i gni ti on coi l (s). Wi th certai n
emi ssi ons packages i t al so suppl i es 12–vol ts to the
oxygen sensor heati ng el ements.
The ground ci rcui t for the coi l wi thi n the ASD
rel ay i s control l ed by the Powertrai n Control Modul e
(PCM). The PCM operates the ASD rel ay by swi tch-
i ng i ts ground ci rcui t on and off.
The ASD rel ay wi l l be shut–down, meani ng the
12–vol t power suppl y to the ASD rel ay wi l l be de-ac-
ti vated by the PCM i f:
• the i gni ti on key i s l eft i n the ON posi ti on. Thi s
i s i f the engi ne has not been runni ng for approxi -
matel y 1.8 seconds.
• there i s a crankshaft posi ti on sensor si gnal to
the PCM that i s l ower than pre-determi ned val ues.
DIAGNOSIS AND TESTING - ASD AND FUEL
PUMP RELAYS
The following description of operation and
tests apply only to the Automatic Shutdown
(ASD) and fuel pump relays. The termi nal s on the
bottom of each rel ay are numbered. Two di fferent
types of rel ays may be used, (Fi g. 1) or (Fi g. 2).
• Termi nal number 30 i s connected to battery vol t-
age. For both the ASD and fuel pump rel ays, termi -
nal 30 i s connected to battery vol tage at al l ti mes.
• The PCM grounds the coi l si de of the rel ay
through termi nal number 85.
• Termi nal number 86 suppl i es vol tage to the coi l
si de of the rel ay.
• When the PCM de-energi zes the ASD and fuel
pump rel ays, termi nal number 87A connects to termi -
nal 30. Thi s i s the Off posi ti on. I n the off posi ti on,
vol tage i s not suppl i ed to the rest of the ci rcui t. Ter-
mi nal 87A i s the center termi nal on the rel ay.
• When the PCM energi zes the ASD and fuel
pump rel ays, termi nal 87 connects to termi nal 30.
Thi s i s the On posi ti on. Termi nal 87 suppl i es vol tage
to the rest of the ci rcui t.
The fol l owi ng procedure appl i es to the ASD and
fuel pump rel ays.
(1) Remove rel ay from connector before testi ng.
(2) Wi th the rel ay removed from the vehi cl e, use
an ohmmeter to check the resi stance between termi -
nal s 85 and 86. The resi stance shoul d be 75 ohms +/-
5 ohms.
(3) Connect the ohmmeter between termi nal s 30
and 87A. The ohmmeter shoul d show conti nui ty
between termi nal s 30 and 87A.
(4) Connect the ohmmeter between termi nal s 87
and 30. The ohmmeter shoul d not show conti nui ty at
thi s ti me.
Fig. 1 ASD and Fuel Pump Relay Terminals—Type 1
30 - COMMON FEED
85 - COIL GROUND
86 - COIL BATTERY
87 - NORMALLY OPEN
87A - NORMALLY CLOSED
Fig. 2 ASD and Fuel Pump Relay Terminals—Type 2
30 - COMMON FEED
85 - COIL GROUND
86 - COIL BATTERY
87 - NORMALLY OPEN
87A - NORMALLY CLOSED
8I - 4 IGNITION CONTROL TJ
(5) Connect one end of a jumper wi re (16 gauge or
smal l er) to rel ay termi nal 85. Connect the other end
of the jumper wi re to the ground si de of a 12 vol t
power source.
(6) Connect one end of another jumper wi re (16
gauge or smal l er) to the power si de of the 12 vol t
power source. Do not attach the other end of the
jumper wire to the relay at this time.
WARNING: DO NOT ALLOW OHMMETER TO CON-
TACT TERMINALS 85 OR 86 DURING THIS TEST.
DAMAGE TO OHMMETER MAY RESULT.
(7) Attach the other end of the jumper wi re to
rel ay termi nal 86. Thi s acti vates the rel ay. The ohm-
meter shoul d now show conti nui ty between rel ay ter-
mi nal s 87 and 30. The ohmmeter shoul d not show
conti nui ty between rel ay termi nal s 87A and 30.
(8) Di sconnect jumper wi res.
(9) Repl ace the rel ay i f i t di d not pass the conti nu-
i ty and resi stance tests. I f the rel ay passed the tests,
i t operates properl y. Check the remai nder of the ASD
and fuel pump rel ay ci rcui ts. Refer to 8, Wi ri ng Di a-
grams.
REMOVAL
The ASD rel ay i s l ocated i n the Power Di stri buti on
Center (PDC) (Fi g. 3). Refer to l abel on PDC cover
for rel ay l ocati on.
(1) Remove PDC cover.
(2) Remove rel ay from PDC.
(3) Check condi ti on of rel ay termi nal s and PDC
connector termi nal s for damage or corrosi on. Repai r
i f necessary before i nstal l i ng rel ay.
(4) Check for pi n hei ght (pi n hei ght shoul d be the
same for al l termi nal s wi thi n the PDC connector).
Repai r i f necessary before i nstal l i ng rel ay.
INSTALLATION
The ASD rel ay i s l ocated i n the Power Di stri buti on
Center (PDC) (Fi g. 3). Refer to l abel on PDC cover
for rel ay l ocati on.
(1) I nstal l rel ay to PDC.
(2) I nstal l cover to PDC.
CAMSHAFT POSITION
SENSOR - 2.4L
DESCRIPTION - 2. 4L
The Camshaft Posi ti on Sensor (CMP) on the 2.4L
4–cyl i nder engi ne i s bol ted to the ri ght-front si de of
the cyl i nder head (Fi g. 4).
OPERATION - 2. 4L
The Camshaft Posi ti on Sensor (CMP) sensor con-
tai ns a hal l effect devi ce referred to as a sync si gnal
generator. A rotati ng target wheel (tonewheel ) for the
CMP i s l ocated behi nd the exhaust val ve-camshaft
dri ve gear (Fi g. 5). The target wheel i s equi pped wi th
a cutout (notch) around 180 degrees of the wheel .
The CMP detects thi s cutout every 180 degrees of
camshaft gear rotati on. I ts si gnal i s used i n conjunc-
ti on wi th the Crankshaft Posi ti on Sensor (CKP) to
di fferenti ate between fuel i njecti on and spark events.
I t i s al so used to synchroni ze the fuel i njectors wi th
thei r respecti ve cyl i nders.
When the l eadi ng edge of the target wheel cutout
enters the ti p of the CMP, the i nterrupti on of mag-
Fig. 3 Power Distribution Center (PDC)
1 - BATTERY
2 - POWER DISTRIBUTION CENTER (PDC)
Fig. 4 CMP LOCATION - 2.4L
1 - CMP SENSOR
2 - ELECTRICAL CONNECTOR
3 - SLOTTED HOLES
4 - MOUNTING BOLTS (2)
TJ IGNITION CONTROL 8I - 5
AUTO SHUT DOWN RELAY (Continued)
neti c fi el d causes the vol tage to swi tch hi gh, resul t-
i ng i n a sync si gnal of approxi matel y 5 vol ts.
When the trai l i ng edge of the target wheel cutout
l eaves the ti p of the CMP, the change of the magneti c
fi el d causes the sync si gnal vol tage to swi tch l ow to 0
vol ts.
REMOVAL - 2. 4L
The Camshaft Posi ti on Sensor (CMP) on the 2.4L
4–cyl i nder engi ne i s bol ted to the ri ght-front si de of
the cyl i nder head (Fi g. 6). Sensor posi ti on (depth) i s
adjustabl e.
(1) Di sconnect el ectri cal connector at CMP sensor.
(2) Remove 2 sensor mounti ng bol ts.
(3) Remove sensor from cyl i nder head by sl i di ng
towards rear of engi ne.
INSTALLATION - 2. 4L
The Camshaft Posi ti on Sensor (CMP) on the 2.4L
4–cyl i nder engi ne i s bol ted to the ri ght-front si de of
the cyl i nder head. Sensor position (depth) is
adjustable.
(1) Remove pl asti c, upper ti mi ng bel t cover (ti mi ng
gear cover) (Fi g. 7) by removi ng 3 bol ts. Before
attempti ng to remove cover, remove el ectri cal connec-
tor from Engi ne Cool ant Temperature (ECT) sensor
(Fi g. 7). Thi s wi l l prevent damage to sensor.
(2) Rotate (bump over) engi ne unti l camshaft ti m-
i ng gear and target wheel (tonewheel ) are posi ti oned
and al i gned to face of sensor as shown i n (Fi g. 8). If
not positioned as shown in (Fig. 8), damage to
both sensor and target wheel will occur when
attempting to start engine. Face of sensor
MUST be behind target wheel while adjusting.
(3) Posi ti on sensor to cyl i nder head and i nstal l 2
sensor mounti ng bol ts fi nger ti ght.
(4) SENSOR AIR GAP: .030”Set ai r gap between
rear of target wheel and face of sensor to .030”. Thi s
can best be accompl i shed usi ng an L-shaped, wi re-
type spark pl ug gappi ng gauge (Fi g. 9). A pi ece of
.030” brass shi m stock may al so be used.
Fig. 7 UPPER TIMING BELT COVER/BOLTS-2.4L
1 - UPPER TIMING BELT COVER
2 - ELECTRICAL CONNECTOR (ECT)
3 - MOUNTING BOLTS (3)
Fig. 5 CMP FACE AT TARGET WHEEL-2.4L
1 - CAMSHAFT DRIVE GEAR
2 - TARGETWHEEL (TONEWHEEL)
3 - FACE OF CMP SENSOR
4 - CUTOUT (NOTCH)
Fig. 6 CMP LOCATION - 2.4L
1 - CMP SENSOR
2 - ELECTRICAL CONNECTOR
3 - SLOTTED HOLES
4 - MOUNTING BOLTS (2)
8I - 6 IGNITION CONTROL TJ
CAMSHAFT POSITION SENSOR - 2.4L (Continued)
(5) Gentl y push sensor forward unti l i t contacts
gappi ng gauge. Do not push hard on sensor.
Ti ghten 2 sensor mounti ng bol ts. Refer to torque
speci fi cati ons.
CAUTION: After tightening sensor mounting bolts,
recheck air gap and adjust as necessary. Retorque
bolts.
(6) I nstal l upper ti mi ng bel t cover and 3 bol ts.
(7) Connect el ectri cal connector to ECT sensor.
(8) Connect el ectri cal connector to CMP sensor.
CAMSHAFT POSITION
SENSOR - 4.0L
DESCRIPTION - 4. 0L
The Camshaft Posi ti on Sensor (CMP) on the 4.0L
6–cyl i nder engi ne i s bol ted to the top of the oi l pump
dri ve shaft assembl y (Fi g. 10). The sensor and dri ve
shaft assembl y i s l ocated on the ri ght si de of the
engi ne near the oi l fi l ter (Fi g. 11).
OPERATION - 4. 0L
The CMP sensor contai ns a hal l effect devi ce cal l ed
a sync si gnal generator to generate a fuel sync si g-
nal . Thi s sync si gnal generator detects a rotati ng
pul se ri ng (shutter) on the oi l pump dri ve shaft (Fi g.
10). The pul se ri ng rotates 180 degrees through the
sync si gnal generator. I ts si gnal i s used i n conjunc-
ti on wi th the crankshaft posi ti on sensor to di fferenti -
ate between fuel i njecti on and spark events. I t i s al so
Fig. 8 CMP FACE AT TARGET WHEEL-2.4L
1 - CAMSHAFT DRIVE GEAR
2 - TARGETWHEEL (TONEWHEEL)
3 - FACE OF CMP SENSOR
4 - CUTOUT (NOTCH)
Fig. 9 CMP ADJUSTMENT - 2.4L
1 - FACE OF SENSOR
2 - WIRE GAPPING TOOL
Fig. 10 CMP and Oil Pump Drive Shaft—4.0L Engine
1 - CAMSHAFT POSITION SENSOR
2 - MOUNTING BOLTS (2)
3 - PULSE RING
4 - DRIVE GEAR (TO CAMSHAFT)
5 - OIL PUMP DRIVESHAFT
6 - SENSOR BASE (OIL PUMP DRIVESHAFT ASSEMBLY)
TJ IGNITION CONTROL 8I - 7
CAMSHAFT POSITION SENSOR - 2.4L (Continued)
used to synchroni ze the fuel i njectors wi th thei r
respecti ve cyl i nders.
When the l eadi ng edge of the pul se ri ng (shutter)
enters the sync si gnal generator, the fol l owi ng occurs:
The i nterrupti on of magneti c fi el d causes the vol tage
to swi tch hi gh resul ti ng i n a sync si gnal of approxi -
matel y 5 vol ts.
When the trai l i ng edge of the pul se ri ng (shutter)
l eaves the sync si gnal generator, the fol l owi ng occurs:
The change of the magneti c fi el d causes the sync si g-
nal vol tage to swi tch l ow to 0 vol ts.
REMOVAL - 4. 0L
The Camshaft Posi ti on Sensor (CMP) on the 4.0L
6–cyl i nder engi ne i s bol ted to the top of the oi l pump
dri ve shaft assembl y (Fi g. 12). The sensor and dri ve
shaft assembl y i s l ocated on the ri ght si de of the
engi ne near the oi l fi l ter (Fi g. 13).
The rotati onal posi ti on of oi l pump dri ve deter-
mi nes fuel synchroni zati on onl y. I t does not deter-
mi ne i gni ti on ti mi ng.
NOTE: Do not attempt to rotate the oil pump drive
to modify ignition timing.
Two different procedures are used for removal
and i nstal l ati on. The fi rst procedure wi l l detai l
removal and i nstal l ati on of the sensor onl y. The sec-
ond procedure wi l l detai l removal and i nstal l ati on of
the sensor and oi l pump dri ve shaft assembl y. The
second procedure i s to be used i f the engi ne has been
di sassembl ed.
An i nternal oi l seal i s used i n the dri ve shaft hous-
i ng that prevents engi ne oi l at the bottom of the sen-
sor. The seal i s not servi ceabl e.
SENSOR ONLY - 4. 0L
(1) Di sconnect el ectri cal connector at CMP sensor
(Fi g. 13).
(2) Remove 2 sensor mounti ng bol ts (Fi g. 12) or
(Fi g. 13).
(3) Remove sensor from oi l pump dri ve.
OIL PUMP DRIVE AND SENSOR - 4. 0L
If the CMP and oil pump drive are to be
removed and installed, do not allow engine
crankshaft or camshaft to rotate. CMP sensor
relationship will be lost.
(1) Di sconnect el ectri cal connector at CMP sensor
(Fi g. 13).
(2) Remove 2 sensor mounti ng bol ts (Fi g. 12) or
(Fi g. 13).
(3) Remove sensor from oi l pump dri ve.
Fig. 11 CMP Location—4.0L Engine
1 - OIL FILTER
2 - CAMSHAFT POSITION SENSOR
3 - CLAMP BOLT
4 - HOLD-DOWN CLAMP
5 - MOUNTING BOLTS (2)
6 - ELEC. CONNECTOR
Fig. 12 CMP and Oil Pump Drive Shaft - 4.0L Engine
1 - CAMSHAFT POSITION SENSOR
2 - MOUNTING BOLTS (2)
3 - PULSE RING
4 - DRIVE GEAR (TO CAMSHAFT)
5 - OIL PUMP DRIVESHAFT
6 - SENSOR BASE (OIL PUMP DRIVESHAFT ASSEMBLY)
8I - 8 IGNITION CONTROL TJ
CAMSHAFT POSITION SENSOR - 4.0L (Continued)
(4) Before proceedi ng to next step, mark and note
rotati onal posi ti on of oi l pump dri ve i n rel ati onshi p
to engi ne bl ock. After i nstal l ati on, the CMP sensor
shoul d face rear of engi ne 0°.
(5) Remove hol d-down bol t and cl amp (Fi g. 13).
(6) Whi l e pul l i ng assembl y from engi ne, note di rec-
ti on and posi ti on of pul se ri ng (Fi g. 12). After
removal , l ook down i nto top of oi l pump and note
di recti on and posi ti on of sl ot at top of oi l pump gear.
(7) Remove and di scard ol d oi l pump dri ve-to-en-
gi ne bl ock gasket.
INSTALLATION - 4. 0L
SENSOR ONLY - 4. 0L
The Camshaft Posi ti on Sensor (CMP) on the 4.0L
6–cyl i nder engi ne i s bol ted to the top of the oi l pump
dri ve shaft assembl y (Fi g. 12). The sensor and dri ve
shaft assembl y i s l ocated on the ri ght si de of the
engi ne near the oi l fi l ter (Fi g. 13).
(1) I nstal l sensor to oi l pump dri ve.
(2) I nstal l 2 sensor mounti ng bol ts and ti ghten to
2 N·m (15 i n. l bs.) torque.
(3) Connect el ectri cal connector to CMP sensor.
OIL PUMP DRIVE AND SENSOR - 4. 0L
(1) Cl ean oi l pump dri ve mounti ng hol e area of
engi ne bl ock.
(2) I nstal l new oi l pump dri ve-to-engi ne bl ock gasket.
(3) Temporari l y i nstal l a toothpi ck or si mi l ar tool
through access hol e at si de of oi l pump dri ve housi ng.
Al i gn toothpi ck i nto mati ng hol e on pul se ri ng (Fi g. 14).
(4) I nstal l oi l pump dri ve i nto engi ne whi l e al i gn-
i ng i nto sl ot on oi l pump. Rotate oi l pump dri ve back
to i ts ori gi nal posi ti on and i nstal l hol d-down cl amp
Fig. 13 CMP Location - 4.0L Engine
1 - OIL FILTER
2 - CAMSHAFT POSITION SENSOR
3 - CLAMP BOLT
4 - HOLD-DOWN CLAMP
5 - MOUNTING BOLTS (2)
6 - ELEC. CONNECTOR
Fig. 14 CMP Pulse Ring Alignment - 4.0L Engine
1 - PULSE RING (SHUTTER)
2 - TOOTHPICK
3 - SENSOR BASE (OIL PUMP DRIVESHAFT ASSEMBLY)
Fig. 15 Align Timing Marks - 4.0L Engine
1 - CRANKSHAFT VIBRATION DAMPER TIMING MARK
TJ IGNITION CONTROL 8I - 9
CAMSHAFT POSITION SENSOR - 4.0L (Continued)
and bol t. Fi nger ti ghten bol t. Do not do a fi nal ti ght-
eni ng of bol t at thi s ti me.
(5) I f engi ne crankshaft or camshaft has been
rotated, such as duri ng engi ne tear-down, CMP sen-
sor rel ati onshi p must be reestabl i shed.
(a) Remove i gni ti on coi l rai l assembl y. Refer to
I gni ti on Coi l Removal /I nstal l ati on.
(b) Remove cyl i nder number 1 spark pl ug.
(c) Hol d a fi nger over the open spark pl ug hol e.
Rotate engi ne at vi brati on dampener bol t unti l
compressi on (pressure) i s fel t.
(d) Sl owl y conti nue to rotate engi ne. Do thi s
unti l ti mi ng i ndex mark on vi brati on damper pul -
l ey al i gns wi th top dead center (TDC) mark (0
degree) on ti mi ng degree scal e (Fi g. 15). Al ways
rotate engi ne i n di recti on of normal rotati on. Do
not rotate engi ne backward to al i gn ti mi ng marks.
(e) I nstal l oi l pump dri ve i nto engi ne whi l e
al i gni ng i nto sl ot on oi l pump. I f pump dri ve wi l l
not drop down fl ush to engi ne bl ock, the oi l pump
sl ot i s not al i gned. Remove oi l pump dri ve and
al i gn sl ot i n oi l pump to shaft at bottom of dri ve.
I nstal l i nto engi ne. Rotate oi l pump dri ve back to
i ts ori gi nal posi ti on and i nstal l hol d-down cl amp
and bol t. Fi nger ti ghten bol t. Do not do a fi nal
ti ghteni ng of bol t at thi s ti me.
(f) Remove toothpi ck from housi ng.
(6) I nstal l sensor to oi l pump dri ve. After i nstal l a-
ti on, the CMP sensor shoul d face rear of engi ne 0°.
(7) I nstal l 2 sensor mounti ng bol ts and ti ghten to
2 N·m (15 i n. l bs.) torque.
(8) Connect el ectri cal connector to CMP sensor.
(9) I f removed, i nstal l spark pl ug and i gni ti on coi l rai l .
To veri fy correct rotati onal posi ti on of oi l pump
dri ve, the DRB scan tool must be used.
WARNING: WHEN PERFORMING THE FOLLOWING
TEST, THE ENGINE WILL BE RUNNING. BE CAREFUL
NOT TO STAND IN LINE WITH THE FAN BLADES OR
FAN BELT. DO NOT WEAR LOOSE CLOTHING.
(10) Connect DRB scan tool to data l i nk connector.
The data l i nk connector i s l ocated i n passenger com-
partment, bel ow and to l eft of steeri ng col umn.
(11) Gai n access to SET SYNC screen on DRB.
(12) Fol l ow di recti ons on DRB screen and start
engi ne. Bri ng to operati ng temperature (engi ne must
be i n “cl osed l oop” mode).
(13) Wi th engi ne runni ng at idle speed, the words
I N RANGE shoul d appear on screen al ong wi th 0°.
Thi s i ndi cates correct posi ti on of oi l pump dri ve.
(14) I f a pl us (+) or a mi nus (-) i s di spl ayed next to
degree number, and/or the degree di spl ayed i s not
zero, l oosen but do not remove hol d-down cl amp bol t.
Rotate oi l pump dri ve unti l I N RANGE appears on
screen. Conti nue to rotate oi l pump dri ve unti l
achi evi ng as cl ose to 0° as possi bl e.
The degree scal e on SET SYNC screen of DRB i s
referri ng to fuel synchroni zati on onl y. It is not
referring to ignition timing. Because of thi s, do
not attempt to adjust i gni ti on ti mi ng usi ng thi s
method. Rotati ng oi l pump dri ve wi l l have no effect
on i gni ti on ti mi ng. Al l i gni ti on ti mi ng val ues are con-
trol l ed by powertrai n control modul e (PCM).
(15) Ti ghten hol d-down cl amp bol t to 23 N·m (17
ft. l bs.) torque.
COIL RAIL - 4.0L
DESCRIPTION - 4. 0L
A one-pi ece coi l rai l assembl y contai ni ng three
i ndi vi dual coi l s i s used on the 4.0L 6–cyl i nder engi ne
(Fi g. 16). The coi l rai l must be repl aced as one
assembl y. The bottom of the coi l i s equi pped wi th 6
i ndi vi dual rubber boots (Fi g. 16) to seal the 6 spark
pl ugs to the coi l . I nsi de each rubber boot i s a spri ng.
The spri ng i s used for a mechani cal contact between
the coi l and the top of the spark pl ug. These rubber
boots and spri ngs are a permanent part of the coi l
and are not servi ced separatel y.
Fig. 16 Ignition Coil Assembly—4.0L 6–Cylinder
Engine
1 - CYL. #6
2 - CYL. #5
3 - CYL. #4
4 - CYL. #3
5 - CYL. #2
6 - CYL. #1
7 - COILS (3)
8 - MOUNTING BOLTS (4)
9 - BOLT BASES (4)
10 - RUBBER BOOTS (6)
8I - 10 IGNITION CONTROL TJ
CAMSHAFT POSITION SENSOR - 4.0L (Continued)
(1) The coi l i s bol ted di rectl y to the cyl i nder head
(Fi g. 17). One el ectri cal connector (l ocated at rear of
coi l ) i s used for al l three coi l s.
OPERATION - 4. 0L
Al though cyl i nder fi ri ng order i s the same as 4.0L
Jeep engi nes of previ ous years, spark pl ug fi ri ng i s
not. The 3 coi l s dual -fi re the spark pl ugs on cyl i nders
1-6, 2-5 and/or 3-4. When one cyl i nder i s bei ng fi red
(on compressi on stroke), the spark to the opposi te
cyl i nder i s bei ng wasted (on exhaust stroke).
Battery vol tage i s suppl i ed to the three i gni ti on
coi l s from the ASD rel ay. The Powertrai n Control
Modul e (PCM) opens and cl oses the i gni ti on coi l
ground ci rcui t for i gni ti on coi l operati on.
Base ignition timing is not adjustable. By con-
trol l i ng the coi l ground ci rcui t, the PCM i s abl e to set
the base ti mi ng and adjust the i gni ti on ti mi ng
advance. Thi s i s done to meet changi ng engi ne oper-
ati ng condi ti ons.
The i gni ti on coi l i s not oi l fi l l ed. The wi ndi ngs are
embedded i n an epoxy compound. Thi s provi des heat
and vi brati on resi stance that al l ows the i gni ti on coi l
to be mounted on the engi ne.
Because of coi l desi gn, spark pl ug cabl es (second-
ary cabl es) are not used. The cabl es are i ntegral
wi thi n the coi l rai l .
REMOVAL - 4. 0L
A one-pi ece coi l rai l assembl y contai ni ng three
i ndi vi dual coi l s i s used on the 4.0L engi ne (Fi g. 18).
The coi l rai l must be repl aced as one assembl y. The
bottom of the coi l i s equi pped wi th 6 i ndi vi dual rub-
ber boots (Fi g. 18) to seal the 6 spark pl ugs to the
coi l . I nsi de each rubber boot i s a spri ng. The spri ng
i s used for an el ectri cal contact between the coi l and
the top of the spark pl ug. These rubber boots and
spri ngs are a permanent part of the coi l and are not
servi ced separatel y.
(1) Di sconnect negati ve battery cabl e at battery.
(2) The coi l i s bol ted di rectl y to the cyl i nder head.
Remove 4 coi l mounti ng bol ts (Fi g. 19).
(3) Careful l y pry up coi l assembl y from spark
pl ugs. Do thi s by pryi ng al ternatel y at each end of
coi l unti l rubber boots have di sengaged from al l
spark pl ugs. I f boots wi l l not rel ease from spark
pl ugs, use a commerci al l y avai l abl e spark pl ug boot
removal tool . Twi st and l oosen a few boots from a few
spark pl ugs to hel p remove coi l .
(4) After coi l has cl eared spark pl ugs, posi ti on coi l
for access to pri mary el ectri cal connector. Di sconnect
connector from coi l by pushi ng sl i de tab outwards to
ri ght si de of vehi cl e (Fi g. 20). After sl i de tab has been
posi ti oned outwards, push i n on secondary rel ease
l ock (Fi g. 20) on si de of connector and pul l connector
from coi l .
(5) Remove coi l from vehi cl e.
INSTALLATION - 4. 0L
(1) Connect engi ne harness connector to coi l by
snappi ng i nto posi ti on. Move sl i de tab towards
engi ne (Fi g. 20) for a posi ti ve l ock.
Fig. 17 Coil Location—4.0L Engine
1 - COIL RAIL
2 - COIL MOUNTING BOLTS (4)
3 - COIL
4 - COIL ELECTRICAL CONNECTION
Fig. 18 Ignition Coil Assembly—4.0L 6–Cylinder
Engine
1 - CYL. #6
2 - CYL. #5
3 - CYL. #4
4 - CYL. #3
5 - CYL. #2
6 - CYL. #1
7 - COILS (3)
8 - MOUNTING BOLTS (4)
9 - BOLT BASES (4)
10 - RUBBER BOOTS (6)
TJ IGNITION CONTROL 8I - 11
COIL RAIL - 4.0L (Continued)
(2) Posi ti on i gni ti on coi l rubber boots to al l spark
pl ugs. Push down on coi l assembl y unti l bol t bases
have contacted cyl i nder head
(3) I nstal l 4 coi l mounti ng bol ts. Loosel y ti ghten 4
bol ts just enough to al l ow bol t bases to contact cyl i n-
der head. Do a fi nal ti ghteni ng of each bol t i n steps
down to 29 N·m (250 i n. l bs.) torque. Do not appl y
ful l torque to any bol t fi rst.
(4) Connect negati ve battery cabl e to battery.
IGNITION COIL - 2.4L
DESCRIPTION - 2. 4L
The coi l assembl y consi sts of 2 di fferent coi l s
mol ded together. The assembl y i s mounted to the top
of the engi ne (Fi g. 21).
OPERATION - 2. 4L
The coi l fi res two spark pl ugs si mul taneousl y. One
pl ug i s under compressi on, the other pl ug fi res on the
exhaust stroke (l ost spark). Coi l number one fi res
cyl i nders 1 and 4, and coi l number two fi res cyl i nders
2 and 3.
The Auto Shutdown (ASD) rel ay provi des battery
vol tage to the i gni ti on coi l . The PCM provi des a
ground contact (ci rcui t) for energi zi ng the coi l (s). The
PCM wi l l de-energi ze the ASD rel ay i f i t does not
recei ve the crankshaft posi ti on sensor and camshaft
posi ti on sensor i nputs.
Base ignition timing is not adjustable. By con-
trol l i ng the coi l ground ci rcui t, the PCM i s abl e to set
the base ti mi ng and adjust the i gni ti on ti mi ng
advance. Thi s i s done to meet changi ng engi ne oper-
ati ng condi ti ons.
The i gni ti on coi l i s not oi l fi l l ed. The wi ndi ngs are
embedded i n an epoxy compound. Thi s provi des heat
and vi brati on resi stance that al l ows the i gni ti on coi l
to be mounted on the engi ne.
Fig. 19 Ignition Coil Rail Location—4.0L 6–Cylinder
Engine
1 - COIL RAIL
2 - COIL MOUNTING BOLTS (4)
3 - COIL
4 - COIL ELECTRICAL CONNECTION
Fig. 20 Ignition Coil Electrical Connector—4.0L
6–Cylinder Engine
1 - REAR OF VALVE COVER
2 - COIL RAIL
3 - SLIDE TAB
4 - RELEASE LOCK
5 - COIL CONNECTOR
Fig. 21 IGNITION COIL - 2.4L
1 - IGNITION COIL
2 - MOUNTING BOLTS (4)
8I - 12 IGNITION CONTROL TJ
COIL RAIL - 4.0L (Continued)
Spark pl ug cabl es (secondary wi res or cabl es) are
used wi th the 2.4L engi ne.
REMOVAL - 2. 4L
(1) Di sconnect el ectri cal connector at rear of coi l .
(2) Remove al l secondary cabl es from coi l .
(3) Remove 4 coi l mounti ng bol ts (Fi g. 22).
(4) Remove coi l from vehi cl e.
INSTALLATION - 2. 4L
(1) Posi ti on coi l to engi ne.
(2) I nstal l 4 mounti ng bol ts. Refer to torque speci -
fi cati ons.
(3) I nstal l secondary cabl es.
(4) I nstal l el ectri cal connector at rear of coi l .
(5) I nstal l ai r cl eaner tube and housi ng.
SPARK PLUG
DESCRIPTION
Resi stor type spark pl ugs are used.
Spark pl ug resi stance val ues range from 6,000 to
20,000 ohms (when checked wi th at l east a 1000 vol t
spark pl ug tester). Do not use an ohmmeter to
check the resistance values of the spark plugs.
Inaccurate readings will result.
OPERATION
To prevent possi bl e pre-i gni ti on and/or mechani cal
engi ne damage, the correct type/heat range/number
spark pl ug must be used.
Al ways use the recommended torque when ti ghten-
i ng spark pl ugs. I ncorrect torque can di stort the
spark pl ug and change pl ug gap. I t can al so pul l the
pl ug threads and do possi bl e damage to both the
spark pl ug and the cyl i nder head.
Remove the spark pl ugs and exami ne them for
burned el ectrodes and foul ed, cracked or broken por-
cel ai n i nsul ators. Keep pl ugs arranged i n the order
i n whi ch they were removed from the engi ne. A si n-
gl e pl ug di spl ayi ng an abnormal condi ti on i ndi cates
that a probl em exi sts i n the correspondi ng cyl i nder.
Repl ace spark pl ugs at the i nterval s recommended i n
Group O, Lubri cati on and Mai ntenance
Spark pl ugs that have l ow mi l eage may be cl eaned
and reused i f not otherwi se defecti ve, carbon or oi l
foul ed. Al so refer to Spark Pl ug Condi ti ons.
CAUTION: Never use a motorized wire wheel brush
to clean the spark plugs. Metallic deposits will
remain on the spark plug insulator and will cause
plug misfire.
DIAGNOSIS AND TESTING - SPARK PLUG
CONDITIONS
NORMAL OPERATING
The few deposi ts present on the spark pl ug wi l l
probabl y be l i ght tan or sl i ghtl y gray i n col or. Thi s i s
evi dent wi th most grades of commerci al gasol i ne
(Fi g. 23). There wi l l not be evi dence of el ectrode
burni ng. Gap growth wi l l not average more than
approxi matel y 0.025 mm (.001 i n) per 3200 km (2000
mi l es) of operati on. Spark pl ugs that have normal
wear can usual l y be cl eaned, have the el ectrodes
fi l ed, have the gap set and then be i nstal l ed.
Fig. 22 IGNITION COIL - 2.4L
1 - IGNITION COIL
2 - MOUNTING BOLTS (4)
Fig. 23 Normal Operation and Cold (Carbon) Fouling
1 - NORMAL
2 - DRY BLACK DEPOSITS
3 - COLD (CARBON) FOULING
TJ IGNITION CONTROL 8I - 13
IGNITION COIL - 2.4L (Continued)
Some fuel refi ners i n several areas of the Uni ted
States have i ntroduced a manganese addi ti ve (MMT)
for unl eaded fuel . Duri ng combusti on, fuel wi th MMT
causes the enti re ti p of the spark pl ug to be coated
wi th a rust col ored deposi t. Thi s rust col or can be
mi sdi agnosed as bei ng caused by cool ant i n the com-
busti on chamber. Spark pl ug performance may be
affected by MMT deposi ts.
COLD FOULING/CARBON FOULING
Col d foul i ng i s someti mes referred to as carbon
foul i ng. The deposi ts that cause col d foul i ng are basi -
cal l y carbon (Fi g. 23). A dry, bl ack deposi t on one or
two pl ugs i n a set may be caused by sti cki ng val ves
or defecti ve spark pl ug cabl es. Col d (carbon) foul i ng
of the enti re set of spark pl ugs may be caused by a
cl ogged ai r cl eaner el ement or repeated short operat-
i ng ti mes (short tri ps).
WET FOULING OR GAS FOULING
A spark pl ug coated wi th excessi ve wet fuel or oi l
i s wet foul ed. I n ol der engi nes, worn pi ston ri ngs,
l eaki ng val ve gui de seal s or excessi ve cyl i nder wear
can cause wet foul i ng. I n new or recentl y overhaul ed
engi nes, wet foul i ng may occur before break-i n (nor-
mal oi l control ) i s achi eved. Thi s condi ti on can usu-
al l y be resol ved by cl eani ng and rei nstal l i ng the
foul ed pl ugs.
OIL OR ASH ENCRUSTED
I f one or more spark pl ugs are oi l or oi l ash
encrusted (Fi g. 24), eval uate engi ne condi ti on for the
cause of oi l entry i nto that parti cul ar combusti on
chamber.
ELECTRODE GAP BRIDGING
El ectrode gap bri dgi ng may be traced to l oose
deposi ts i n the combusti on chamber. These deposi ts
accumul ate on the spark pl ugs duri ng conti nuous
stop-and-go dri vi ng. When the engi ne i s suddenl y
subjected to a hi gh torque l oad, deposi ts parti al l y l i q-
uefy and bri dge the gap between el ectrodes (Fi g. 25).
Thi s short ci rcui ts the el ectrodes. Spark pl ugs wi th
el ectrode gap bri dgi ng can be cl eaned usi ng standard
procedures.
Fig. 24 Oil or Ash Encrusted
Fig. 25 Electrode Gap Bridging
1 - GROUND ELECTRODE
2 - DEPOSITS
3 - CENTER ELECTRODE
8I - 14 IGNITION CONTROL TJ
SPARK PLUG (Continued)
SCAVENGER DEPOSITS
Fuel scavenger deposi ts may be ei ther whi te or yel -
l ow (Fi g. 26). They may appear to be harmful , but
thi s i s a normal condi ti on caused by chemi cal addi -
ti ves i n certai n fuel s. These addi ti ves are desi gned to
change the chemi cal nature of deposi ts and decrease
spark pl ug mi sfi re tendenci es. Noti ce that accumul a-
ti on on the ground el ectrode and shel l area may be
heavy, but the deposi ts are easi l y removed. Spark
pl ugs wi th scavenger deposi ts can be consi dered nor-
mal i n condi ti on and can be cl eaned usi ng standard
procedures.
CHIPPED ELECTRODE INSULATOR
A chi pped el ectrode i nsul ator usual l y resul ts from
bendi ng the center el ectrode whi l e adjusti ng the
spark pl ug el ectrode gap. Under certai n condi ti ons,
severe detonati on can al so separate the i nsul ator
from the center el ectrode (Fi g. 27). Spark pl ugs wi th
thi s condi ti on must be repl aced.
PREIGNITION DAMAGE
Prei gni ti on damage i s usual l y caused by excessi ve
combusti on chamber temperature. The center el ec-
trode di ssol ves fi rst and the ground el ectrode di s-
sol ves somewhat l atter (Fi g. 28). I nsul ators appear
rel ati vel y deposi t free. Determi ne i f the spark pl ug
has the correct heat range rati ng for the engi ne.
Determi ne i f i gni ti on ti mi ng i s over advanced or i f
other operati ng condi ti ons are causi ng engi ne over-
heati ng. (The heat range rati ng refers to the operat-
i ng temperature of a parti cul ar type spark pl ug.
Spark pl ugs are desi gned to operate wi thi n speci fi c
temperature ranges. Thi s depends upon the thi ck-
ness and l ength of the center el ectrodes porcel ai n
i nsul ator.)
Fig. 26 Scavenger Deposits
1 - GROUND ELECTRODE COVERED WITH WHITE OR YELLOW
DEPOSITS
2 - CENTER ELECTRODE
Fig. 27 Chipped Electrode Insulator
1 - GROUND ELECTRODE
2 - CENTER ELECTRODE
3 - CHIPPED INSULATOR
Fig. 28 Preignition Damage
1 - GROUND ELECTRODE STARTING TO DISSOLVE
2 - CENTER ELECTRODE DISSOLVED
TJ IGNITION CONTROL 8I - 15
SPARK PLUG (Continued)
SPARK PLUG OVERHEATING
Overheati ng i s i ndi cated by a whi te or gray center
el ectrode i nsul ator that al so appears bl i stered (Fi g.
29). The i ncrease i n el ectrode gap wi l l be consi der-
abl y i n excess of 0.001 i nch per 2000 mi l es of opera-
ti on. Thi s suggests that a pl ug wi th a cool er heat
range rati ng shoul d be used. Over advanced i gni ti on
ti mi ng, detonati on and cool i ng system mal functi ons
can al so cause spark pl ug overheati ng.
REMOVAL
2. 4L
I f spark pl ug for #2 or #3 cyl i nder i s bei ng
removed, throttl e body must be removed. Refer to
Throttl e Body Removal .
(1) Remove ai r cl eaner tube and housi ng.
(2) Twi st secondary cabl e at cyl i nder head to break
l oose at spark pl ug. Remove cabl e from pl ug.
(3) Pri or to removi ng spark pl ug, spray com-
pressed ai r i nto cyl i nder head openi ng. Thi s wi l l hel p
prevent forei gn materi al from enteri ng combusti on
chamber.
(4) Remove spark pl ug from cyl i nder head usi ng a
qual i ty socket wi th a rubber or foam i nsert.
(5) I nspect spark pl ug condi ti on. Refer to Spark
Pl ug Condi ti ons.
4. 0L
On the 4.0L 6–cyl i nder engi ne the spark pl ugs are
l ocated bel ow the coi l rai l assembl y. To gai n access to
any/al l spark pl ug(s), refer to I gni ti on Coi l -4.0L
Engi ne Removal /I nstal l ati on.
(1) Pri or to removi ng the spark pl ug, spray com-
pressed ai r around the spark pl ug hol e and the area
around the spark pl ug. Thi s wi l l hel p prevent forei gn
materi al from enteri ng the combusti on chamber.
(2) Remove the spark pl ug usi ng a qual i ty socket
wi th a rubber or foam i nsert.
(3) I nspect the spark pl ug condi ti on. Refer to
Spark Pl ugs Condi ti ons.
CLEANING
CLEANING SPARK PLUGS
The pl ugs may be cl eaned usi ng commerci al l y
avai l abl e spark pl ug cl eani ng equi pment. After cl ean-
i ng, fi l e the center el ectrode fl at wi th a smal l poi nt
fi l e or jewel ers fi l e before adjusti ng gap.
CAUTION: Never use a motorized wire wheel brush
to clean the spark plugs. Metallic deposits will
remain on the spark plug insulator and will cause
plug misfire.
INSTALLATION
Al ways ti ghten spark pl ugs to the speci fi ed torque.
Over ti ghteni ng can cause di storti on. Thi s may resul t
i n a change i n the spark pl ug gap, or a cracked por-
cel ai n i nsul ator.
When repl aci ng the spark pl ug and i gni ti on coi l
cabl es, route the cabl es correctl y and secure them i n
the appropri ate retai ners. Fai l ure to route the cabl es
properl y can cause the radi o to reproduce i gni ti on
noi se. I t coul d cause cross i gni ti on of the spark pl ugs,
or short ci rcui t the cabl es to ground.
2. 4L
CAUTION: Spark plug tightening on the 2.4L is
torque critical. The plugs are equipped with tapered
seats. Do not exceed 15 ft. lbs. torque.
Speci al care shoul d be taken when i nstal l i ng spark
pl ugs i nto the cyl i nder head spark pl ug wel l s. Be
sure the pl ugs do not drop i nto the pl ug wel l s as el ec-
trodes can be damaged.
Al ways ti ghten spark pl ugs to the speci fi ed torque.
Over ti ghteni ng can cause di storti on resul ti ng i n a
change i n the spark pl ug gap or a cracked porcel ai n
i nsul ator.
(1) Start the spark pl ug i nto the cyl i nder head by
hand to avoi d cross threadi ng.
(2) Ti ghten spark pl ugs. Refer to torque speci fi ca-
ti ons.
(3) I nstal l throttl e body (i f necessary). Refer to
Throttl e Body I nstal l ati on.
(4) I nstal l ai r cl eaner tube and housi ng.
Fig. 29 Spark Plug Overheating
1 - BLISTERED WHITE OR GRAY COLORED INSULATOR
8I - 16 IGNITION CONTROL TJ
SPARK PLUG (Continued)
4. 0L
Speci al care shoul d be taken when i nstal l i ng spark
pl ugs i nto the cyl i nder head spark pl ug wel l s. Be
sure the pl ugs do not drop i nto the pl ug wel l s as el ec-
trodes can be damaged.
Al ways ti ghten spark pl ugs to the speci fi ed torque.
Over ti ghteni ng can cause di storti on resul ti ng i n a
change i n the spark pl ug gap or a cracked porcel ai n
i nsul ator.
(1) Start the spark pl ug i nto the cyl i nder head by
hand to avoi d cross threadi ng.
(2) Ti ghten spark pl ugs. Refer to torque speci fi ca-
ti ons.
(3) I nstal l coi l rai l . Refer to I gni ti on Coi l -4.0L
Engi ne Removal /I nstal l ati on.
SPARK PLUG CABLE
DESCRIPTION
Spark pl ug cabl es are used onl y on the 2.4L 4–cyl -
i nder engi ne. They are someti mes referred to as sec-
ondary i gni ti on wi res.
OPERATION
2.4L 4–cyl i nder engi ne onl y: The spark pl ug cabl es
transfer el ectri cal current from the i gni ti on coi l (s)
and/or di stri butor, to i ndi vi dual spark pl ugs at each
cyl i nder. The resi sti ve spark pl ug cabl es are of non-
metal l i c constructi on. The cabl es provi de suppressi on
of radi o frequency emi ssi ons from the i gni ti on sys-
tem.
DIAGNOSIS AND TESTING
TESTING
Check the spark pl ug cabl e connecti ons for good
contact at the coi l (s) and spark pl ugs. Termi nal s
shoul d be ful l y seated. The i nsul ators shoul d be i n
good condi ti on and shoul d fi t ti ghtl y on the coi l and
spark pl ugs. Spark pl ug cabl es wi th i nsul ators that
are cracked or torn must be repl aced.
Cl ean hi gh vol tage i gni ti on cabl es wi th a cl oth
moi stened wi th a non-fl ammabl e sol vent. Wi pe the
cabl es dry. Check for bri ttl e or cracked i nsul ati on.
When testi ng secondary cabl es for damage wi th an
osci l l oscope, fol l ow the i nstructi ons of the equi pment
manufacturer.
I f an osci l l oscope i s not avai l abl e, spark pl ug cabl es
may be tested as fol l ows:
CAUTION: Do not leave any one spark plug cable
disconnected for longer than necessary during test-
ing. This may cause possible heat damage to the
catalytic converter. Total test time must not exceed
ten minutes.
Wi th the engi ne runni ng, remove spark pl ug cabl e
from spark pl ug (one at a ti me) and hol d next to a
good engi ne ground. I f the cabl e and spark pl ug are
i n good condi ti on, the engi ne rpm shoul d drop and
the engi ne wi l l run poorl y. I f engi ne rpm does not
drop, the cabl e and/or spark pl ug may not be operat-
i ng properl y and shoul d be repl aced. Al so check
engi ne cyl i nder compressi on.
Wi th the engi ne not runni ng, connect one end of a
test probe to a good ground. Start the engi ne and run
the other end of the test probe al ong the enti re
l ength of al l spark pl ug cabl es. I f cabl es are cracked
or punctured, there wi l l be a noti ceabl e spark jump
from the damaged area to the test probe. Cracked,
damaged or faul ty cabl es shoul d be repl aced wi th
resi stance type cabl e. Thi s can be i denti fi ed by the
words ELECTRONI C SUPPRESSI ON pri nted on the
cabl e jacket.
Use an ohmmeter to test for open ci rcui ts, exces-
si ve resi stance or l oose termi nal s. Remove the cabl e
at i gni ti on coi l , and from spark pl ug. Connect ohm-
meter to each end of cabl e. Resi stance shoul d be 250
to 1000 Ohms per i nch of cabl e. I f resi stance i s not
wi thi n speci fi cati ons as found i n the SPARK PLUG
CABLE RESI STANCE chart, repl ace the cabl e. Test
al l spark pl ug cabl es i n thi s manner.
SPARK PLUG CABLE RESISTANCE
MINIMUM MAXIMUM
250 Ohms Per Inch 1000 Ohms Per Inch
3000 Ohms Per Foot 12,000 Ohms Per Foot
TJ IGNITION CONTROL 8I - 17
SPARK PLUG (Continued)
REMOVAL - 2. 4L
CAUTION: When disconnecting a high voltage cable
from a spark plug or from the distributor cap, twist
the rubber boot slightly (1/2 turn) to break it loose
(Fig. 30).
(1) Grasp the boot (not the cabl e) and pul l i t off
wi th a steady, even force.
INSTALLATION
(1) Push the cabl e fi rml y onto the sparkpl ug.
Fig. 30 CABLE REMOVAL
1 - SPARK PLUG CABLE AND BOOT
2 - SPARK PLUG BOOT PULLER
3 - TWIST AND PULL
4 - SPARK PLUG
8I - 18 IGNITION CONTROL TJ
SPARK PLUG CABLE (Continued)
INSTRUMENT CLUSTER
TABLE OF CONTENTS
page page
INSTRUMENT CLUSTER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 2
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
DIAGNOSIS AND TESTING - INSTRUMENT
CLUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 17
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 19
ABS INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 20
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
DIAGNOSIS AND TESTING - ABS INDICATOR . 20
AIRBAG INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 21
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
BRAKE/PARK BRAKE INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 22
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
DIAGNOSIS AND TESTING - BRAKE
INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . 23
CHECK GAUGES INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 24
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
CRUISE INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 25
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
ENGINE TEMPERATURE GAUGE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 25
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
FOG LAMP INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 26
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
DIAGNOSIS AND TESTING - FRONT/REAR
FOG LAMP INDICATOR . . . . . . . . . . . . . . . . . 27
FRONT LOCK INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 27
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
FUEL GAUGE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 29
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
HIGH BEAM INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 30
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
DIAGNOSIS AND TESTING - HIGH BEAM
INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . 30
LOW FUEL INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 31
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
MALFUNCTION INDICATOR LAMP (MIL)
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 32
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
ODOMETER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 33
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
OIL PRESSURE GAUGE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 34
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
REAR LOCK INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 35
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
SEATBELT INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 36
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
SHIFT INDICATOR (TRANSFER CASE)
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 37
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
DIAGNOSIS AND TESTING - 4WD INDICATOR . 38
SKIS INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 39
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
SPEEDOMETER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 40
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
TACHOMETER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 41
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
TURN SIGNAL INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 41
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
UPSHIFT INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 42
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
VOLTAGE GAUGE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 43
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
TJ INSTRUMENT CLUSTER 8J - 1
INSTRUMENT CLUSTER
DESCRIPTION
The i nstrument cl uster for thi s model i s an El ec-
troMechani cal I nstrument Cl uster (EMI C) that i s
l ocated i n the i nstrument panel above the steeri ng
col umn openi ng, di rectl y i n front of the dri ver (Fi g.
1). The remai nder of the EMI C, i ncl udi ng the mounts
and the el ectri cal connecti ons, are conceal ed wi thi n
the i nstrument panel behi nd the cl uster bezel .
Besi des anal og gauges and i ndi cators, the EMI C
modul e i ncorporates a bl ue-green di gi tal Vacuum
Fl uorescent Di spl ay (VFD) uni t for di spl ayi ng odom-
eter/tri p odometer i nformati on and certai n di agnosti c
i nformati on. The i nstrument cl uster for thi s model
al so i ncl udes the hardware and software necessary to
serve as an el ectroni c body control modul e.
The EMI C gauges and i ndi cators are vi si bl e
through a dedi cated openi ng i n the cl uster bezel on
the i nstrument panel and are protected by a cl ear
pl asti c cl uster l ens (Fi g. 2). Ei ght i ntegral l atch for-
mati ons around the outer peri meter of the l ens
secure the l ens uni t to the cl uster hood and the cl us-
ter housi ng. On the l ower edge of the cl uster l ens
just ri ght of center, a smal l mol ded rubber boot cov-
ers the odometer/tri p odometer swi tch button and
seal s a dedi cated pocketed hol e i n the l ens through
whi ch the swi tch button protrudes. Just behi nd the
cl uster l ens i s the cl uster hood and an i ntegral cl us-
ter mask, whi ch are constructed of mol ded bl ack
pl asti c. The cl uster hood serves as a vi sor and shi el ds
the face of the cl uster from ambi ent l i ght and refl ec-
ti ons to reduce gl are, whi l e the cl uster mask tri ms
the outsi de peri meter of the cl uster overl ay. The cl us-
ter hood and mask uni t i s secured to the cl uster
housi ng wi th fi ve i ntegral l atch formati ons around i ts
peri meter.
The rear of the cl uster housi ng and the EMI C el ec-
troni c ci rcui try are protected by a mol ded pl asti c rear
cover, whi ch i s secured to the cl uster housi ng wi th
two screws, ei ght i ntegral l atch formati ons around i ts
peri meter, and a si ngl e l atch that i s i ntegral to the
cl uster housi ng. The rear cover i ncl udes cl earance
hol es for servi ce access to each of the fi ve general
i l l umi nati on l i ghti ng and the one hi gh beam i ndi ca-
tor i ncandescent bul b and bul b hol der uni ts i nstal l ed
on the cl uster ci rcui t board, and for the two col or-
coded cl uster connector receptacl es. The connector
receptacl es on the back of the cl uster el ectroni c ci r-
cui t board connect the EMI C to the vehi cl e el ectri cal
system through two take outs wi th col or-coded con-
nectors from the i nstrument panel wi re harness.
Sandwi ched between the rear cover and the l ens,
hood and mask uni t i s the cl uster housi ng. The
mol ded pl asti c cl uster housi ng serves as the carri er
for the cl uster ci rcui t board and ci rcui try, the cl uster
connector receptacl es, the gauges, a Li ght Emi tti ng
Di ode (LED) for each cl uster i ndi cator, the VFD uni t,
an audi bl e tone generator, the cl uster overl ay, the
gauge poi nters, the odometer/tri p odometer swi tch
and the swi tch button. The mol ded pl asti c EMI C
housi ng has four i ntegral mounti ng tabs, two on the
l ower outboard edges of the housi ng and one on each
si de. A screw through each of these four mounti ng
tabs secures the EMI C to the i nstrument panel struc-
tural support.
The cl uster overl ay i s a l ami nated pl asti c uni t. The
dark, vi si bl e, outer surface of the overl ay i s marked
wi th al l of the gauge di al faces and graduati ons, but
Fig. 1 Instrument Cluster
1 - CLUSTER BEZEL
2 - INSTRUMENT CLUSTER
Fig. 2 Instrument Cluster Components
1 - REAR COVER
2 - CLUSTER HOUSING
3 - CLUSTER HOOD & MASK
4 - CLUSTER LENS
5 - SWITCH BUTTON BOOT
8J - 2 INSTRUMENT CLUSTER TJ
thi s l ayer i s al so transl ucent. The darkness of thi s
outer l ayer prevents the cl uster from appeari ng cl ut-
tered or busy by conceal i ng the cl uster i ndi cators
that are not i l l umi nated, whi l e the transl ucence of
thi s l ayer al l ows those i ndi cators and i cons that are
i l l umi nated to be readi l y vi si bl e. The underl yi ng
l ayer of the overl ay i s opaque and al l ows l i ght from
the LED or i ncandescent l amp for each of the vari ous
i ndi cators and the i ncandescent i l l umi nati on l amps
behi nd i t to be vi si bl e through the outer l ayer of the
overl ay onl y through predetermi ned stenci l -l i ke cut-
outs. A rectangul ar openi ng near the base of the
overl ay between the speedometer and tachometer
di al faces has a smoked cl ear l ens through whi ch the
i l l umi nated VFD uni t can be vi ewed.
Several versi ons of the EMI C modul e are offered
on thi s model . These versi ons accommodate al l of the
vari ati ons of opti onal equi pment and regul atory
requi rements for the vari ous markets i n whi ch the
vehi cl e wi l l be offered. The mi croprocessor-based
EMI C uti l i zes i ntegrated ci rcui try and i nformati on
carri ed on the Programmabl e Communi cati ons I nter-
face (PCI ) data bus network al ong wi th several hard
wi red anal og and mul ti pl exed i nputs to moni tor sen-
sors and swi tches throughout the vehi cl e. I n response
to those i nputs, the i nternal ci rcui try and program-
mi ng of the EMI C al l ow i t to control and i ntegrate
many el ectroni c functi ons and features of the vehi cl e
through both hard wi red outputs and the transmi s-
si on of el ectroni c message outputs to other el ectroni c
modul es i n the vehi cl e over the PCI data bus. (Refer
to 8 - ELECTRI CAL/ELECTRONI C CONTROL
MODULES/COMMUNI CATI ON - DESCRI PTI ON -
PCI BUS).
Besi des typi cal i nstrument cl uster gauge and i ndi -
cator support, the el ectroni c functi ons and features
that the EMI C supports or control s i ncl ude the fol -
l owi ng:
• Audible Warnings - The EMI C el ectroni c ci r-
cui t board i s equi pped wi th an audi bl e tone generator
and programmi ng that al l ows i t to provi de vari ous
audi bl e chi me tone al erts to the vehi cl e operator.
(Refer to 8 - ELECTRI CAL/CHI ME/BUZZER -
DESCRI PTI ON).
• Audio System Cabin Equalization - The
EMI C stores the cabi n equal i zati on curves for vari -
ous opti onal speaker system archi tectures for use by
the radi o. The EMI C provi des thi s i nformati on when
requested by the radi o over the PCI data bus. Chang-
i ng the cabi n equal i zati on setti ngs of the EMI C
requi res the use of a DRBI I I ௡ scan tool . Refer to the
appropri ate di agnosti c i nformati on.
• Axle Locker Control - The EMI C provi des the
l ogi c that control s the operati on of the rear and front
axl e l ocker feature found on model s equi pped wi th
the opti onal off-road package.
• Electronic Pinion Factor - The EMI C stores
the ti re si ze, axl e rati o, and transfer case type i nfor-
mati on for use i n cal i brati ng the proper vehi cl e speed
and di stance val ues for di spl ay by the speedometer
and odometer, as wel l as for use by other el ectroni c
modul es i n the vehi cl e. The EMI C provi des thi s
i nformati on when requested by other modul es over
the PCI data bus. Changi ng the el ectroni c pi ni on fac-
tor setti ngs of the EMI C requi res the use of a
DRBI I I ௡ scan tool . Refer to the appropri ate di agnos-
ti c i nformati on.
• Interior Lamp Load Shedding - The EMI C
provi des a battery saver feature whi ch wi l l automat-
i cal l y turn off al l i nteri or l amps that remai n on after
a ti med i nterval of about twenty mi nutes.
• Interior Lighting Control - The EMI C moni -
tors i nputs from the i nteri or l i ghti ng swi tch and the
door ajar swi tches to provi de courtesy l amp control .
Thi s i ncl udes support for a ti med i l l umi nated entry
wi th a theater-styl e fade-to-off feature.
• Panel Lamps Dimming Control - The EMI C
provi des a hard wi red 12-vol t Pul se-Wi dth Modul ated
(PWM) output that synchroni zes the di mmi ng l evel
of al l panel l amps di mmer control l ed l amps wi th that
of the cl uster i l l umi nati on l amps. Thi s i ncl udes pro-
vi di ng features such as VFD uni t i l l umi nati on when
a door i s ajar (rental car mode), radi o i l l umi nati on
control , a parade mode, and one step di mmabl e front
and rear l ock, crui se, four-wheel dri ve, and upshi ft
i ndi cators.
• Rear Window Defogger Control - The EMI C
provi des control and ti mer functi ons for the output to
the rear wi ndow defogger on vehi cl es so equi pped,
whi ch el i mi nates the need for a separate control and
ti mer modul e for the rear wi ndow defogger system.
(Refer to 8 - ELECTRI CAL/WI NDOW DEFOGGER -
DESCRI PTI ON).
• Vacuum Fluorescent Display Synchroniza-
tion - The EMI C transmi ts el ectroni c panel l amp
di mmi ng l evel messages whi ch al l ows al l other el ec-
troni c modul es wi th Vacuum Fl uorescent Di spl ay
(VFD) uni ts on the PCI data bus to coordi nate thei r
i l l umi nati on i ntensi ty wi th that of the EMI C VFD
uni t.
The EMI C houses si x anal og gauges and has pro-
vi si ons for up to seventeen i ndi cators (Fi g. 3). The
EMI C i ncl udes the fol l owi ng anal og gauges:
• Coolant Temperature Gauge
• Fuel Gauge
• Oil Pressure Gauge
• Speedometer
• Tachometer
• Voltage Gauge
Some of the EMI C i ndi cators are automati cal l y
confi gured when the EMI C i s connected to the vehi -
cl e el ectri cal system for compati bi l i ty wi th certai n
TJ INSTRUMENT CLUSTER 8J - 3
INSTRUMENT CLUSTER (Continued)
opti onal equi pment or equi pment requi red for regul a-
tory purposes i n certai n markets. Whi l e each EMI C
may have provi si ons for i ndi cators to support every
avai l abl e opti on, the confi gurabl e i ndi cators wi l l not
be functi onal i n a vehi cl e that does not have the
equi pment that an i ndi cator supports. The EMI C
i ncl udes provi si ons for the fol l owi ng i ndi cators
(Fi g. 3):
• Airbag Indicator (with Airbag System only)
• Antilock Brake System (ABS) Indicator
(with ABS brakes only)
• Brake Indicator
• Check Gauges Indicator
• Cruise Indicator (with Speed Control only)
• Fog Lamp Indicator (with Front or Rear
Fog Lamps only)
• Four-Wheel Drive (4WD) Indicator
• Front Lock Indicator (with Off-Road Pack-
age only)
• High Beam Indicator
• Low Fuel Indicator
• Malfunction Indicator Lamp (MIL)
• Rear Lock Indicator (with Off-Road Pack-
age only)
• Seatbelt Indicator
• Sentry Key Immobilizer System (SKIS)
Indicator (with SKIS only)
• Turn Signal (Right and Left) Indicators
• Upshift Indicator (with Manual Transmis-
sion only)
The EMI C hi gh beam i ndi cator i s i l l umi nated by a
dedi cated i ncandescent bul b. Each remai ni ng i ndi ca-
tor i n the EMI C i s i l l umi nated by a dedi cated LED
that i s sol dered onto the EMI C el ectroni c ci rcui t
board. The LED uni ts are not avai l abl e for servi ce
repl acement and, i f damaged or faul ty, the enti re
EMI C must be repl aced. Cl uster i l l umi nati on i s
accompl i shed by di mmabl e i ncandescent back l i ght-
i ng, whi ch i l l umi nates the gauges for vi si bi l i ty when
the exteri or l i ghti ng i s turned on. Each of the i ncan-
descent bul bs i s secured by an i ntegral bul b hol der to
Fig. 3 Gauges & Indicators
1 - FOG LAMP INDICATOR 14 - 4WD INDICATOR
2 - VOLTAGE GAUGE 15 - UPSHIFT INDICATOR
3 - CRUISE INDICATOR 16 - ENGINE TEMPERATURE GAUGE
4 - SKIS INDICATOR 17 - AIRBAG INDICATOR
5 - TACHOMETER 18 - CHECK GAUGES INDICATOR
6 - LEFT TURN INDICATOR 19 - MALFUNCTION INDICATOR LAMP
7 - HIGH BEAM INDICATOR 20 - ODOMETER/TRIP ODOMETER SWITCH BUTTON
8 - SEATBELT INDICATOR 21 - ODOMETER/TRIP ODOMETER DISPLAY
9 - RIGHT TURN INDICATOR 22 - ABS INDICATOR
10 - SPEEDOMETER 23 - BRAKE INDICATOR
11 - FRONT LOCK INDICATOR 24 - LOW FUEL INDICATOR
12 - REAR LOCK INDICATOR 25 - FUEL GAUGE
13 - OIL PRESSURE GAUGE
8J - 4 INSTRUMENT CLUSTER TJ
INSTRUMENT CLUSTER (Continued)
the el ectroni c ci rcui t board from the back of the cl us-
ter housi ng.
Hard wi red ci rcui try connects the EMI C to the
el ectri cal system of the vehi cl e. These hard wi red ci r-
cui ts are i ntegral to several wi re harnesses, whi ch
are routed throughout the vehi cl e and retai ned by
many di fferent methods. These ci rcui ts may be con-
nected to each other, to the vehi cl e el ectri cal system
and to the EMI C through the use of a combi nati on of
sol dered spl i ces, spl i ce bl ock connectors, and many
di fferent types of wi re harness termi nal connectors
and i nsul ators. Refer to the appropri ate wi ri ng i nfor-
mati on. The wi ri ng i nformati on i ncl udes wi ri ng di a-
grams, proper wi re and connector repai r procedures,
further detai l s on wi re harness routi ng and reten-
ti on, as wel l as pi n-out and l ocati on vi ews for the
vari ous wi re harness connectors, spl i ces and grounds.
The EMI C modul es for thi s model are servi ced onl y
as compl ete uni ts. The EMI C modul e cannot be
adjusted or repai red. I f a gauge, an LED i ndi cator, a
VFD uni t, the el ectroni c ci rcui t board, the ci rcui t
board hardware, the cl uster overl ay, or the EMI C
housi ng are damaged or faul ty, the enti re EMI C mod-
ul e must be repl aced. The cl uster l ens, the cl uster
hood and mask uni t, the cl uster housi ng rear cover,
the odometer/tri p odometer swi tch button boot, and
the i ncandescent l amp bul bs wi th hol ders are avai l -
abl e for i ndi vi dual servi ce repl acement.
OPERATION
The El ectroMechani cal I nstrument Cl uster (EMI C)
i n thi s model al so i ncl udes the hardware and soft-
ware necessary to serve as the el ectroni c body control
modul e. The fol l owi ng i nformati on deal s pri mari l y
wi th the i nstrument cl uster functi ons of thi s uni t.
Addi ti onal detai l s of the el ectroni c body control func-
ti ons of thi s uni t may be found wi thi n the servi ce
i nformati on for the system or component that the
EMI C control s. For exampl e: Addi ti onal detai l s of the
audi bl e warni ng functi ons of the EMI C are found
wi thi n the Chi me/Buzzer servi ce i nformati on.
The EMI C i s desi gned to al l ow the vehi cl e operator
to moni tor the condi ti ons of many of the vehi cl e com-
ponents and operati ng systems. The gauges and i ndi -
cators i n the EMI C provi de val uabl e i nformati on
about the vari ous standard and opti onal powertrai ns,
fuel and emi ssi ons systems, cool i ng systems, l i ghti ng
systems, safety systems, and many other conveni ence
i tems. The EMI C i s i nstal l ed i n the i nstrument panel
so that al l of these moni tors can be easi l y vi ewed by
the vehi cl e operator when dri vi ng, whi l e sti l l al l ow-
i ng rel ati ve ease of access for servi ce. The mi cropro-
cessor-based EMI C hardware and software uses
vari ous i nputs to control the gauges and i ndi cators
vi si bl e on the face of the cl uster. Some of these
i nputs are hard wi red, but most are i n the form of
el ectroni c messages that are transmi tted by other
el ectroni c modul es over the Programmabl e Commuta-
ti ons I nterface (PCI ) data bus network. (Refer to 8 -
ELECTRI CAL/ELECTRONI C CONTROL MOD-
ULES/COMMUNI CATI ON - OPERATI ON).
The EMI C mi croprocessor smooths the i nput data
usi ng al gori thms to provi de gauge readi ngs that are
accurate, stabl e, and responsi ve to operati ng condi -
ti ons. These al gori thms are desi gned to provi de
gauge readi ngs duri ng normal operati on that are con-
si stent wi th customer expectati ons. However, when
abnormal condi ti ons exi st, such as l ow/hi gh battery
vol tage, l ow oi l pressure, or hi gh cool ant tempera-
ture, the al gori thm can dri ve the gauge poi nter to an
extreme posi ti on and the mi croprocessor can turn on
the Check Gauges i ndi cator and/or sound a chi me
through the on-board tone generator to provi de di s-
ti nct vi sual and/or audi bl e i ndi cati ons of a probl em to
the vehi cl e operator. The i nstrument cl uster ci rcui try
may al so produce audi bl e warni ngs for other el ec-
troni c modul es i n the vehi cl e based upon el ectroni c
tone request messages recei ved over the PCI data
bus. Each audi bl e warni ng i s i ntended to provi de the
vehi cl e operator wi th an audi bl e al ert to suppl ement
a vi sual i ndi cati on.
The EMI C ci rcui try operates on battery current
recei ved through the I gni ti on-Off Draw (I OD) fuse i n
the Power Di stri buti on Center (PDC) on a non-
swi tched fused B(+) ci rcui t, and on battery current
recei ved through a fuse i n the fuse bl ock on a fused
i gni ti on swi tch output (run-start) ci rcui t. Thi s
arrangement al l ows the EMI C to provi de some fea-
tures regardl ess of the i gni ti on swi tch posi ti on, whi l e
other features wi l l operate onl y wi th the i gni ti on
swi tch i n the On or Start posi ti ons. The EMI C ci r-
cui try i s grounded through a ground ci rcui t and take
out of the i nstrument panel wi re harness wi th an
eyel et termi nal connector that i s secured under a
ground screw to the back of the i nstrument panel
structural support near the l ower l eft corner of the
i nstrument panel , just i nboard of the l eft i nstrument
panel end bracket.
The EMI C al so has a sel f-di agnosti c actuator test
capabi l i ty, whi ch wi l l test each of the PCI bus mes-
sage-control l ed functi ons of the cl uster by l i ghti ng
the appropri ate i ndi cators, posi ti oni ng the gauge nee-
dl es at several predetermi ned cal i brati on poi nts
across the gauge faces, and i l l umi nati ng al l segments
of the odometer/tri p odometer Vacuum-Fl uorescent
Di spl ay (VFD) uni t. (Refer to 8 - ELECTRI CAL/I N-
STRUMENT CLUSTER - DI AGNOSI S AND TEST-
I NG). See the owner’s manual i n the vehi cl e gl ove
box for more i nformati on on the features, use and
operati on of the EMI C.
TJ INSTRUMENT CLUSTER 8J - 5
INSTRUMENT CLUSTER (Continued)
GAUGES
Al l gauges recei ve battery current through the
EMI C ci rcui try onl y when the i gni ti on swi tch i s i n
the On or Start posi ti ons. Wi th the i gni ti on swi tch i n
the Off posi ti on battery current i s not suppl i ed to
any gauges, and the EMI C ci rcui try i s programmed
to move al l of the gauge needl es back to the l ow end
of thei r respecti ve scal es. Therefore, the gauges do
not accuratel y i ndi cate any vehi cl e condi ti on unl ess
the i gni ti on swi tch i s i n the On or Start posi ti ons.
Al l of the EMI C gauges are ai r core magneti c
uni ts. Two fi xed el ectromagneti c coi l s are l ocated
wi thi n each gauge. These coi l s are wrapped at ri ght
angl es to each other around a movabl e permanent
magnet. The movabl e magnet i s suspended wi thi n
the coi l s on one end of a pi vot shaft, whi l e the gauge
needl e i s attached to the other end of the shaft. One
of the coi l s has a fi xed current fl owi ng through i t to
mai ntai n a constant magneti c fi el d strength. Current
fl ow through the second coi l changes, whi ch causes
changes i n i ts magneti c fi el d strength. The current
fl owi ng through the second coi l i s changed by the
EMI C ci rcui try i n response to messages recei ved over
the PCI data bus. The gauge needl e moves as the
movabl e permanent magnet al i gns i tsel f to the
changi ng magneti c fi el ds created around i t by the
el ectromagnets.
The gauges are di agnosed usi ng the EMI C sel f-di -
agnosti c actuator test. (Refer to 8 - ELECTRI CAL/
I NSTRUMENT CLUSTER - DI AGNOSI S AND
TESTI NG). Proper testi ng of the PCI data bus and
the el ectroni c data bus message i nputs to the EMI C
that control each gauge requi re the use of a DRBI I I ௡
scan tool . Refer to the appropri ate di agnosti c i nfor-
mati on. Speci fi c operati on detai l s for each gauge may
be found el sewhere i n thi s servi ce i nformati on.
VACUUM-FLUORESCENT DISPLAY
The Vacuum-Fl uorescent Di spl ay (VFD) uni t i s sol -
dered to the EMI C el ectroni c ci rcui t board. Wi th the
i gni ti on swi tch i n the Off or Accessory posi ti ons, the
odometer di spl ay i s acti vated when ei ther door i s
opened (Rental Car mode) and i s deacti vated after
both doors are cl osed. I f a door i s l eft open wi th the
i gni ti on swi tch i n any posi ti on except On or Start,
the VFD wi l l remai n i l l umi nated unti l the i nteri or
l i ghts control battery saver (l oad sheddi ng) ti mer
expi res after about twenty mi nutes. Otherwi se, the
di spl ay uni t i s acti ve when the i gni ti on swi tch i s i n
the On or Start posi ti ons, and i nacti ve when the i gni -
ti on swi tch i s i n the Off or Accessory posi ti ons.
The i l l umi nati on i ntensi ty of the VFD uni t i s con-
trol l ed by the EMI C ci rcui try based upon an i nput
from the headl amp swi tch ci rcui try and a di mmi ng
l evel i nput recei ved from the panel l amp di mmer
swi tch ci rcui try. The EMI C synchroni zes the i l l umi -
nati on i ntensi ty of other VFD uni ts wi th that of the
uni t i n the EMI C by sendi ng el ectroni c di mmi ng
l evel messages to other el ectroni c modul es i n the
vehi cl e over the PCI data bus.
The EMI C VFD uni t has several di spl ay capabi l i -
ti es i ncl udi ng odometer, tri p odometer, software ver-
si on, and can di spl ay vari ous di agnosti c i nformati on
when certai n faul t condi ti ons exi st. An odometer/tri p
odometer swi tch on the EMI C ci rcui t board i s used to
control some of the di spl ay modes. Thi s swi tch i s
actuated manual l y by depressi ng the odometer/tri p
odometer swi tch button that extends through the
l ower edge of the cl uster l ens, just ri ght of center.
Actuati ng thi s swi tch momentari l y wi th the i gni ti on
swi tch i n the On posi ti on wi l l toggl e the VFD
between the odometer and tri p odometer modes.
Depressi ng the swi tch button for about two seconds
whi l e the VFD i s i n the tri p odometer mode wi l l
reset the tri p odometer val ue to zero. Hol di ng thi s
swi tch depressed whi l e turni ng the i gni ti on swi tch
from the Off posi ti on to the On posi ti on wi l l i ni ti ate
the EMI C sel f-di agnosti c actuator test. Refer to the
appropri ate di agnosti c i nformati on for addi ti onal
detai l s on thi s VFD functi on. The EMI C mi croproces-
sor remembers whi ch di spl ay mode i s acti ve when
the i gni ti on swi tch i s turned to the Off posi ti on, and
returns the VFD di spl ay to that mode when the i gni -
ti on swi tch i s turned On agai n.
The VFD i s di agnosed usi ng the EMI C sel f-di ag-
nosti c actuator test. (Refer to 8 - ELECTRI CAL/I N-
STRUMENT CLUSTER - DI AGNOSI S AND
TESTI NG). Proper testi ng of the PCI data bus and
the el ectroni c data bus message i nputs to the EMI C
that control some of the VFD functi ons requi res the
use of a DRBI I I ௡ scan tool . Refer to the appropri ate
di agnosti c i nformati on. Speci fi c operati on detai l s for
the odometer and tri p odometer functi ons of the VFD
may be found el sewhere i n thi s servi ce i nformati on.
INDICATORS
I ndi cators are l ocated i n vari ous posi ti ons wi thi n
the EMI C and are al l connected to the EMI C el ec-
troni c ci rcui t board. The anti l ock brake system i ndi -
cator, headl amp hi gh beam i ndi cator, fog l amp
i ndi cator, and turn si gnal i ndi cators operate based
upon hard wi red i nputs to the EMI C. The brake i ndi -
cator i s control l ed by the EMI C programmi ng and
hard wi red park brake and brake warni ng i ndi cator
swi tch i nputs to the EMI C. I n vehi cl es wi thout the
opti onal off-road package the four-wheel dri ve i ndi ca-
tor i s control l ed by a hard wi red i nput from the
transfer case swi tch, whi l e i n vehi cl es equi pped wi th
the off-road package thi s i ndi cator i s control l ed by
PCI data bus messages from the Powertrai n Control
Modul e (PCM). The rear and front l ock i ndi cators are
control l ed by the EMI C programmi ng and hard wi red
8J - 6 INSTRUMENT CLUSTER TJ
INSTRUMENT CLUSTER (Continued)
i nputs from the axl e l ocker swi tch and the rear/front
l ocker i ndi cator swi tches. The seatbel t i ndi cator i s
control l ed by the EMI C programmi ng and a hard
wi red seat bel t swi tch i nput to the EMI C. The Mal -
functi on I ndi cator Lamp (MI L) i s normal l y control l ed
by PCI data bus messages from the PCM; however, i f
the EMI C l oses PCI data bus communi cati ons, the
EMI C ci rcui try wi l l automati cal l y turn the MI L on
and di spl ay the message “no BuS” i n the odometer
VFD uni t unti l PCI data bus communi cati on i s
restored. The EMI C uses PCI data bus messages
from the PCM, Ai rbag Control Modul e (ACM), and
the Sentry Key I mmobi l i zer Modul e (SKI M) to con-
trol al l of the remai ni ng i ndi cators.
The vari ous EMI C i ndi cators are control l ed by di f-
ferent strategi es; some recei ve fused i gni ti on swi tch
output from the EMI C ci rcui try and have a swi tched
ground, others are grounded through the EMI C ci r-
cui try and have a swi tched battery feed. However, al l
i ndi cators except those for the anti l ock brake system,
turn si gnal s, and fog l amps are compl etel y control l ed
by the EMI C mi croprocessor based upon vari ous hard
wi red and el ectroni c message i nputs. The crui se,
four-wheel dri ve, upshi ft and both axl e l ock i ndi ca-
tors are one-step di mmabl e based upon an i nput to
the EMI C from the headl amp swi tch ci rcui try. When
the exteri or l amps are off, these i ndi cators are i l l u-
mi nated at a fi xed maxi mum i ntensi ty; and, when
the exteri or l amps are on, these i ndi cators are
di mmed by the EMI C to a fi xed l ower i ntensi ty. Al l
remai ni ng i ndi cators are i l l umi nated at a fi xed i nten-
si ty, whi ch i s not affected by the status of the exte-
ri or l i ghti ng or the sel ected i l l umi nati on i ntensi ty of
the EMI C general i l l umi nati on l amps.
I n addi ti on, certai n i ndi cators i n thi s i nstrument
cl uster are automati cal l y confi gured or sel f-confi g-
ured. Thi s feature al l ows the confi gurabl e i ndi cators
to be enabl ed by the EMI C ci rcui try for compati bi l i ty
wi th certai n opti onal equi pment. The ai rbag i ndi ca-
tor, crui se i ndi cator, and the Sentry Key I mmobi l i zer
System (SKI S) i ndi cator are automati cal l y confi g-
ured. The automati cal l y confi gured or sel f-confi gured
i ndi cators remai n l atent i n each EMI C at al l ti mes
and wi l l be acti ve onl y when the EMI C recei ves the
appropri ate PCI message i nputs for that opti onal sys-
tem or equi pment. Once a confi gurabl e i ndi cator i s
enabl ed by the EMI C, i t i s l earned and stored i n
cl uster memory for the remai nder of the cl uster l i fe.
The hard wi red i ndi cator i nputs may be di agnosed
usi ng conventi onal di agnosti c methods. However, the
EMI C ci rcui try and PCI bus message control l ed i ndi -
cators are di agnosed usi ng the EMI C sel f-di agnosti c
actuator test. (Refer to 8 - ELECTRI CAL/I NSTRU-
MENT CLUSTER - DI AGNOSI S AND TESTI NG).
Proper testi ng of the PCI data bus and the el ectroni c
message i nputs to the EMI C that control an i ndi cator
requi res the use of a DRBI I I ௡ scan tool . Refer to the
appropri ate di agnosti c i nformati on. Speci fi c detai l s of
the operati on for each i ndi cator may be found el se-
where i n thi s servi ce i nformati on.
CLUSTER ILLUMINATION
The EMI C has several i l l umi nati on l amps that are
i l l umi nated when the exteri or l i ghti ng i s turned on
wi th the headl amp swi tch ci rcui try of the l eft mul ti -
functi on swi tch. The i l l umi nati on i ntensi ty of these
l amps i s adjusted when the i nteri or l amps control
ri ng on the l eft mul ti -functi on swi tch control stal k i s
rotated (downward to di m, upward to bri ghten). I n
response to that i nput, an anal og/di gi tal (A/D) con-
verter i n the EMI C converts the anal og panel l amps
di mmer resi stor mul ti pl exed i nput from the l eft
mul ti -functi on swi tch i nto a di gi tal di mmi ng l evel
message and a 12-vol t Pul se-Wi dth Modul ated
(PWM) output. The EMI C uses the PWM output to
power the cl uster i l l umi nati on l amps and the VFD
uni t on the EMI C ci rcui t board, then provi des a syn-
chroni zed PWM output on the hard wi red fused
panel l amp feed output ci rcui t to control and syn-
chroni ze the i l l umi nati on i ntensi ty of other i ncandes-
cent i l l umi nati on l amps i n the vehi cl e. The cl uster
i l l umi nati on l amps are grounded at al l ti mes.
The EMI C al so sends el ectroni c di mmi ng l evel
messages over the PCI data bus to other el ectroni c
modul es i n the vehi cl e to control and synchroni ze the
i l l umi nati on i ntensi ty of thei r VFD uni ts wi th that of
the EMI C VFD uni t. I n addi ti on, the i nteri or l amps
control ri ng on the l eft mul ti -functi on swi tch control
stal k has a Parade Mode posi ti on to provi de a parade
mode. The EMI C moni tors the request for thi s mode
from the l eft mul ti -functi on swi tch, then sends an
el ectroni c di mmi ng l evel message over the PCI data
bus to i l l umi nate al l VFD uni ts i n the vehi cl e at ful l
(dayti me) i ntensi ty for easi er vi si bi l i ty when dri vi ng
i n dayl i ght wi th the exteri or l i ghti ng turned on.
The hard wi red l eft mul ti -functi on swi tch cl uster
i l l umi nati on i nputs and the EMI C fused panel l amp
feed output may be di agnosed usi ng conventi onal
di agnosti c methods. However, proper testi ng of the
PWM control of the EMI C and the el ectroni c di m-
mi ng l evel messages sent by the EMI C over the PCI
data bus requi res the use of a DRBI I I ௡ scan tool .
Refer to the appropri ate di agnosti c i nformati on.
AUDIO SYSTEM CABIN EQUALIZATION
Each ti me the EMI C recei ves an el ectroni c cabi n
equal i zati on request message from the radi o over the
PCI data bus, i t provi des an el ectroni c response to
the radi o contai ni ng the appropri ate equal i zati on
curve i nformati on. Because there are numerous
opti onal radi os whi ch are common to many pl atforms
and avai l abl e wi th vari ous speaker archi tectures,
TJ INSTRUMENT CLUSTER 8J - 7
INSTRUMENT CLUSTER (Continued)
each radi o contai ns a Di gi tal Si gnal Processi ng (DSP)
mi croprocessor chi p. Thi s DSP chi p uses the equal -
i zati on curve i nformati on to opti mi ze the radi o’s
sound output characteri sti cs for the uni que cabi n and
speaker archi tecture found wi thi n the parti cul ar
vehi cl e i nto whi ch the radi o has been i nstal l ed.
Proper testi ng of the PCI data bus and the el ec-
troni c data bus message i nputs to and outputs from
the EMI C that control audi o system cabi n equal i za-
ti on requi res the use of a DRBI I I ௡ scan tool . Refer to
the appropri ate di agnosti c i nformati on.
AXLE LOCKER CONTROL
The EMI C contai ns a l ogi c ci rcui t and program-
mi ng to perform the axl e l ocker control functi ons for
model s equi pped wi th the opti onal off-road package.
The EMI C moni tors hard wi red i nputs from the i gni -
ti on swi tch on the fused i gni ti on swi tch output (run-
start) ci rcui t and the key-i n i gni ti on swi tch on the
key-i n i gni ti on swi tch sense ci rcui t. The EMI C al so
moni tors vehi cl e speed and transfer case shi ft posi -
ti on swi tch el ectroni c message i nputs recei ved from
the Powertrai n Control Modul e (PCM) over the PCI
data bus. The i nternal programmi ng of the EMI C
then determi nes whether to acti vate or deacti vate
the axl e l ocker functi on by enabl i ng or di sabl i ng the
axl e l ock swi tch l ocated i n the i nstrument panel
accessory swi tch bezel .
The EMI C programmi ng control s the axl e l ock
swi tch through two separate axl e l ock swi tch enabl e
ci rcui ts, enabl e 1 and enabl e 2. I n al l cases, the
EMI C wi l l not acti vate ei ther enabl e ci rcui t i f there
are any transfer case shi ft posi ti on swi tch or vehi cl e
speed sensor faul ts present. Whenever the i gni ti on
swi tch i s i n the On or Start posi ti ons, the key i s i n
the i gni ti on l ock cyl i nder, the transfer case i s i n 4 X
4 Low range, and the vehi cl e speed i s l ess than about
72 ki l ometers per hour (45 mi l es per hour) the fi rst
enabl e (enabl e 1) ci rcui t i s acti vated. The second
enabl e (enabl e 2) ci rcui t i s acti vated onl y i f the vehi -
cl e speed i s l ess than about 16 ki l ometers per hour
(10 mi l es per hour). When both enabl e ci rcui ts are
acti vated, the axl e l ock swi tch becomes functi onal .
Once acti vated, the enabl e 1 ci rcui t i s automati -
cal l y deacti vated whenever the transfer case i s
moved out of the 4 X 4 Low range, or i f the vehi cl e
speed i s greater than about 72 ki l ometers per hour
(45 mi l es per hour). I f the enabl e 1 ci rcui t i s deacti -
vated after the rear or the front and rear axl e l ockers
are engaged, al l outputs from the axl e l ock swi tch
are dropped causi ng both axl es to unl ock. The enabl e
2 ci rcui t i s automati cal l y deacti vated whenever the
vehi cl e speed i s greater than about 16 ki l ometers per
hour (10 mi l es per hour). I f the enabl e 2 ci rcui t i s
deacti vated after the rear or the front and rear axl e
l ockers are engaged, the outputs from the axl e l ock
swi tch are unaffected and the l ocked axl es remai n
l ocked. However, an unl ocked axl e cannot be l ocked
unti l the vehi cl e speed i s reduced and the enabl e 2
ci rcui t i s agai n acti vated.
I n addi ti on, once acti vated, both enabl e ci rcui ts
wi l l remai n acti ve regardl ess of the status of the
i gni ti on swi tch i nput. Therefore, any l ocked axl e wi l l
remai n l ocked and the vari ous components of the
axl e l ocker system wi l l remai n functi onal after the
i gni ti on swi tch i s turned to the Off posi ti on. How-
ever, whi l e the currentl y sel ected axl e l ocker mode
remai ns acti ve wi th the i gni ti on swi tch turned Off, i f
the key i s removed from the i gni ti on l ock cyl i nder,
Off i s the onl y other axl e l ocker mode that can be
sel ected wi th the axl e l ock swi tch. For as l ong as the
key i s removed from the i gni ti on l ock cyl i nder, the
cl uster l ogi c wi l l i nterpret any revi si on to the i nput
status of ei ther request ci rcui t from the axl e l ock
swi tch as a cancel l ati on request and wi l l deacti vate
the enabl e 1 ci rcui t and al l outputs from the axl e
l ock swi tch are dropped, causi ng both axl es to
unl ock. Otherwi se, once l ocked, any l ocked axl e wi l l
remai n l ocked unti l the axl e l ock swi tch i s deacti -
vated (enabl e 1 ci rcui t i s deacti vated), or unti l the
Off mode i s manual l y sel ected by movi ng the axl e
l ock swi tch rocker to the Off posi ti on. The EMI C al so
provi des the vehi cl e operator wi th di sti nct vi sual
and/or audi bl e i ndi cati ons as to the current status of
the axl e l ocker system through chi me warni ngs and
i l l umi nati on of the rear/front l ock i ndi cators i n the
cl uster as outl i ned el sewhere i n thi s servi ce i nforma-
ti on.
The hard wi red i nput and output ci rcui ts of the
EMI C axl e l ocker control may be di agnosed usi ng
conventi onal di agnosti c methods. However, proper
testi ng of the EMI C programmi ng and the el ectroni c
vehi cl e speed and transfer case shi ft posi ti on swi tch
messages recei ved by the EMI C over the PCI data
bus requi res the use of a DRBI I I ௡ scan tool . Refer to
the appropri ate di agnosti c i nformati on.
CHIME SERVICE
The EMI C i s equi pped wi th hardware and software
to provi de chi me servi ce for al l avai l abl e features i n
the chi me warni ng system. Upon recei vi ng the proper
chi me i nputs, the EMI C acti vates an i ntegral
on-board audi bl e tone generator to provi de audi bl e
chi me tones to the vehi cl e operator. The chi me tone
generator i n the EMI C i s capabl e of produci ng si ngl e
chi me tones or repeated chi me tones at two di fferent
rates: a sl ow rate of about fi fty chi me tones per
mi nute, and a fast rate of about 180 chi me tones per
mi nute. The i nternal programmi ng of the EMI C
determi nes the pri ori ty of each chi me tone request
i nput that i s recei ved, as wel l as the rate and dura-
ti on of each chi me tone that i s to be generated.
8J - 8 INSTRUMENT CLUSTER TJ
INSTRUMENT CLUSTER (Continued)
The EMI C rel i es upon hard wi red i nputs from the
door ajar swi tches, the l eft mul ti -functi on swi tch, the
i gni ti on swi tch, and the park brake/brake warni ng
i ndi cator swi tches to provi de chi me servi ce for the
dri ver/passenger door ajar warni ng, the head/park
l i ghts-on remi nder, and the key-i n i gni ti on remi nder.
For the remai ni ng chi me warni ng functi ons, the
EMI C uses a combi nati on of hard wi red i nputs, el ec-
troni c message i nputs recei ved from other modul es
over the PCI data bus, and i nternal programmi ng.
(Refer to 8 - ELECTRI CAL/CHI ME/BUZZER -
OPERATI ON).
The hard wi red chi me i nputs to the EMI C may be
di agnosed usi ng conventi onal di agnosti c methods.
However, proper testi ng of the EMI C programmi ng
and the el ectroni c chi me request messages recei ved
by the EMI C over the PCI data bus requi res the use
of a DRBI I I ௡ scan tool . Refer to the appropri ate di ag-
nosti c i nformati on.
ELECTRONIC PINION FACTOR
Each ti me the EMI C recei ves an el ectroni c pi ni on
factor request message from the Powertrai n Control
Modul e (PCM) over the PCI data bus, i t provi des a
response to the PCM contai ni ng the appropri ate el ec-
troni c pi ni on factor i nformati on. Because there are
numerous opti onal combi nati ons of ti re si ze, axl e
rati o, and transfer case type whi ch are avai l abl e for
thi s vehi cl e, the el ectroni c pi ni on factor needs to be
consi dered for accurate processi ng of the vehi cl e
speed and di stance i nformati on. The i nstrument cl us-
ter stores the el ectroni c pi ni on factor i nformati on and
broadcasts i t over the PCI data bus upon request by
the PCM. Usi ng thi s factor and the Vehi cl e Speed
Sensor (VSS) i nput, the PCM then cal cul ates the
proper vehi cl e speed and di stance i nformati on, and
transmi ts the appropri ate el ectroni c vehi cl e speed
messages over the PCI data bus for use by other el ec-
troni c modul es i n the vehi cl e.
Proper testi ng of the PCI data bus and the el ec-
troni c data bus message i nputs to and outputs from
the EMI C that control the el ectroni c pi ni on factor
functi on requi res the use of a DRBI I I ௡ scan tool .
Refer to the appropri ate di agnosti c i nformati on.
INTERIOR LIGHTING CONTROL
The EMI C contai ns an i ntegral ti mer and l ogi c ci r-
cui t to perform both ti mer and control functi ons for
the i nteri or courtesy l amps. The EMI C uses hard
wi red i nputs from the i gni ti on swi tch, both door ajar
swi tches on separate dri ver and passenger door ajar
swi tch sense ci rcui ts, from the resi stor mul ti pl exed
panel l amps di mmer ci rcui try of the l eft mul ti -func-
ti on swi tch on the panel l amps di mmer si gnal ci rcui t
and i ts control l ogi c to provi de a battery current out-
put to the courtesy l amps on a courtesy l amp feed
ci rcui t. The EMI C control provi des a theater-type
fade-to-off feature that wi l l sl owl y di m the courtesy
l amps about fi ve seconds after both doors are cl osed.
The EMI C i nteri or l i ghti ng control programmi ng
provi des an i l l umi nated entry/exi t feature by moni -
tori ng the door ajar and i gni ti on swi tch i nputs. When
a door i s opened wi th the i gni ti on swi tch i n the Off
posi ti on, the EMI C turns on the courtesy l amps.
When the i gni ti on swi tch i s turned to the On or Start
posi ti ons, the EMI C turns the courtesy l amps off
i mmedi atel y wi th no theater di mmi ng. When the
i gni ti on swi tch i s turned from the On posi ti on to the
Off posi ti on, the EMI C turns on the i nteri or l i ghts
for about ten seconds or unti l the i gni ti on swi tch i s
agai n turned to the On or Start posi ti ons, whi chever
occurs fi rst.
The EMI C i nteri or l i ghti ng control programmi ng
al so provi des a battery saver feature (l oad sheddi ng)
for the i nteri or l i ghti ng. Unl ess the engi ne i s run-
ni ng, the EMI C wi l l automati cal l y turn off the i nte-
ri or l i ghts i f they are l eft on for more than about
twenty mi nutes, regardl ess of the status of the i gni -
ti on swi tch, door ajar swi tch, or l eft mul ti -functi on
swi tch i nputs to the cl uster.
The hard wi red i nputs and output of the EMI C
i nteri or l i ghti ng control may be di agnosed usi ng con-
venti onal di agnosti c methods; however, there are no
other di agnosti c tool s avai l abl e for the EMI C ti mer
and l ogi c ci rcui try. I f the i nput and output compo-
nents and ci rcui ts of the i nteri or l i ghti ng system test
OK, but the system fai l s to operate as desi gned, the
EMI C must be repl aced.
REAR WINDOW DEFOGGER CONTROL
The EMI C contai ns an i ntegral ti mer and l ogi c ci r-
cui t to perform the rear wi ndow defogger ti mer and
control functi ons for the opti onal rear wi ndow defog-
ger system. The EMI C uses a hard wi red i nput from
the rear wi ndow defogger swi tch on the rear wi ndow
defogger swi tch sense ci rcui t and i ts control l ogi c to
determi ne the correct output to the rear wi ndow
defogger rel ay. The EMI C control s the ground path of
the rear wi ndow defogger rel ay control coi l through
an output on the rear wi ndow defogger rel ay control
ci rcui t.
The EMI C i s programmed to i nterpret each
momentary ground si gnal i t recei ves on the rear wi n-
dow defogger swi tch sense ci rcui t as a request to
change the current state of the output on the rear
wi ndow defogger rel ay control ci rcui t. Therefore, wi th
the i gni ti on swi tch i n the On posi ti on, the fi rst
ground i nput on the rear wi ndow defogger swi tch
sense ci rcui t turns the system On, the second ground
i nput turns the system Off, and so forth. Once the
rear wi ndow defogger system has been turned On, i t
can be turned off manual l y by depressi ng the rear
TJ INSTRUMENT CLUSTER 8J - 9
INSTRUMENT CLUSTER (Continued)
wi ndow defogger swi tch a second ti me or by turni ng
the i gni ti on swi tch to the Off posi ti on.
The ti mer functi on of the EMI C wi l l al so automat-
i cal l y turn the rear wi ndow defogger system Off. The
ti mer turns the system Off after about ten mi nutes of
operati on; however, after the fi rst ti med i nterval has
expi red, each ti me the system i s turned On agai n
duri ng that same i gni ti on cycl e, the ti mer wi l l auto-
mati cal l y turn i t Off after about fi ve mi nutes of oper-
ati on.
The hard wi red i nput and output of the EMI C rear
wi ndow defogger control may be di agnosed usi ng con-
venti onal di agnosti c methods; however, there are no
other di agnosti c tool s avai l abl e for the EMI C rear
wi ndow defogger ti mer and l ogi c ci rcui try. I f the
i nput and output components and ci rcui ts of the rear
wi ndow defogger system test OK, but the system
fai l s to operate as desi gned, the EMI C must be
repl aced.
INPUT AND OUTPUT CIRCUITS
HARD WIRED INPUTS
The hard wi red i nputs to the EMI C i ncl ude the fol -
l owi ng:
• ABS Warning Indicator Driver
• Brake Warning Indicator Sense
• Driver Door Ajar Switch Sense
• Fog Lamp Feed
• Front Axle Lock Request (w/Off-Road Pack-
age Only)
• Front Lock Indicator Switch Sense (w/Off-
Road Package Only)
• Fused B(+) - Ignition-Off Draw
• Fused Ignition Switch Output (Run-Start)
• Headlamp Switch Output
• High Beam Indicator Driver
• Key-In Ignition Switch Sense
• Left Turn Signal
• Panel Lamps Dimmer Signal
• Passenger Door Ajar Switch Sense
• Rear Axle Lock Request (w/Off-Road Pack-
age Only)
• Rear Lock Indicator Switch Sense (w/Off-
Road Package Only)
• Rear Window Defogger Switch Sense
• Right Turn Signal
• Seat Belt Switch Sense
• 4WD Switch Sense (w/o Off-Road Package
only)
Refer to the appropri ate wi ri ng i nformati on for
addi ti onal detai l s.
HARD WIRED OUTPUTS
The hard wi red outputs of the EMI C i ncl ude the
fol l owi ng:
• Courtesy Lamp Feed
• Axle Lock Switch Enable 1 (w/Off-Road
Package Only)
• Axle Lock Switch Enable 2 (w/Off-Road
Package Only)
• Panel Lamp Feed
• Rear Window Defogger Relay Control
Refer to the appropri ate wi ri ng i nformati on for
addi ti onal detai l s.
GROUNDS
The EMI C recei ves a ground path through the fol -
l owi ng hard wi red ci rcui t:
• Ground - G201
Refer to the appropri ate wi ri ng i nformati on for
addi ti onal detai l s.
COMMUNICATION
The EMI C has the fol l owi ng data bus communi ca-
ti on ci rcui t:
• PCI Data Bus
Refer to the appropri ate wi ri ng i nformati on for
addi ti onal detai l s.
DIAGNOSIS AND TESTING - INSTRUMENT
CLUSTER
I f al l of the i nstrument cl uster gauges and/or i ndi -
cators are i noperati ve, refer to PRELI MI NARY
DI AGNOSI S. I f an i ndi vi dual gauge or Programma-
bl e Communi cati ons I nterface (PCI ) data bus mes-
sage-control l ed i ndi cator i s i noperati ve, refer to
ACTUATOR TEST. I f an i ndi vi dual hard wi red i ndi -
cator i s i noperati ve, refer to the di agnosi s and testi ng
i nformati on for that speci fi c i ndi cator. I f the i nstru-
ment cl uster i nteri or l i ghti ng control functi on i s i nop-
erati ve, refer to I NTERI OR LI GHTI NG CONTROL
DI AGNOSI S. I f the axl e l ocker control i s i noperati ve,
refer to AXLE LOCKER CONTROL DI AGNOSI S. I f
the i nstrument cl uster rear wi ndow defogger control
functi on i s i noperati ve, refer to REAR WI NDOW
DEFOGGER CONTROL DI AGNOSI S.
Refer to the appropri ate wi ri ng i nformati on. The
wi ri ng i nformati on i ncl udes wi ri ng di agrams, proper
wi re and connector repai r procedures, detai l s of wi re
harness routi ng and retenti on, connector pi n-out
i nformati on and l ocati on vi ews for the vari ous wi re
harness connectors, spl i ces and grounds.
8J - 10 INSTRUMENT CLUSTER TJ
INSTRUMENT CLUSTER (Continued)
CAUTION: Instrument clusters used in this model
automatically configure themselves for compatibil-
ity with the features and optional equipment in the
vehicle in which they are initially installed. The
instrument cluster is programmed to do this by
embedding the Vehicle Identification Number (VIN)
and other information critical to proper cluster
operation into electronic memory. This embedded
information is learned through electronic messages
received from other electronic modules in the vehi-
cle over the Programmable Communications Inter-
face (PCI) data bus, and through certain hard wired
inputs received when the cluster is connected to
the vehicle electrically. Once configured, the instru-
ment cluster memory may be irreparably damaged
and certain irreversible configuration errors may
occur if the cluster is connected electrically to
another vehicle; or, if an electronic module from
another vehicle is connected that provides data to
the instrument cluster (including odometer values)
that conflicts with that which was previously
learned and stored. Therefore, the practice of
exchanging (swapping) instrument clusters and
other electronic modules in this vehicle with those
removed from another vehicle must always be
avoided. Failure to observe this caution may result
in instrument cluster damage, which is not reim-
bursable under the terms of the product warranty.
Service replacement instrument clusters are pro-
vided with the correct VIN, and the certified odom-
eter value embedded into cluster memory, but will
otherwise be automatically configured for compati-
bility with the features and optional equipment in
the vehicle in which they are initially installed.
NOTE: Certain indicators in this instrument cluster
are automatically configured. This feature allows
those indicators to be activated for deactivated for
compatibility with certain optional equipment. If the
problem being diagnosed involves improper illumi-
nation of the airbag indicator, the cruise indicator,
or the SKIM indicator when the vehicle does not
have this equipment, the instrument cluster must
be replaced with a new unit.
PRELIMINARY DIAGNOSIS
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE SUPPLEMENTAL RESTRAINT SYS-
TEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, AIRBAG, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE BEFORE PERFORMING FURTHER DIAG-
NOSIS OR SERVICE. THIS IS THE ONLY SURE WAY
TO DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT.
(1) Check the fused B(+) fuse (Fuse 24 - 10
ampere) i n the Power Di stri buti on Center (PDC). I f
OK, go to Step 2. I f not OK, repai r the shorted ci rcui t
or component as requi red and repl ace the faul ty fuse.
(2) Check for battery vol tage at the fused B(+) fuse
(Fuse 24 - 10 ampere) i n the PDC. I f OK, go to Step
3. I f not OK, repai r the open B(+) ci rcui t between the
PDC and the battery as requi red.
(3) Di sconnect and i sol ate the battery negati ve
cabl e. Remove the i nstrument cl uster. Reconnect the
battery negati ve cabl e. Check for battery vol tage at
the fused B(+) ci rcui t cavi ty of the i nstrument panel
wi re harness connector (Connector C1) for the i nstru-
ment cl uster. I f OK, refer to ACTUATOR TEST. I f
not OK, repai r the open fused B(+) ci rcui t between
the i nstrument cl uster and the PDC as requi red.
(4) Check the fused i gni ti on swi tch output (run-
start) fuse (Fuse 10 - 10 ampere) i n the fuse bl ock. I f
OK, go to Step 5. I f not OK, repai r the shorted ci rcui t
or component as requi red and repl ace the faul ty fuse.
(5) Turn the i gni ti on swi tch to the On posi ti on.
Check for battery vol tage at the fused i gni ti on swi tch
output (run-start) fuse (Fuse 10 - 10 ampere) i n the
fuse bl ock. I f OK, go to Step 6. I f not OK, repai r the
open fused i gni ti on swi tch output (run-start) ci rcui t
between the fuse bl ock and the i gni ti on swi tch as
requi red.
(6) Turn the i gni ti on swi tch to the On posi ti on.
Check for battery vol tage at the fused i gni ti on swi tch
output (run-start) ci rcui t cavi ty of the i nstrument
panel wi re harness connector (Connector C1) for the
i nstrument cl uster. I f OK, refer to ACTUATOR TEST.
I f not OK, repai r the open fused i gni ti on swi tch out-
put (run-start) ci rcui t between the i nstrument cl uster
and the fuse bl ock as requi red.
(7) Check for conti nui ty between the ground ci r-
cui t cavi ty of the i nstrument panel wi re harness con-
nector (Connector C1) for the i nstrument cl uster and
a good ground. There shoul d be conti nui ty. I f OK,
refer to ACTUATOR TEST. I f not OK, repai r the
open ground ci rcui t to ground (G201) as requi red.
TJ INSTRUMENT CLUSTER 8J - 11
INSTRUMENT CLUSTER (Continued)
ACTUATOR TEST
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE SUPPLEMENTAL RESTRAINT SYS-
TEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, AIRBAG, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE BEFORE PERFORMING FURTHER DIAG-
NOSIS OR SERVICE. THIS IS THE ONLY SURE WAY
TO DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT.
The i nstrument cl uster actuator test wi l l put the
i nstrument cl uster i nto i ts sel f-di agnosti c mode. I n
thi s mode the i nstrument cl uster can perform a sel f-
di agnosti c test that wi l l confi rm that the i nstrument
cl uster ci rcui try, the gauges, the PCI data bus mes-
sage control l ed i ndi cators, and the chi me tone gener-
ator are capabl e of operati ng as desi gned. Duri ng the
actuator test the i nstrument cl uster ci rcui try wi l l
sound the chi me tone generator, posi ti on each of the
gauge needl es at vari ous cal i brati on poi nts, i l l umi -
nate al l of the segments i n the Vacuum-Fl uorescent
Di spl ay (VFD) uni t, turn al l of the PCI data bus mes-
sage-control l ed i ndi cators on and off agai n, and di s-
pl ay messages i n the VFD for certai n faul ts that
have been set. I t i s suggested that a note pad and
penci l be used to wri te down any faul t i nformati on
that i s di spl ayed duri ng the test for reference.
Successful compl eti on of the actuator test wi l l con-
fi rm that the i nstrument cl uster i s operati onal . How-
ever, there may sti l l be a probl em wi th the PCI data
bus, the Powertrai n Control Modul e (PCM), the Ai r-
bag Control Modul e (ACM), the Sentry Key I mmobi -
l i zer Modul e (SKI M), or the i nputs to one of these
el ectroni c control modul es. Use a DRBI I I ௡ scan tool
to di agnose these components. Refer to the appropri -
ate di agnosti c i nformati on.
I f an i ndi vi dual gauge does not respond properl y,
or does not respond at al l duri ng the actuator test,
the i nstrument cl uster shoul d be removed. However,
check that the four screws securi ng the i noperati ve
gauge to the i nstrument cl uster el ectroni c ci rcui t
board are properl y ti ghtened before consi deri ng
i nstrument cl uster repl acement. I f the gauge mount-
i ng screws check OK, repl ace the faul ty i nstrument
cl uster.
(1) Begi n the test wi th the i gni ti on swi tch i n the
Off posi ti on.
(2) Depress the odometer/tri p odometer swi tch but-
ton.
(3) Whi l e sti l l hol di ng the odometer/tri p odometer
swi tch button depressed, turn the i gni ti on swi tch to
the On posi ti on, but do not start the engi ne.
(4) Rel ease the odometer/tri p odometer swi tch but-
ton.
(5) The i nstrument cl uster wi l l automati cal l y
begi n the actuator test sequence, as fol l ows:
(a) The cl uster wi l l generate a si ngl e chi me tone
to confi rm the functi onal i ty of the chi me tone gen-
erator and the chi me control ci rcui try.
(b) The cl uster wi l l scrol l the number “8” across
the odometer/tri p odometer VFD to confi rm the
functi onal i ty of al l VFD segments and thei r control
ci rcui try.
(c) The cl uster wi l l i l l umi nate the deci mal poi nt
i n the odometer/tri p odometer VFD to confi rm the
functi onal i ty of thi s VFD segment and i ts control
ci rcui try.
(d) The cl uster wi l l di spl ay the EMI C software
l evel i n the odometer/tri p odometer VFD (exampl e:
“SOF 8.9”).
(e) The cl uster wi l l di spl ay the l ast si x di gi ts
(sequence number) of the Vehi cl e I denti fi cati on
Number (VI N) i n the odometer/tri p odometer VFD.
(f) I f any faul ts have been set by the cl uster, the
cl uster wi l l di spl ay the faul t i nformati on i n the
odometer/tri p odometer VFD I NSTRUMENT
CLUSTER FAI LURE MESSAGE. I f no faul ts have
been set, the cl uster wi l l scrol l “no FAULtS” across
the odometer/tri p odometer VFD.
(g) The cl uster wi l l turn on, then off agai n each
of the fol l owi ng i ndi cators, one at a ti me, i n
sequence to confi rm the functi onal i ty of the i ndi ca-
tor and the cl uster control ci rcui try:
− Hi gh Beam
− Brake
− Seatbel t
− MI L
− Check Gauges
− Low Fuel
− 4WD
− SKI S
− Crui se
− Upshi ft
(h) The cl uster wi l l sweep the needl es for each of
the fol l owi ng gauges, one at a ti me, to several cal -
i brati on poi nts i n sequence to confi rm the functi on-
al i ty of the gauge and the cl uster control ci rcui try:
− Speedometer
− Fuel
− Temperature
− Tachometer
− Vol tage
− Oi l Pressure
8J - 12 INSTRUMENT CLUSTER TJ
INSTRUMENT CLUSTER (Continued)
INSTRUMENT CLUSTER FAILURE MESSAGE
VFD Message Description Correction
ЉbuS b0Љ PCM - MIL Message The cluster is not receiving a MIL lamp
message from the PCM. A DRBIIIா scan tool
is required for further diagnosis. Refer to the
appropriate diagnostic information.
ЉbuS b1Љ SKIM - SKIM Message The cluster is not receiving a SKIS lamp
message from the SKIM. A DRBIIIா scan tool
is required for further diagnosis. Refer to the
appropriate diagnostic information.
ЉbuS b8Љ ACM - Airbag Message The cluster is not receiving an Airbag lamp
message from the ACM. A DRBIIIா scan tool
is required for further diagnosis. Refer to the
appropriate diagnostic information.
ЉPanEL OPEnЉ Panel Sense - Open Circuit The cluster is not receiving an input from the
the panel lamps dimmer circuitry of the left
multi-function switch on the panel lamps
dimmer signal circuit. Repair the open circuit
or replace the faulty switch as required.
ЉAirbagЉ Telltale Open/Shorted The EMIC airbag indicator is open or shorted.
Replace the faulty cluster.
(6) The actuator test i s now compl eted. The i nstru-
ment cl uster wi l l automati cal l y exi t the sel f-di agnos-
ti c mode and return to normal operati on at the
compl eti on of the test, i f the i gni ti on swi tch i s turned
to the Off posi ti on duri ng the test, or i f a vehi cl e
speed message i ndi cati ng that the vehi cl e i s movi ng
i s recei ved from the PCM over the PCI data bus dur-
i ng the test.
(7) Go back to Step 1 to repeat the test, i f neces-
sary.
INTERIOR LIGHTING CONTROL DIAGNOSIS
Before performi ng thi s test, compl ete the testi ng of
each of the hard wi red i nteri or l i ghti ng swi tches.
Refer to the appropri ate wi ri ng i nformati on. The wi r-
i ng i nformati on i ncl udes wi ri ng di agrams, proper
wi re and connector repai r procedures, detai l s of wi re
harness routi ng and retenti on, connector pi n-out
i nformati on and l ocati on vi ews for the vari ous wi re
harness connectors, spl i ces and grounds.
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE SUPPLEMENTAL RESTRAINT SYS-
TEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, AIRBAG, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE BEFORE PERFORMING FURTHER DIAG-
NOSIS OR SERVICE. THIS IS THE ONLY SURE WAY
TO DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT.
NOTE: The following tests may not prove conclu-
sive in the diagnosis of this system. The most reli-
able, efficient, and accurate means to diagnose the
Interior Lighting Control function of the instrument
cluster requires the use of a DRBIIIா scan tool.
Refer to the appropriate diagnostic information.
(1) Check the door ajar swi tch output fuse (Fuse 4
- 10 ampere) i n the fuse bl ock. I f OK, go to Step 2. I f
not OK, repai r the shorted ci rcui t or component as
requi red and repl ace the faul ty fuse.
(2) Check for conti nui ty between the door ajar
swi tch output fuse (Fuse 4 - 10 ampere) i n the fuse
bl ock and a good ground. There shoul d be conti nui ty.
I f OK, go to Step 3. I f not OK, repai r the open
ground ci rcui t between the fuse bl ock and ground
(G300) as requi red.
(3) Di sconnect and i sol ate the battery negati ve
cabl e. Di sconnect the body wi re harness connector for
the dri ver and/or passenger door ajar swi tch from the
swi tch connector receptacl e. Check for conti nui ty
between the door ajar swi tch output ci rcui t cavi ty of
the dri ver or passenger door ajar swi tch and a good
ground. There shoul d be conti nui ty. I f OK, go to Step
4. I f not OK, repai r the open door ajar swi tch output
TJ INSTRUMENT CLUSTER 8J - 13
INSTRUMENT CLUSTER (Continued)
ci rcui t between the dri ver or passenger door ajar
swi tch and the fuse bl ock as requi red.
(4) Remove the i nstrument cl uster from the i nstru-
ment panel . Di sconnect the i nstrument panel wi re
harness connector (Connector C2) for the i nstrument
cl uster from the cl uster connector receptacl e. Check
for conti nui ty between the dri ver and/or passenger
door ajar swi tch sense ci rcui t cavi ti es of the i nstru-
ment panel wi re harness connector (Connector C2)
for the i nstrument cl uster and a good ground. There
shoul d be no conti nui ty. I f OK, go to Step 5. I f not
OK, repai r the shorted dri ver and/or passenger door
ajar swi tch sense ci rcui ts between the i nstrument
cl uster and the dri ver and/or passenger door ajar
swi tches as requi red.
(5) Check for conti nui ty between the dri ver and/or
passenger door ajar swi tch sense ci rcui t cavi ti es of
the i nstrument panel wi re harness connector (Con-
nector C2) for the i nstrument cl uster and the body
wi re harness connector for the dri ver and/or passen-
ger door ajar swi tches. There shoul d be conti nui ty. I f
OK, use a DRBI I I ௡ scan tool to compl ete the di agno-
si s of the i nstrument cl uster i nteri or l i ghti ng control .
Refer to the appropri ate di agnosti c i nformati on. I f
not OK, repai r the open dri ver and/or passenger door
ajar swi tch sense ci rcui ts between the i nstrument
cl uster and the dri ver and/or passenger door ajar
swi tches as requi red.
AXLE LOCKER CONTROL DIAGNOSIS
I f the probl em bei ng di agnosed i nvol ves a rear or
front l ock i ndi cator i n the i nstrument cl uster that i s
bl i nki ng on and off, be certai n to compl ete i nspecti on
of the appropri ate front or rear axl e l ocker rel ays,
l ocker pumps, pneumati c l i nes, l ocker i ndi cator
swi tches, and axl e l ocker mechani sms before per-
formi ng the fol l owi ng tests. I f the probl em bei ng
di agnosed i nvol ves a rear or front l ock i ndi cator i n
the i nstrument cl uster that stays on when i t shoul d
be off, or stays off when i t shoul d be on, compl ete the
testi ng of the axl e l ocker swi tch before performi ng
the fol l owi ng tests.
These tests wi l l establ i sh the i ntegri ty of the hard
wi red ci rcui ts rel ated to the axl e l ocker control func-
ti on of the i nstrument cl uster. However, proper test-
i ng of the i nstrument cl uster programmi ng and the
el ectroni c vehi cl e speed and transfer case shi ft posi -
ti on messages recei ved by the cl uster over the PCI
data bus requi res the use of a DRBI I I ௡ scan tool .
Refer to the appropri ate di agnosti c i nformati on.
Refer to the appropri ate wi ri ng i nformati on. The wi r-
i ng i nformati on i ncl udes wi ri ng di agrams, proper
wi re and connector repai r procedures, detai l s of wi re
harness routi ng and retenti on, connector pi n-out
i nformati on and l ocati on vi ews for the vari ous wi re
harness connectors, spl i ces and grounds.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, DRIVER AIRBAG,
PASSENGER AIRBAG, OR INSTRUMENT PANEL
COMPONENT DIAGNOSIS OR SERVICE. DISCON-
NECT AND ISOLATE THE BATTERY NEGATIVE
(GROUND) CABLE, THEN WAIT TWO MINUTES FOR
THE SYSTEM CAPACITOR TO DISCHARGE BEFORE
PERFORMING FURTHER DIAGNOSIS OR SERVICE.
THIS IS THE ONLY SURE WAY TO DISABLE THE
SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO
TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
(1) Di sconnect and i sol ate the battery negati ve
cabl e. Remove the rear and front axl e l ocker rel ays
from thei r receptacl es i n the Power Di stri buti on Cen-
ter (PDC). Remove the axl e l ock swi tch from the
i nstrument panel . Di sconnect the i nstrument panel
wi re harness connector for the axl e l ock swi tch from
the swi tch connector receptacl e. Remove the i nstru-
ment cl uster from the i nstrument panel .
(2) Check for conti nui ty between each of the rear
and front axl e l ock request ci rcui t cavi ti es of the
appropri ate i nstrument panel wi re harness connec-
tors (Connector C1 for rear, Connector C2 for front)
for the i nstrument cl uster and a good ground. There
shoul d be no conti nui ty. I f OK, go to Step 3. I f not
OK, repai r the shorted rear or front axl e l ock request
ci rcui t between the i nstrument cl uster, the axl e l ock
swi tch, and the rear or front axl e l ocker rel ay as
requi red.
(3) Check for conti nui ty between each of the rear
and/or front axl e l ock request ci rcui t cavi ti es of the
i nstrument panel wi re harness connectors (Connector
C1 for rear, Connector C2 for front) for the i nstru-
ment cl uster, the i nstrument panel wi re harness con-
nector for the axl e l ock swi tch, and the rear or front
axl e l ocker rel ay receptacl e i n the PDC. I n each case,
there shoul d be conti nui ty. I f OK, go to Step 4. I f not
OK, repai r the open rear and/or front axl e l ock
request ci rcui t between the i nstrument cl uster, the
axl e l ock swi tch, and the PDC as requi red.
(4) Check for conti nui ty between the axl e l ock
swi tch enabl e 1 and/or enabl e 2 ci rcui t cavi ty of the
i nstrument panel wi re harness connector (Connector
C1 for enabl e 1, Connector C2 for enabl e 2) for the
i nstrument cl uster and a good ground. There shoul d
be no conti nui ty. I f OK, go to Step 5. I f not OK,
repai r the shorted axl e l ock swi tch enabl e 1 or enabl e
2 ci rcui t between the i nstrument cl uster and the axl e
l ock swi tch as requi red.
(5) Check for conti nui ty between the axl e l ock
swi tch enabl e 1 and/or enabl e 2 ci rcui t cavi ti es of the
i nstrument panel wi re harness connector (Connector
8J - 14 INSTRUMENT CLUSTER TJ
INSTRUMENT CLUSTER (Continued)
C1 for enabl e 1, Connector C2 for enabl e 2) for the
i nstrument cl uster and the i nstrument panel wi re
harness connector for the axl e l ock swi tch. There
shoul d be conti nui ty. I f OK, go to Step 6. I f not OK,
repai r the open axl e l ock swi tch enabl e 1 or enabl e 2
ci rcui t between the i nstrument cl uster and the axl e
l ock swi tch as requi red.
(6) Di sconnect the rear and/or front l ocker i ndi ca-
tor swi tch pi gtai l harness connector from the rear or
front axl e jumper harness connector. Check for conti -
nui ty between the ground ci rcui t cavi ty of the rear or
front axl e jumper harness connector and a good
ground. There shoul d be conti nui ty. I f OK, go to Step
7. I f not OK, repai r the open ground ci rcui t between
the rear or front axl e jumper harness connector for
the rear or front l ocker i ndi cator swi tch and ground
(G105) as requi red.
(7) Check for conti nui ty between the ground ci r-
cui t and the rear or front l ocker i ndi cator swi tch
sense ci rcui t cavi ti es of the rear or front l ocker i ndi -
cator swi tch pi gtai l harness connector. There shoul d
be conti nui ty wi th the axl e l ocker engaged, and no
conti nui ty wi th the axl e l ocker di sengaged. I f OK, go
to Step 8. I f not OK, repl ace the faul ty rear or front
l ocker i ndi cator swi tch.
(8) Check for conti nui ty between the rear or front
l ocker i ndi cator swi tch sense ci rcui t cavi ty of the rear
or front axl e jumper harness connector for the l ocker
i ndi cator swi tch and a good ground. There shoul d be
no conti nui ty. I f OK, go to Step 9. I f not OK, repai r
the shorted rear or front l ocker i ndi cator swi tch
sense ci rcui t between the rear or front axl e jumper
harness connector for the l ocker i ndi cator swi tch and
the i nstrument cl uster as requi red.
(9) Check for conti nui ty between the rear or front
l ocker i ndi cator swi tch sense ci rcui t cavi ti es of the
rear or front axl e jumper harness connector for the
l ocker i ndi cator swi tch and the i nstrument cl uster.
There shoul d be conti nui ty. I f OK, use a DRBI I I ௡
scan tool to perform addi ti onal testi ng of the i nstru-
ment cl uster. Refer to the appropri ate di agnosti c
i nformati on. I f not OK, repai r the open rear or front
l ocker i ndi cator swi tch sense ci rcui t between the rear
or front axl e jumper harness connector for the l ocker
i ndi cator swi tch and the i nstrument cl uster as
requi red.
REAR WINDOW DEFOGGER CONTROL DIAGNOSIS
Before performi ng thi s test, compl ete the testi ng of
the rear wi ndow defogger swi tch and the rear wi n-
dow defogger rel ay. Refer to the appropri ate wi ri ng
i nformati on. The wi ri ng i nformati on i ncl udes wi ri ng
di agrams, proper wi re and connector repai r proce-
dures, detai l s of wi re harness routi ng and retenti on,
connector pi n-out i nformati on and l ocati on vi ews for
the vari ous wi re harness connectors, spl i ces and
grounds.
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE SUPPLEMENTAL RESTRAINT SYS-
TEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, AIRBAG, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE BEFORE PERFORMING FURTHER DIAG-
NOSIS OR SERVICE. THIS IS THE ONLY SURE WAY
TO DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT.
(1) Di sconnect and i sol ate the battery negati ve
cabl e. Remove the rear wi ndow defogger rel ay from
the receptacl e i n the Power Di stri buti on Center
(PDC). Di sconnect the i nstrument panel wi re harness
connector for the rear wi ndow defogger swi tch from
the swi tch connector receptacl e. Remove the i nstru-
ment cl uster from the i nstrument panel .
(2) Check for conti nui ty between the rear wi ndow
defogger swi tch sense ci rcui t cavi ty of the i nstrument
panel wi re harness connector (Connector C2) for the
i nstrument cl uster and a good ground. There shoul d
be no conti nui ty. I f OK, go to Step 3. I f not OK,
repai r the shorted rear wi ndow defogger swi tch sense
ci rcui t between the i nstrument cl uster and the rear
wi ndow defogger swi tch as requi red.
(3) Check for conti nui ty between the rear wi ndow
defogger swi tch sense ci rcui t cavi ti es of the i nstru-
ment panel wi re harness connectors for the i nstru-
ment cl uster (Connector C2) and the rear wi ndow
defogger swi tch. There shoul d be conti nui ty. I f OK,
go to Step 4. I f not OK, repai r the open rear wi ndow
defogger swi tch sense ci rcui t between the i nstrument
cl uster and the rear wi ndow defogger swi tch as
requi red.
(4) Check for conti nui ty between the rear wi ndow
defogger rel ay control ci rcui t cavi ty of the i nstrument
panel wi re harness connector (Connector C2) for the
i nstrument cl uster and a good ground. There shoul d
be no conti nui ty. I f OK, go to Step 5. I f not OK,
repai r the shorted rear wi ndow defogger rel ay control
ci rcui t between the i nstrument cl uster and the PDC
as requi red.
(5) Check for conti nui ty between the rear wi ndow
defogger rel ay control ci rcui t cavi ti es of the i nstru-
ment panel wi re harness connector (Connector C2)
for the i nstrument cl uster and the rear wi ndow
defogger rel ay receptacl e i n the PDC. There shoul d
be conti nui ty. I f OK, repl ace the faul ty i nstrument
TJ INSTRUMENT CLUSTER 8J - 15
INSTRUMENT CLUSTER (Continued)
cl uster. I f not OK, repai r the open rear wi ndow
defogger rel ay control ci rcui t between the i nstrument
cl uster and the PDC as requi red.
CLUSTER ILLUMINATION DIAGNOSIS
The di agnosi s found here addresses an i noperati ve
i nstrument cl uster i l l umi nati on l amp condi ti on. I f
the probl em bei ng di agnosed i s a si ngl e i noperati ve
i l l umi nati on l amp, be certai n that the bul b and bul b
hol der uni t are properl y i nstal l ed i n the i nstrument
cl uster el ectroni c ci rcui t board. I f no i nstal l ati on
probl ems are found repl ace the faul ty bul b and bul b
hol der uni t. I f al l of the cl uster i l l umi nati on l amps
are i noperati ve and the probl em bei ng di agnosed
i ncl udes i noperati ve exteri or l i ghti ng control l ed by
the l eft mul ti -functi on swi tch, that system needs to
be repai red fi rst. I f the exteri or l amps control l ed by
the l eft mul ti -functi on swi tch are i noperati ve, (Refer
to 8 - ELECTRI CAL/LAMPS/LI GHTI NG - EXTERI -
OR/HEADLAMP - DI AGNOSI S AND TESTI NG). I f
no exteri or l i ghti ng system probl ems are found, the
fol l owi ng procedure wi l l hel p l ocate a short or open
i n the cl uster i l l umi nati on l amp ci rcui t. Refer to the
appropri ate wi ri ng i nformati on. The wi ri ng i nforma-
ti on i ncl udes wi ri ng di agrams, proper wi re and con-
nector repai r procedures, detai l s of wi re harness
routi ng and retenti on, connector pi n-out i nformati on
and l ocati on vi ews for the vari ous wi re harness con-
nectors, spl i ces and grounds.
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE SUPPLEMENTAL RESTRAINT SYS-
TEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, AIRBAG, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE BEFORE PERFORMING FURTHER DIAG-
NOSIS OR SERVICE. THIS IS THE ONLY SURE WAY
TO DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT.
(1) Di sconnect and i sol ate the battery negati ve
cabl e. Di sconnect the body wi re harness connector for
the l eft mul ti -functi on swi tch from the swi tch connec-
tor receptacl e. Check for conti nui ty between the
ground ci rcui t cavi ty of the body wi re harness con-
nector for the l eft mul ti -functi on swi tch and a good
ground. There shoul d be conti nui ty. I f OK, go to Step
2. I f not OK, repai r the open ground ci rcui t to ground
(G300) as requi red.
(2) Remove the i nstrument cl uster from the i nstru-
ment panel . Di sconnect the i nstrument panel wi re
harness connector (Connector C2) for the i nstrument
cl uster from the cl uster connector receptacl e. Check
for conti nui ty between the panel l amp di mmer si gnal
ci rcui t cavi ty of the i nstrument panel wi re harness
connector (Connector C2) for the i nstrument cl uster
and a good ground. There shoul d be no conti nui ty. I f
OK, go to Step 3. I f not OK, repai r the shorted panel
l amp di mmer si gnal ci rcui t between the i nstrument
cl uster and the l eft mul ti -functi on swi tch as requi red.
(3) Check for conti nui ty between the panel l amp
di mmer si gnal ci rcui t cavi ti es of the i nstrument
panel wi re harness connector (Connector C2) for the
i nstrument cl uster and the body wi re harness con-
nector for the l eft mul ti -functi on swi tch. There
shoul d be conti nui ty. I f OK, use a DRBI I I ௡ scan tool
to compl ete the di agnosi s of the i nstrument cl uster
i l l umi nati on l i ghti ng. Refer to the appropri ate di ag-
nosti c i nformati on. I f not OK, repai r the open panel
l amp di mmer si gnal ci rcui t between the i nstrument
cl uster and the l eft mul ti -functi on swi tch as requi red.
REMOVAL
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE SUPPLEMENTAL RESTRAINT SYS-
TEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, AIRBAG, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE BEFORE PERFORMING FURTHER DIAG-
NOSIS OR SERVICE. THIS IS THE ONLY SURE WAY
TO DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT.
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the cl uster bezel from the i nstrument
panel . (Refer to 23 - BODY/I NSTRUMENT PANEL/
CLUSTER BEZEL - REMOVAL).
(3) Remove the four screws that secure the i nstru-
ment cl uster to the i nstrument panel structural sup-
port (Fi g. 4).
(4) Pul l the i nstrument cl uster rearward far
enough to access and di sconnect the two i nstrument
panel wi re harness connectors for the i nstrument
cl uster from the connector receptacl es on the back of
the cl uster housi ng.
(5) Remove the i nstrument cl uster from the i nstru-
ment panel .
8J - 16 INSTRUMENT CLUSTER TJ
INSTRUMENT CLUSTER (Continued)
DISASSEMBLY
Some of the components for the i nstrument cl uster
used i n thi s vehi cl e are servi ced i ndi vi dual l y. The
servi ced components i ncl ude: the i ncandescent
i nstrument cl uster i ndi cator and i l l umi nati on l amp
bul bs (i ncl udi ng the i ntegral bul b hol ders), the cl us-
ter l ens, the tri p odometer reset button boot, the
cl uster hood and mask uni t, and the cl uster housi ng
rear cover. Fol l owi ng are the procedures for di sas-
sembl i ng these components from the i nstrument cl us-
ter uni t.
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE SUPPLEMENTAL RESTRAINT SYS-
TEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, AIRBAG, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE BEFORE PERFORMING FURTHER DIAG-
NOSIS OR SERVICE. THIS IS THE ONLY SURE WAY
TO DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT.
CLUSTER BULB
Thi s procedure appl i es to each of the i ncandescent
cl uster i l l umi nati on l amp or i ndi cator bul b and bul b
hol der uni ts. However, the i l l umi nati on l amps and
the i ndi cators use di fferent bul b and bul b hol der uni t
si zes. They must never be i nterchanged.
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the i nstrument cl uster from the i nstru-
ment panel . (Refer to 8 - ELECTRI CAL/I NSTRU-
MENT CLUSTER - REMOVAL).
(3) Turn the bul b hol der countercl ockwi se about
si xty degrees on the cl uster el ectroni c ci rcui t board
(Fi g. 5).
(4) Pul l the bul b and bul b hol der uni t strai ght
back to remove i t from the bul b mounti ng hol e i n the
cl uster el ectroni c ci rcui t board.
CLUSTER LENS
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the i nstrument cl uster from the i nstru-
ment panel . (Refer to 8 - ELECTRI CAL/I NSTRU-
MENT CLUSTER - REMOVAL).
(3) Work around the peri meter of the cl uster l ens
and di sengage each of the ei ght l atches that secure
the l ens to the cl uster mask and the cl uster housi ng
(Fi g. 6).
(4) Gentl y pul l the cl uster l ens away from the face
of the i nstrument cl uster.
TRIP ODOMETER RESET BUTTON BOOT
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the i nstrument cl uster from the i nstru-
ment panel . (Refer to 8 - ELECTRI CAL/I NSTRU-
MENT CLUSTER - REMOVAL).
(3) Remove the cl uster l ens from the cl uster hous-
i ng. Refer to CLUSTER LENS.
(4) Remove the odometer reset button boot by pul l -
i ng i t strai ght out of the pocketed hol e from the face
of the cl uster l ens (Fi g. 6).
Fig. 4 Instrument Cluster Remove/Install
1 - WIRE HARNESS CONNECTORS
2 - INSTRUMENT CLUSTER
3 - SCREW (4)
4 - INSTRUMENT PANEL
Fig. 5 Cluster Bulb Locations
1 - CLUSTER INCANDESCENT BULBS
TJ INSTRUMENT CLUSTER 8J - 17
INSTRUMENT CLUSTER (Continued)
CLUSTER HOOD AND MASK
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the i nstrument cl uster from the i nstru-
ment panel . (Refer to 8 - ELECTRI CAL/I NSTRU-
MENT CLUSTER - REMOVAL).
(3) Remove the cl uster l ens from the cl uster hous-
i ng. Refer to CLUSTER LENS.
(4) Work around the peri meter of the cl uster hood
and mask uni t and di sengage each of the fi ve l atches
that secure the cl uster hood and mask uni t to the
cl uster housi ng (Fi g. 6).
(5) Gentl y pul l the cl uster hood and mask uni t
away from the face of the i nstrument cl uster hous-
i ng.
CLUSTER HOUSING REAR COVER
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the i nstrument cl uster from the i nstru-
ment panel . (Refer to 8 - ELECTRI CAL/I NSTRU-
MENT CLUSTER - REMOVAL).
(3) Remove the screw adjacent to each of the two
cl uster connector receptacl es that secure the rear
cover to the cl uster housi ng.
(4) Work around the peri meter of the cl uster hous-
i ng rear cover and di sengage each of the ei ght
l atches that secure the cover to the outsi de of the
cl uster housi ng (Fi g. 6).
(5) Di sengage the one i nboard l atch l ocated i n a
receptacl e near the l ower edge of the rear cover just
to the ri ght of center that secures the rear cover to
the cl uster housi ng.
(6) Gentl y pul l the cl uster housi ng rear cover away
from the back of the cl uster housi ng.
ASSEMBLY
Some of the components for the i nstrument cl uster
used i n thi s vehi cl e are servi ced i ndi vi dual l y. The
servi ced components i ncl ude: the i ncandescent
i nstrument cl uster i ndi cator and i l l umi nati on l amp
bul bs (i ncl udi ng the i ntegral bul b hol ders), the cl us-
ter l ens, the tri p odometer reset button boot, the
cl uster hood and mask uni t, and the cl uster housi ng
rear cover. Fol l owi ng are the procedures for di sas-
sembl i ng these components from the i nstrument cl us-
ter uni t.
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE SUPPLEMENTAL RESTRAINT SYS-
TEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, AIRBAG, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE BEFORE PERFORMING FURTHER DIAG-
NOSIS OR SERVICE. THIS IS THE ONLY SURE WAY
TO DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT.
CLUSTER BULB
Thi s procedure appl i es to each of the i ncandescent
cl uster i l l umi nati on l amp or i ndi cator bul b and bul b
hol der uni ts. However, the i l l umi nati on l amps and
the i ndi cators use di fferent bul b and bul b hol der uni t
si zes. They must never be i nterchanged.
CAUTION: Be certain that any bulb and bulb holder
unit removed from the cluster electronic circuit
board is reinstalled in the correct position. Always
use the correct bulb size and type for replacement.
An incorrect bulb size or type may overheat and
cause damage to the instrument cluster, the elec-
tronic circuit board and/or the gauges.
(1) I nsert the bul b and bul b hol der uni t strai ght
i nto the correct bul b mounti ng hol e i n the cl uster
el ectroni c ci rcui t board (Fi g. 5).
(2) Wi th the bul b hol der ful l y seated agai nst the
cl uster el ectroni c ci rcui t board, turn the bul b hol der
cl ockwi se about si xty degrees to l ock i t i nto pl ace.
(3) Rei nstal l the i nstrument cl uster onto the
i nstrument panel . (Refer to 8 - ELECTRI CAL/I N-
STRUMENT CLUSTER - I NSTALLATI ON).
(4) Reconnect the battery negati ve cabl e.
Fig. 6 Instrument Cluster Components
1 - REAR COVER
2 - CLUSTER HOUSING
3 - CLUSTER HOOD & MASK
4 - CLUSTER LENS
5 - SWITCH BUTTON BOOT
8J - 18 INSTRUMENT CLUSTER TJ
INSTRUMENT CLUSTER (Continued)
CLUSTER LENS
(1) Posi ti on the cl uster l ens over the cl uster hood
and mask uni t on the face of the i nstrument cl uster
(Fi g. 6). Be certai n that the tri p odometer reset
swi tch button i s al i gned wi th and i nserted i nto the
reset button boot i n the l ens.
(2) Press fi rml y and evenl y on the cl uster l ens to
i nstal l i t onto the i nstrument cl uster housi ng.
(3) Work around the peri meter of the cl uster l ens
maki ng certai n that each of the ei ght l atches that
secure the l ens to the cl uster mask and the cl uster
housi ng i s ful l y engaged.
(4) Rei nstal l the i nstrument cl uster onto the
i nstrument panel . (Refer to 8 - ELECTRI CAL/I N-
STRUMENT CLUSTER - I NSTALLATI ON).
(5) Reconnect the battery negati ve cabl e.
TRIP ODOMETER RESET BUTTON BOOT
(1) Posi ti on the tri p odometer reset button boot
i nto the pocketed mounti ng hol e from the back of the
cl uster l ens (Fi g. 6).
(2) Gentl y pul l the ti p of the tri p odometer reset
button boot from the face of the cl uster l ens unti l i t
i s ful l y seated i n the pocketed mounti ng hol e.
(3) Rei nstal l the cl uster l ens onto the cl uster hous-
i ng. Refer to CLUSTER LENS.
(4) Rei nstal l the i nstrument cl uster onto the
i nstrument panel . (Refer to 8 - ELECTRI CAL/I N-
STRUMENT CLUSTER - I NSTALLATI ON).
(5) Reconnect the battery negati ve cabl e.
CLUSTER HOOD AND MASK
(1) Al i gn the cl uster hood and mask uni t wi th the
face of the i nstrument cl uster housi ng (Fi g. 6).
(2) Press fi rml y and evenl y on the cl uster hood
and mask uni t to i nstal l i t onto the cl uster housi ng.
(3) Work around the peri meter of the cl uster hood
and mask uni t maki ng certai n that each of the fi ve
l atches that secure the hood and mask uni t to the
i nstrument cl uster housi ng i s ful l y engaged.
(4) Rei nstal l the cl uster l ens onto the cl uster hous-
i ng. Refer to CLUSTER LENS.
(5) Rei nstal l the i nstrument cl uster onto the
i nstrument panel . (Refer to 8 - ELECTRI CAL/I N-
STRUMENT CLUSTER - I NSTALLATI ON).
(6) Reconnect the battery negati ve cabl e.
CLUSTER HOUSING REAR COVER
(1) Posi ti on the cl uster housi ng rear cover to the
back of the i nstrument cl uster housi ng.
(2) Press fi rml y and evenl y on the cl uster housi ng
rear cover to i nstal l i t onto the back of the i nstru-
ment cl uster housi ng.
(3) Work around the peri meter of the cl uster hous-
i ng rear cover maki ng certai n that each of the ei ght
l atches that secure the rear cover to the i nstrument
cl uster housi ng i s ful l y engaged.
(4) I nstal l and ti ghten the two screws that secures
the rear cover to the i nstrument cl uster housi ng
adjacent to each cl uster connector receptacl e. Ti ghten
the screws to 2 N·m (20 i n. l bs.).
(5) Rei nstal l the i nstrument cl uster onto the
i nstrument panel . (Refer to 8 - ELECTRI CAL/I N-
STRUMENT CLUSTER - I NSTALLATI ON).
(6) Reconnect the battery negati ve cabl e.
INSTALLATION
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE SUPPLEMENTAL RESTRAINT SYS-
TEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, AIRBAG, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE BEFORE PERFORMING FURTHER DIAG-
NOSIS OR SERVICE. THIS IS THE ONLY SURE WAY
TO DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT.
(1) Posi ti on the i nstrument cl uster to the i nstru-
ment panel .
(2) Reconnect the two i nstrument panel wi re har-
ness connectors for the cl uster to the connector recep-
tacl es on the back of the cl uster housi ng (Fi g. 4).
(3) Posi ti on the i nstrument cl uster i nto the i nstru-
ment panel structural support.
(4) I nstal l and ti ghten the four screws that secure
the i nstrument cl uster to the i nstrument panel struc-
tural support. Ti ghten the screws to 2.2 N·m (20 i n.
l bs.).
(5) Rei nstal l the cl uster bezel onto the i nstrument
panel . (Refer to 23 - BODY/I NSTRUMENT PANEL/
CLUSTER BEZEL - I NSTALLATI ON).
(6) Reconnect the battery negati ve cabl e.
NOTE: Certain indicators in this instrument cluster
are automatically configured. This feature allows
those indicators to be activated for deactivated for
compatibility with certain optional equipment. If the
problem being diagnosed involves improper illumi-
nation of the airbag indicator, the cruise indicator,
or the SKIM indicator when the vehicle does not
have this equipment, the instrument cluster must
be replaced with a new unit.
TJ INSTRUMENT CLUSTER 8J - 19
INSTRUMENT CLUSTER (Continued)
ABS INDICATOR
DESCRIPTION
An Anti l ock Brake System (ABS) i ndi cator i s stan-
dard equi pment on al l i nstrument cl usters (Fi g. 7).
However, thi s i ndi cator i s onl y functi onal on vehi cl es
equi pped wi th the ABS opti on. The ABS i ndi cator i s
l ocated near the l ower edge of the i nstrument cl uster,
to the l eft of center. The ABS i ndi cator consi sts of a
stenci l -l i ke cutout of the I nternati onal Control and
Di spl ay Symbol i con for “Fai l ure of Anti -l ock Braki ng
System” i n the opaque l ayer of the i nstrument cl us-
ter overl ay. The dark outer l ayer of the overl ay pre-
vents the i ndi cator from bei ng cl earl y vi si bl e when i t
i s not i l l umi nated. An amber Li ght Emi tti ng Di ode
(LED) behi nd the cutout i n the opaque l ayer of the
overl ay causes the i con to appear i n amber through
the transl ucent outer l ayer of the overl ay when the
i ndi cator i s i l l umi nated from behi nd by the LED,
whi ch i s sol dered onto the i nstrument cl uster el ec-
troni c ci rcui t board. The ABS i ndi cator i s servi ced as
a uni t wi th the i nstrument cl uster.
OPERATION
The ABS i ndi cator gi ves an i ndi cati on to the vehi -
cl e operator when the ABS system i s faul ty or i nop-
erati ve. Thi s i ndi cator i s hard wi red on the
i nstrument cl uster el ectroni c ci rcui t board, and i s
compl etel y control l ed by the Control l er Anti l ock
Brake (CAB). The ABS i ndi cator Li ght Emi tti ng
Di ode (LED) recei ves battery current on the i nstru-
ment cl uster el ectroni c ci rcui t board through the
fused i gni ti on swi tch output (run-start) ci rcui t when-
ever the i gni ti on swi tch i s i n the On or Start posi -
ti ons; therefore, the LED wi l l al ways be off when the
i gni ti on swi tch i s i n any posi ti on except On or Start.
The LED onl y i l l umi nates when i t i s provi ded a path
to ground by the CAB through the CAB rel ay i n the
Power Di stri buti on Center (PDC). The CAB wi l l turn
on the ABS i ndi cator for the fol l owi ng reasons:
• Bulb Test - Each ti me the i gni ti on swi tch i s
turned to the On posi ti on the ABS i ndi cator i s i l l u-
mi nated by the cl uster for about two seconds as a
bul b test.
• ABS Self-Test Fault - Each ti me the CAB
detects a faul t i n a moni tored ABS ci rcui t, the ABS
i ndi cator wi l l be i l l umi nated. The i ndi cator remai ns
i l l umi nated unti l the faul t condi ti on i s corrected, or
unti l the i gni ti on swi tch i s turned to the Off posi ti on,
whi chever occurs fi rst.
• ABS Diagnostic Test - The ABS i ndi cator i s
bl i nked on and off by the CAB duri ng the perfor-
mance of the ABS di agnosti c tests.
The CAB conti nual l y moni tors the ABS ci rcui ts
and sensors to deci de whether the system i s i n good
operati ng condi ti on. I f the CAB turns the ABS i ndi -
cator on after the bul b test, i t i ndi cates that the CAB
has detected a system mal functi on and/or that the
ABS system has become i noperati ve. The CAB wi l l
store a Di agnosti c Troubl e Code (DTC) for any mal -
functi on i t detects. (Refer to 5 - BRAKES -
DESCRI PTI ON). The ABS i ndi cator can be di agnosed
usi ng conventi onal di agnosti c tool s and methods.
DIAGNOSIS AND TESTING - ABS INDICATOR
The di agnosi s found here addresses an i noperati ve
Anti l ock Brake System (ABS) i ndi cator condi ti on. I f
there are probl ems wi th several i ndi cators i n the
i nstrument cl uster, (Refer to 8 - ELECTRI CAL/I N-
STRUMENT CLUSTER - DI AGNOSI S AND TEST-
I NG). I f the ABS i ndi cator stays on wi th the i gni ti on
swi tch i n the On posi ti on or comes on and stays on
whi l e dri vi ng, proceed to the di agnosi s for the ABS
brake system. (Refer to 5 - BRAKES - DI AGNOSI S
AND TESTI NG). I f no ABS probl em i s found, the fol -
l owi ng procedure wi l l hel p to l ocate a short or open
i n the ABS warni ng i ndi cator dri ver ci rcui t. Refer to
the appropri ate wi ri ng i nformati on. The wi ri ng i nfor-
mati on i ncl udes wi ri ng di agrams, proper wi re and
connector repai r procedures, detai l s of wi re harness
routi ng and retenti on, connector pi n-out i nformati on
and l ocati on vi ews for the vari ous wi re harness con-
nectors, spl i ces and grounds.
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE SUPPLEMENTAL RESTRAINT SYS-
TEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, AIRBAG, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE BEFORE PERFORMING FURTHER DIAG-
NOSIS OR SERVICE. THIS IS THE ONLY SURE WAY
TO DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT.
(1) Di sconnect and i sol ate the battery negati ve
cabl e. Remove the i nstrument cl uster from the
i nstrument panel . Di sconnect the i nstrument panel
wi re harness connector (Connector C2) for the i nstru-
ment cl uster from the connector receptacl e on the
back of the cl uster housi ng. Reconnect the battery
negati ve cabl e. Turn the i gni ti on swi tch to the On
Fig. 7 ABS Indicator
8J - 20 INSTRUMENT CLUSTER TJ
posi ti on and wi thi n about two seconds check for con-
ti nui ty between the ABS warni ng i ndi cator dri ver ci r-
cui t cavi ty of the i nstrument panel wi re harness
connector (Connector C2) for the i nstrument cl uster
and a good ground. There shoul d be conti nui ty for
about two seconds after i gni ti on On, and then an
open ci rcui t. I f OK, proceed to the di agnosi s for the
ABS brake system. (Refer to 5 - BRAKES - DI AGNO-
SI S AND TESTI NG). I f not OK, go to Step 2.
(2) Turn the i gni ti on swi tch to the Off posi ti on.
Di sconnect and i sol ate the battery negati ve cabl e.
Remove the Control l er Anti l ock Brake (CAB) rel ay
from the Power Di stri buti on Center (PDC). Check for
conti nui ty between the ABS warni ng i ndi cator dri ver
ci rcui t cavi ty of the i nstrument panel wi re harness
connector (Connector C2) for the i nstrument cl uster
and a good ground. There shoul d be no conti nui ty. I f
OK, go to Step 3. I f not OK, repai r the shorted ABS
warni ng i ndi cator dri ver ci rcui t between the i nstru-
ment cl uster and the PDC as requi red.
(3) Check for conti nui ty between the ABS warni ng
i ndi cator dri ver ci rcui t cavi ti es of the i nstrument
panel wi re harness connector (Connector C2) for the
i nstrument cl uster and the CAB rel ay receptacl e i n
the PDC. There shoul d be conti nui ty. I f OK, proceed
to the di agnosi s for the ABS brake system. (Refer to
5 - BRAKES - DI AGNOSI S AND TESTI NG). I f not
OK, repai r the open ABS warni ng i ndi cator dri ver
ci rcui t between the i nstrument cl uster and the PDC
as requi red.
AIRBAG INDICATOR
DESCRIPTION
An ai rbag i ndi cator i s standard equi pment on al l
i nstrument cl usters (Fi g. 8). However, the i nstrument
cl uster can be programmed to di sabl e thi s i ndi cator
on vehi cl es that are not equi pped wi th the ai rbag
system, whi ch i s not avai l abl e i n some markets. The
ai rbag i ndi cator i s l ocated near the l ower edge of the
i nstrument cl uster, to the ri ght of center. The ai rbag
i ndi cator consi sts of a stenci l -l i ke cutout of the I nter-
nati onal Control and Di spl ay Symbol i con for “Ai r-
bag” i n the opaque l ayer of the i nstrument cl uster
overl ay. The dark outer l ayer of the overl ay prevents
the i ndi cator from bei ng cl earl y vi si bl e when i t i s not
i l l umi nated. A red Li ght Emi tti ng Di ode (LED)
behi nd the cutout i n the opaque l ayer of the overl ay
causes the i con to appear i n red through the transl u-
cent outer l ayer of the overl ay when the i ndi cator i s
i l l umi nated from behi nd by the LED, whi ch i s sol -
dered onto the i nstrument cl uster el ectroni c ci rcui t
board. The ai rbag i ndi cator i s servi ced as a uni t wi th
the i nstrument cl uster.
OPERATION
The ai rbag i ndi cator gi ves an i ndi cati on to the
vehi cl e operator when the ai rbag system i s faul ty or
i noperati ve. The ai rbag i ndi cator i s control l ed by a
transi stor on the i nstrument cl uster ci rcui t board
based upon cl uster programmi ng and el ectroni c mes-
sages recei ved by the cl uster from the Ai rbag Control
Modul e (ACM) over the Programmabl e Communi ca-
ti ons I nterface (PCI ) data bus. The ai rbag i ndi cator
Li ght Emi tti ng Di ode (LED) i s compl etel y control l ed
by the i nstrument cl uster l ogi c ci rcui t, and that l ogi c
wi l l onl y al l ow thi s i ndi cator to operate when the
i nstrument cl uster recei ves a battery current i nput
on the fused i gni ti on swi tch output (run-start) ci r-
cui t. Therefore, the LED wi l l al ways be off when the
i gni ti on swi tch i s i n any posi ti on except On or Start.
The LED onl y i l l umi nates when i t i s provi ded a path
to ground by the i nstrument cl uster transi stor. The
i nstrument cl uster wi l l turn on the ai rbag i ndi cator
for the fol l owi ng reasons:
• Bulb Test - Each ti me the i gni ti on swi tch i s
turned to the On posi ti on the ai rbag i ndi cator i s i l l u-
mi nated for about seven seconds. The fi rst two sec-
onds i s the cl uster bul b test functi on, and the
remai nder i s the ACM bul b test functi on.
• ACM Lamp-On Message - Each ti me the cl us-
ter recei ves a l amp-on message from the ACM, the
ai rbag i ndi cator wi l l be i l l umi nated. The i ndi cator
remai ns i l l umi nated for about twel ve seconds or unti l
the cl uster recei ves a l amp-off message from the
ACM, whi chever i s l onger.
• Communication Error - I f the cl uster recei ves
no ai rbag messages for fi ve consecuti ve seconds, the
ai rbag i ndi cator i s i l l umi nated. The i ndi cator
remai ns i l l umi nated unti l the cl uster recei ves a si n-
gl e l amp-off message from the ACM.
• Actuator Test - Each ti me the cl uster i s put
through the actuator test, the ai rbag i ndi cator wi l l be
turned on, then off agai n duri ng the bul b check por-
ti on of the test to confi rm the functi onal i ty of the
LED and the cl uster control ci rcui try. The actuator
test i l l umi nati on of the ai rbag i ndi cator i s a functi on
of the ACM.
The ACM conti nual l y moni tors the ai rbag system
ci rcui ts and sensors to deci de whether the system i s
i n good operati ng condi ti on. The ACM then sends the
proper l amp-on or l amp-off messages to the i nstru-
ment cl uster. I f the ACM sends a l amp-on message
after the bul b test, i t i ndi cates that the ACM has
detected a system mal functi on and/or that the ai r-
bags may not depl oy when requi red, or may depl oy
Fig. 8 Airbag Indicator
TJ INSTRUMENT CLUSTER 8J - 21
ABS INDICATOR (Continued)
when not requi red. The ACM wi l l store a Di agnosti c
Troubl e Code (DTC) for any mal functi on i t detects.
Each ti me the ai rbag i ndi cator fai l s to i l l umi nate due
to an open or short i n the cl uster ai rbag i ndi cator ci r-
cui t, the cl uster sends a message noti fyi ng the ACM
of the condi ti on and stores a DTC. For proper di ag-
nosi s of the ai rbag system, the ACM, the PCI data
bus, or the el ectroni c message i nputs to the i nstru-
ment cl uster that control the ai rbag i ndi cator, a
DRBI I I ௡ scan tool i s requi red. Refer to the appropri -
ate di agnosti c i nformati on.
BRAKE/PARK BRAKE
INDICATOR
DESCRIPTION
A brake i ndi cator i s standard equi pment on al l
i nstrument cl usters (Fi g. 9). The brake i ndi cator i s
l ocated near the l ower edge of the i nstrument cl uster,
to the l eft of center. The brake i ndi cator consi sts of a
stenci l -l i ke cutout of the word “BRAKE” i n the
opaque l ayer of the i nstrument cl uster overl ay. The
dark outer l ayer of the overl ay prevents the i ndi cator
from bei ng cl earl y vi si bl e when i t i s not i l l umi nated.
A red Li ght Emi tti ng Di ode (LED) behi nd the cutout
i n the opaque l ayer of the overl ay causes the
“BRAKE” text to appear i n red through the transl u-
cent outer l ayer of the overl ay when the i ndi cator i s
i l l umi nated from behi nd by the LED, whi ch i s sol -
dered onto the i nstrument cl uster el ectroni c ci rcui t
board. The brake i ndi cator i s servi ced as a uni t wi th
the i nstrument cl uster.
OPERATION
The brake i ndi cator gi ves an i ndi cati on to the vehi -
cl e operator when the parki ng brake i s appl i ed, or
when there are certai n brake hydraul i c system mal -
functi ons. Thi s i ndi cator i s control l ed by a transi stor
on the i nstrument cl uster ci rcui t board based upon
cl uster programmi ng, el ectroni c messages recei ved by
the cl uster from the Powertrai n Control Modul e
(PCM) over the Programmabl e Communi cati ons
I nterface (PCI ) data bus, and hard wi red i nputs to
the i nstrument cl uster from the park brake swi tch
and the brake warni ng i ndi cator swi tch. The brake
i ndi cator Li ght Emi tti ng Di ode (LED) i s compl etel y
control l ed by the i nstrument cl uster l ogi c ci rcui t, and
that l ogi c wi l l onl y al l ow thi s i ndi cator to operate
when the i nstrument cl uster recei ves a battery cur-
rent i nput on the fused i gni ti on swi tch output (run-
start) ci rcui t. Therefore, the LED wi l l al ways be off
when the i gni ti on swi tch i s i n any posi ti on except On
or Start. The cl uster can i l l umi nate the LED sol i d, or
fl ash i t on and off at about one fl ash per second. The
LED onl y i l l umi nates when i t i s provi ded a path to
ground by the i nstrument cl uster transi stor. The
i nstrument cl uster wi l l turn on the brake i ndi cator
for the fol l owi ng reasons:
• Bulb Test - Each ti me the i gni ti on swi tch i s
turned to the On posi ti on the brake i ndi cator i s i l l u-
mi nated by the i nstrument cl uster for about four sec-
onds as a bul b test.
• Park Brake Switch Input - Each ti me the
cl uster detects ground on the red brake warni ng i ndi -
cator dri ver ci rcui t (park brake swi tch cl osed = park
brake appl i ed or not ful l y rel eased) the brake i ndi ca-
tor i s i l l umi nated sol i d. I f a vehi cl e speed message i s
recei ved by the cl uster from the PCM over the PCI
data bus i ndi cati ng the vehi cl e i s movi ng whi l e the
red brake warni ng i ndi cator dri ver i nput i s
grounded, the brake i ndi cator i s fl ashed on and off
repeatedl y. Whether i l l umi nated sol i d or fl ashi ng, the
i ndi cator remai ns i l l umi nated unti l the red brake
warni ng i ndi cator dri ver i nput to the cl uster i s an
open ci rcui t (park brake swi tch open = park brake
ful l y rel eased), or unti l the i gni ti on swi tch i s turned
to the Off posi ti on, whi chever occurs fi rst.
• Brake Hydraulic System Malfunction - Each
ti me the cl uster detects ground on the red brake
warni ng i ndi cator dri ver ci rcui t (brake warni ng i ndi -
cator swi tch cl osed = pressures i n the two hal ves of
the spl i t brake hydraul i c system are unequal ) the
brake i ndi cator i s i l l umi nated sol i d. The i ndi cator
remai ns i l l umi nated unti l the red brake warni ng
i ndi cator dri ver i nput to the cl uster i s an open ci rcui t
(brake warni ng i ndi cator swi tch open = brake
hydraul i c system pressures are equal ), or unti l the
i gni ti on swi tch i s turned to the Off posi ti on, whi ch-
ever occurs fi rst.
• Actuator Test - Each ti me the i nstrument cl us-
ter i s put through the actuator test, the brake i ndi -
cator wi l l be turned on, then off agai n duri ng the
bul b check porti on of the test to confi rm the functi on-
al i ty of the LED and the cl uster control ci rcui try.
The park brake swi tch and the brake warni ng
pressure swi tch are each connected i n paral l el
between ground and the red brake warni ng i ndi cator
dri ver i nput to the i nstrument cl uster so that each of
thei r i nputs wi l l i l l umi nate the i ndi cator i ndepen-
dentl y of the other. The park brake swi tch and brake
warni ng i ndi cator swi tch i nputs to the i nstrument
cl uster can be di agnosed usi ng conventi onal di agnos-
ti c tool s and methods. (Refer to 5 - BRAKES/PARK-
I NG BRAKE - OPERATI ON). (Refer to 5 - BRAKES/
ELECTRI CAL/BRAKE PRESSURE SWI TCH -
OPERATI ON).
Fig. 9 Brake Indicator
8J - 22 INSTRUMENT CLUSTER TJ
AIRBAG INDICATOR (Continued)
For further di agnosi s of the brake i ndi cator or the
i nstrument cl uster ci rcui try that control s the LED,
(Refer to 8 - ELECTRI CAL/I NSTRUMENT CLUS-
TER - DI AGNOSI S AND TESTI NG). For proper
di agnosi s of the PCM, the PCI data bus, or the mes-
sage i nputs to the i nstrument cl uster that control the
brake i ndi cator, a DRBI I I ௡ scan tool i s requi red.
Refer to the appropri ate di agnosti c i nformati on.
DIAGNOSIS AND TESTING - BRAKE INDICATOR
The di agnosi s found here addresses an i noperati ve
brake i ndi cator condi ti on. I f there are probl ems wi th
several i ndi cators i n the i nstrument cl uster, (Refer to
8 - ELECTRI CAL/I NSTRUMENT CLUSTER - DI AG-
NOSI S AND TESTI NG). I f the brake i ndi cator stays
on wi th the i gni ti on swi tch i n the On posi ti on and
the park brake rel eased, or comes on whi l e dri vi ng,
(Refer to 5 - BRAKES - DI AGNOSI S AND TEST-
I NG). I f no brake system probl em i s found, the fol -
l owi ng procedures wi l l hel p to l ocate a shorted or
open ci rcui t, or a faul ty swi tch i nput. Refer to the
appropri ate wi ri ng i nformati on. The wi ri ng i nforma-
ti on i ncl udes wi ri ng di agrams, proper wi re and con-
nector repai r procedures, detai l s of wi re harness
routi ng and retenti on, connector pi n-out i nformati on
and l ocati on vi ews for the vari ous wi re harness con-
nectors, spl i ces and grounds.
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE SUPPLEMENTAL RESTRAINT SYS-
TEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, AIRBAG, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE BEFORE PERFORMING FURTHER DIAG-
NOSIS OR SERVICE. THIS IS THE ONLY SURE WAY
TO DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT.
INDICATOR ILLUMINATES DURING BULB TEST, BUT DOES
NOT WHEN PARK BRAKE APPLIED
(1) Di sconnect and i sol ate the battery negati ve
cabl e. Di sconnect the fl oor wi re harness connector for
the park brake swi tch from the swi tch termi nal .
Appl y the parki ng brake. Check for conti nui ty
between the park brake swi tch termi nal and a good
ground. There shoul d be conti nui ty. I f OK, go to Step
2. I f not OK, repl ace the faul ty park brake swi tch.
(2) Di sconnect the headl amp and dash wi re har-
ness connector for the brake warni ng i ndi cator
swi tch from the swi tch termi nal s. Check for conti nu-
i ty between the red brake warni ng i ndi cator dri ver
(G9) ci rcui t cavi ti es of the fl oor wi re harness connec-
tor for the park brake swi tch and the headl amp and
dash wi re harness connector for the brake warni ng
i ndi cator swi tch. There shoul d be conti nui ty. I f not
OK, repai r the open red brake warni ng i ndi cator
dri ver (G9) ci rcui t between the park brake swi tch
and the brake warni ng i ndi cator swi tch as requi red.
INDICATOR REMAINS ILLUMINATED - BRAKE SYSTEM
CHECKS OK
(1) Di sconnect and i sol ate the battery negati ve
cabl e. Remove the i nstrument cl uster from the
i nstrument panel . Di sconnect the i nstrument panel
wi re harness connector (Connector C2) for the i nstru-
ment cl uster from the connector receptacl e on the
back of the cl uster housi ng. Di sconnect the headl amp
and dash wi re harness connector for the brake warn-
i ng i ndi cator swi tch from the swi tch termi nal s.
Check for conti nui ty between the red brake warni ng
i ndi cator dri ver ci rcui t (G99) cavi ty of the headl amp
and dash wi re harness connector for the brake warn-
i ng i ndi cator swi tch and a good ground. There shoul d
be no conti nui ty. I f OK, go to Step 2. I f not OK,
repai r the shorted red brake warni ng i ndi cator dri ver
ci rcui t (G99) between the brake warni ng i ndi cator
swi tch and the i nstrument cl uster as requi red.
(2) Di sconnect the fl oor wi re harness connector for
the park brake swi tch from the swi tch termi nal .
Check for conti nui ty between the red brake warni ng
i ndi cator dri ver ci rcui t (G9) cavi ty of the headl amp
and dash wi re harness connector for the brake warn-
i ng i ndi cator swi tch and a good ground. There shoul d
be no conti nui ty. I f OK, go to Step 3. I f not OK,
repai r the shorted red brake warni ng i ndi cator dri ver
ci rcui t (G9) between the brake warni ng i ndi cator
swi tch and the park brake swi tch as requi red.
(3) Check for conti nui ty between each of the two
termi nal s of the brake warni ng i ndi cator swi tch and
a good ground. I n each case, there shoul d be no con-
ti nui ty. I f OK, go to Step 4. I f not OK, repl ace the
faul ty brake warni ng i ndi cator swi tch.
(4) Check for conti nui ty between the termi nal of
the park brake swi tch and a good ground. There
shoul d be no conti nui ty wi th the park brake rel eased,
and conti nui ty wi th the park brake appl i ed. I f not
OK, repl ace the faul ty park brake swi tch.
TJ INSTRUMENT CLUSTER 8J - 23
BRAKE/PARK BRAKE INDICATOR (Continued)
CHECK GAUGES INDICATOR
DESCRIPTION
A check gauges i ndi cator i s standard equi pment on
al l i nstrument cl usters (Fi g. 10). The check gauges
i ndi cator i s l ocated on the l ower edge of the i nstru-
ment cl uster, to the ri ght of center. The check gauges
i ndi cator consi sts of a stenci l -l i ke cutout of the words
“CHECK GAUGES” i n the opaque l ayer of the
i nstrument cl uster overl ay. The dark outer l ayer of
the overl ay prevents the i ndi cator from bei ng cl earl y
vi si bl e when i t i s not i l l umi nated. A red Li ght Emi t-
ti ng Di ode (LED) behi nd the cutout i n the opaque
l ayer of the overl ay causes the “CHECK GAUGES”
text to appear i n red through the transl ucent outer
l ayer of the overl ay when the i ndi cator i s i l l umi nated
from behi nd by the LED, whi ch i s sol dered onto the
i nstrument cl uster el ectroni c ci rcui t board. The check
gauges i ndi cator i s servi ced as a uni t wi th the i nstru-
ment cl uster.
OPERATION
The check gauges i ndi cator gi ves an i ndi cati on to
the vehi cl e operator when certai n i nstrument cl uster
gauge readi ngs refl ect a condi ti on requi ri ng i mmedi -
ate attenti on. Thi s i ndi cator i s control l ed by a tran-
si stor on the i nstrument cl uster ci rcui t board based
upon cl uster programmi ng and el ectroni c messages
recei ved by the cl uster from the Powertrai n Control
Modul e (PCM) over the Programmabl e Communi ca-
ti ons I nterface (PCI ) data bus. The check gauges
i ndi cator Li ght Emi tti ng Di ode (LED) i s compl etel y
control l ed by the i nstrument cl uster l ogi c ci rcui t, and
that l ogi c wi l l onl y al l ow thi s i ndi cator to operate
when the i nstrument cl uster recei ves a battery cur-
rent i nput on the fused i gni ti on swi tch output (run-
start) ci rcui t. Therefore, the LED wi l l al ways be off
when the i gni ti on swi tch i s i n any posi ti on except On
or Start. The LED onl y i l l umi nates when i t i s pro-
vi ded a path to ground by the i nstrument cl uster
transi stor. The i nstrument cl uster wi l l turn on the
check gauges i ndi cator for the fol l owi ng reasons:
• Bulb Test - Each ti me the i gni ti on swi tch i s
turned to the On posi ti on the check gauges i ndi cator
i s i l l umi nated for about two seconds as a bul b test.
• Engine Temperature High Message - Each
ti me the cl uster recei ves a message from the PCM
i ndi cati ng the engi ne cool ant temperature i s about
127° C (261° F) or hi gher, the check gauges i ndi cator
wi l l be i l l umi nated. The i ndi cator remai ns i l l umi -
nated unti l the cl uster recei ves a message from the
PCM i ndi cati ng that the engi ne temperature i s about
124° C (255° F) or l ower, or unti l the i gni ti on swi tch
i s turned to the Off posi ti on, whi chever occurs fi rst.
• Engine Oil Pressure Low Message - Each
ti me the cl uster recei ves a message from the PCM
i ndi cati ng the engi ne oi l pressure of a 2.4L engi ne i s
bel ow about 0.2 kg/cm
2
(3 psi ), or of any engi ne other
than a 2.4L i s bel ow about 0.4 kg/cm
2
(6 psi ), the
check gauges i ndi cator wi l l be i l l umi nated. The i ndi -
cator remai ns i l l umi nated unti l the cl uster recei ves a
message from the PCM i ndi cati ng that the engi ne oi l
pressure of a 2.4L engi ne i s above about 0.2 kg/cm
2
(3 psi ), or of any engi ne other than a 2.4L i s above
about 0.4 kg/cm
2
(6 psi ), or unti l the i gni ti on swi tch
i s turned to the Off posi ti on, whi chever occurs fi rst.
The cl uster wi l l onl y turn the i ndi cator on i n
response to an engi ne oi l pressure l ow message i f the
engi ne speed i s 300 rpm or greater for more than
about fi ve seconds.
• System Voltage Low (Charge Fail) Message
- Each ti me the cl uster recei ves a message from the
PCM i ndi cati ng the el ectri cal system vol tage i s about
9.0 vol ts or l ower (charge fai l condi ti on), the check
gauges i ndi cator wi l l be i l l umi nated. The i ndi cator
remai ns i l l umi nated unti l the cl uster recei ves a mes-
sage from the PCM i ndi cati ng the el ectri cal system
vol tage i s greater than about 12.0 vol ts (but l ess than
16.0 vol ts), or unti l the i gni ti on swi tch i s turned to
the Off posi ti on, whi chever occurs fi rst.
• System Voltage High Message - Each ti me
the cl uster recei ves a message from the PCM i ndi cat-
i ng the el ectri cal system vol tage i s greater than
about 16.0 vol ts, the check gauges i ndi cator wi l l be
i l l umi nated. The i ndi cator remai ns i l l umi nated unti l
the cl uster recei ves a message from the PCM i ndi cat-
i ng the el ectri cal system vol tage i s l ess than about
16.0 vol ts (but hi gher than 9.0 vol ts), or unti l the
i gni ti on swi tch i s turned to the Off posi ti on, whi ch-
ever occurs fi rst.
• Actuator Test - Each ti me the cl uster i s put
through the actuator test, the check gauges i ndi cator
wi l l be turned on, then off agai n duri ng the bul b
check porti on of the test i n order to confi rm the func-
ti onal i ty of the LED and the cl uster control ci rcui try.
The PCM conti nual l y moni tors the engi ne temper-
ature, oi l pressure, and el ectri cal system vol tage,
then sends the proper messages to the i nstrument
cl uster. For further di agnosi s of the check gauges
i ndi cator or the i nstrument cl uster ci rcui try that con-
trol s the LED, (Refer to 8 - ELECTRI CAL/I NSTRU-
MENT CLUSTER - DI AGNOSI S AND TESTI NG).
For proper di agnosi s of the PCM, the PCI data bus,
or the el ectroni c message i nputs to the i nstrument
cl uster that control the check gauges i ndi cator, a
DRBI I I ௡ scan tool i s requi red. Refer to the appropri -
ate di agnosti c i nformati on.
Fig. 10 Check Gauges Indicator
8J - 24 INSTRUMENT CLUSTER TJ
CRUISE INDICATOR
DESCRIPTION
A crui se i ndi cator i s standard equi pment on al l
i nstrument cl usters (Fi g. 11). However, on vehi cl es
not equi pped wi th the opti onal speed control system,
thi s i ndi cator i s el ectroni cal l y di sabl ed. The crui se
i ndi cator i s l ocated near the upper edge of the i nstru-
ment cl uster, to the l eft of center. The crui se i ndi ca-
tor consi sts of a stenci l -l i ke cutout of the word
“CRUI SE” i n the opaque l ayer of the i nstrument
cl uster overl ay. The dark outer l ayer of the overl ay
prevents the i ndi cator from bei ng cl earl y vi si bl e
when i t i s not i l l umi nated. A green Li ght Emi tti ng
Di ode (LED) behi nd the cutout i n the opaque l ayer of
the overl ay causes the “CRUI SE” text to appear i n
green through the transl ucent outer l ayer of the
overl ay when the i ndi cator i s i l l umi nated from
behi nd by the LED, whi ch i s sol dered onto the
i nstrument cl uster el ectroni c ci rcui t board. The i l l u-
mi nati on i ntensi ty of the crui se i ndi cator i s one-step
di mmabl e. When the exteri or l i ghti ng i s turned On,
the i ndi cator i s di mmed; and, when the exteri or
l i ghti ng i s turned Off, the i ndi cator i s i l l umi nated at
ful l i ntensi ty. The crui se i ndi cator i s servi ced as a
uni t wi th the i nstrument cl uster.
OPERATION
The crui se i ndi cator gi ves an i ndi cati on to the vehi -
cl e operator when the speed control system i s turned
On, regardl ess of whether the speed control i s
engaged. Thi s i ndi cator i s control l ed by the i nstru-
ment cl uster ci rcui t board based upon cl uster pro-
grammi ng and el ectroni c messages recei ved by the
cl uster from the Powertrai n Control Modul e (PCM)
over the Programmabl e Communi cati ons I nterface
(PCI ) data bus. The crui se i ndi cator Li ght Emi tti ng
Di ode (LED) i s compl etel y control l ed by the i nstru-
ment cl uster l ogi c ci rcui t, and that l ogi c wi l l onl y
al l ow thi s i ndi cator to operate when the i nstrument
cl uster recei ves a battery current i nput on the fused
i gni ti on swi tch output (run-start) ci rcui t. Therefore,
the LED wi l l al ways be off when the i gni ti on swi tch
i s i n any posi ti on except On or Start. The LED onl y
i l l umi nates when i t i s provi ded a path to ground by
the i nstrument cl uster transi stor. The i nstrument
cl uster wi l l turn on the crui se i ndi cator for the fol -
l owi ng reasons:
• Cruise Lamp-On Message - Each ti me the
cl uster recei ves a crui se l amp-on message from the
PCM i ndi cati ng the speed control system has been
turned On, the crui se i ndi cator i s i l l umi nated. The
i ndi cator remai ns i l l umi nated unti l the cl uster
recei ves a crui se l amp-off message from the PCM or
unti l the i gni ti on swi tch i s turned to the Off posi ti on,
whi chever occurs fi rst.
• Actuator Test - Each ti me the cl uster i s put
through the actuator test, the crui se i ndi cator wi l l be
turned on, then off agai n duri ng the bul b check por-
ti on of the test i n order to confi rm the functi onal i ty
of the LED and the cl uster control ci rcui try.
The PCM conti nual l y moni tors the speed control
swi tches to determi ne the proper outputs to the
speed control servo. The PCM then sends the proper
crui se i ndi cator l amp-on and l amp-off messages to
the i nstrument cl uster. For further di agnosi s of the
crui se i ndi cator or the i nstrument cl uster ci rcui try
that control s the i ndi cator, (Refer to 8 - ELECTRI -
CAL/I NSTRUMENT CLUSTER - DI AGNOSI S AND
TESTI NG). For proper di agnosi s of the speed control
system, the PCM, the PCI data bus, or the el ectroni c
message i nputs to the i nstrument cl uster that control
the crui se i ndi cator, a DRBI I I ௡ scan tool i s requi red.
Refer to the appropri ate di agnosti c i nformati on.
ENGINE TEMPERATURE
GAUGE
DESCRIPTION
An engi ne cool ant temperature gauge i s standard
equi pment on al l i nstrument cl usters. The engi ne
cool ant temperature gauge i s l ocated i n the l ower
ri ght quadrant of the i nstrument cl uster, bel ow the
oi l pressure gauge. The engi ne cool ant temperature
gauge consi sts of a movabl e gauge needl e or poi nter
control l ed by the i nstrument cl uster ci rcui try and a
fi xed 90 degree scal e on the cl uster overl ay that
reads l eft-to-ri ght from 40° C (or 100° F) to 125° C
(or 260° F). An I nternati onal Control and Di spl ay
Symbol i con for “Engi ne Cool ant Temperature” i s
l ocated on the cl uster overl ay, di rectl y above the hub
of the gauge needl e (Fi g. 12). The engi ne cool ant tem-
perature gauge graphi cs are whi te and bl ue agai nst a
bl ack fi el d except for a si ngl e red graduati on at the
hi gh end of the gauge scal e, maki ng them cl earl y vi s-
i bl e wi thi n the i nstrument cl uster i n dayl i ght. When
i l l umi nated from behi nd by the panel l amps di mmer
control l ed cl uster i l l umi nati on l i ghti ng wi th the exte-
ri or l amps turned On, the whi te graphi cs appear
whi te, the bl ue graphi cs appear bl ue, and the red
graphi cs appear red. The orange gauge needl e i s
i nternal l y i l l umi nated. Gauge i l l umi nati on i s pro-
vi ded by repl aceabl e i ncandescent bul b and bul b
Fig. 11 Cruise Indicator
Fig. 12 Engine Coolant Temperature Icon
TJ INSTRUMENT CLUSTER 8J - 25
hol der uni ts l ocated on the i nstrument cl uster el ec-
troni c ci rcui t board. The engi ne cool ant temperature
gauge i s servi ced as a uni t wi th the i nstrument cl us-
ter.
OPERATION
The engi ne cool ant temperature gauge gi ves an
i ndi cati on to the vehi cl e operator of the engi ne cool -
ant temperature. Thi s gauge i s control l ed by the
i nstrument cl uster ci rcui t board based upon cl uster
programmi ng and el ectroni c messages recei ved by
the cl uster from the Powertrai n Control Modul e
(PCM) over the Programmabl e Communi cati ons
I nterface (PCI ) data bus. The engi ne cool ant temper-
ature gauge i s an ai r core magneti c uni t that recei ves
battery current on the i nstrument cl uster el ectroni c
ci rcui t board through the fused i gni ti on swi tch out-
put (run-start) ci rcui t whenever the i gni ti on swi tch i s
i n the On or Start posi ti ons. The cl uster i s pro-
grammed to move the gauge needl e back to the l ow
end of the scal e after the i gni ti on swi tch i s turned to
the Off posi ti on. The i nstrument cl uster ci rcui try
control s the gauge needl e posi ti on and provi des the
fol l owi ng features:
• Engine Temperature Message - Each ti me
the cl uster recei ves a message from the PCM i ndi cat-
i ng the engi ne cool ant temperature i s between about
40° C (100° F) and 124° C (255° F), the gauge needl e
i s moved to the actual rel ati ve temperature posi ti on
on the gauge scal e.
• Engine Temperature Low Message - Each
ti me the cl uster recei ves a message from the PCM
i ndi cati ng the engi ne cool ant temperature i s at or
bel ow about 40° C (100° F), the gauge needl e i s hel d
at the 40° C (100° F) graduati on at the far l eft end of
the gauge scal e. The gauge needl e remai ns at the l eft
end of the gauge scal e unti l the cl uster recei ves a
message from the PCM i ndi cati ng that the engi ne
temperature i s above about 40° C (100° F), or unti l
the i gni ti on swi tch i s turned to the Off posi ti on,
whi chever occurs fi rst.
• Engine Temperature High Message - Each
ti me the cl uster recei ves a message from the PCM
i ndi cati ng the engi ne cool ant temperature i s above
about 127° C (261° F), the gauge needl e i s moved
i nto the red zone at the far ri ght end of the gauge
scal e, the check gauges i ndi cator i s i l l umi nated, and
a si ngl e chi me tone i s sounded. The gauge needl e
remai ns i n the red zone and the check gauges i ndi -
cator remai ns i l l umi nated unti l the cl uster recei ves a
message from the PCM i ndi cati ng that the engi ne
temperature i s bel ow about 124° C (255° F), or unti l
the i gni ti on swi tch i s turned to the Off posi ti on,
whi chever occurs fi rst. The chi me tone feature wi l l
occur onl y once per i gni ti on cycl e.
• Engine Temperature Critical Message -
Each ti me the cl uster recei ves a message from the
PCM i ndi cati ng the engi ne cool ant temperature i s
above about 129° C (264° F), the gauge needl e i s
moved to the far ri ght end of the red zone on the
gauge scal e. The gauge needl e remai ns at the far
ri ght end of the red zone unti l the cl uster recei ves a
message from the PCM i ndi cati ng that the engi ne
temperature i s bel ow about 127° C (261° F), or unti l
the i gni ti on swi tch i s turned to the Off posi ti on,
whi chever occurs fi rst.
• Communication Error - I f the cl uster fai l s to
recei ve an engi ne temperature message, i t wi l l hol d
the gauge needl e at the l ast i ndi cati on about twel ve
seconds or unti l the i gni ti on swi tch i s turned to the
Off posi ti on, whi chever occurs fi rst. After twel ve sec-
onds, the cl uster wi l l move the gauge needl e to the
l eft end of the gauge scal e.
• Actuator Test - Each ti me the cl uster i s put
through the actuator test, the gauge needl e wi l l be
swept to several cal i brati on poi nts on the gauge scal e
i n a prescri bed sequence to confi rm the functi onal i ty
of the gauge and the cl uster control ci rcui try.
The PCM conti nual l y moni tors the engi ne cool ant
temperature sensor to determi ne the engi ne operat-
i ng temperature. The PCM then sends the proper
engi ne cool ant temperature messages to the i nstru-
ment cl uster. For further di agnosi s of the engi ne cool -
ant temperature gauge or the i nstrument cl uster
ci rcui try that control s the gauge, (Refer to 8 - ELEC-
TRI CAL/I NSTRUMENT CLUSTER - DI AGNOSI S
AND TESTI NG). I f the i nstrument cl uster turns on
the check gauges i ndi cator due to a hi gh or cri ti cal
engi ne temperature gauge readi ng, i t may i ndi cate
that the engi ne or the engi ne cool i ng system requi res
servi ce. For proper di agnosi s of the engi ne cool ant
temperature sensor, the PCM, the PCI data bus, or
the el ectroni c message i nputs to the i nstrument cl us-
ter that control the engi ne cool ant temperature
gauge, a DRBI I I ௡ scan tool i s requi red. Refer to the
appropri ate di agnosti c i nformati on.
FOG LAMP INDICATOR
DESCRIPTION
A fog l amp i ndi cator i s standard equi pment on al l
i nstrument cl usters, but i s onl y functi onal on vehi -
cl es equi pped wi th the opti onal front and/or rear fog
l amps (Fi g. 13). The fog l amp i ndi cator i s l ocated
near the upper edge of the i nstrument cl uster, to the
l eft of center. The fog l amp i ndi cator consi sts of a
Fig. 13 Fog Lamp Indicator
8J - 26 INSTRUMENT CLUSTER TJ
ENGINE TEMPERATURE GAUGE (Continued)
stenci l -l i ke cutout of the I nternati onal Control and
Di spl ay Symbol i con for “Fog Lamps” i n the opaque
l ayer of the i nstrument cl uster overl ay. The dark
outer l ayer of the overl ay prevents the i ndi cator from
bei ng cl earl y vi si bl e when i t i s not i l l umi nated. A
green Li ght Emi tti ng Di ode (LED) behi nd the cutout
i n the opaque l ayer of the overl ay causes the i con to
appear i n green through the transl ucent outer l ayer
of the overl ay when the i ndi cator i s i l l umi nated from
behi nd by the LED, whi ch i s sol dered onto the
i nstrument cl uster el ectroni c ci rcui t board. The fog
l amp i ndi cator i s servi ced as a uni t wi th the i nstru-
ment cl uster.
OPERATION
The fog l amp i ndi cator gi ves an i ndi cati on to the
vehi cl e operator whenever the opti onal front and/or
rear fog l amps are i l l umi nated. The avai l abi l i ty of
the front fog l amps, or rear fog l amps opti ons vari es
by the market for whi ch the vehi cl e i s manufactured.
Thi s i ndi cator i s control l ed by a hard wi red i nput to
the cl uster from the fog l amp swi tch ci rcui try of the
l eft mul ti -functi on swi tch. The fog l amp i ndi cator
Li ght Emi tti ng Di ode (LED) i s grounded on the
i nstrument cl uster el ectroni c ci rcui t board at al l
ti mes. Therefore, the LED wi l l be on any ti me the
front or rear fog l amps are i l l umi nated, regardl ess of
the i gni ti on swi tch posi ti on. The LED onl y i l l umi -
nates when i t i s provi ded battery current by the fog
l amp swi tch ci rcui try of the l eft mul ti -functi on
swi tch.
The fog l amp swi tch ci rcui try of the l eft mul ti -func-
ti on swi tch i s connected i n seri es between a fused
B(+) fuse i n the Power Di stri buti on Center (PDC)
and the front or rear fog l amp feed i nput to the
i nstrument cl uster through the fog l amp rel ay, whi ch
i s al so i n the PDC. The fog l amp swi tch i nput to the
i nstrument cl uster can be di agnosed usi ng conven-
ti onal di agnosti c tool s and methods. For proper di ag-
nosi s of the fog l amp swi tch and ci rcui ts, (Refer to 8
- ELECTRI CAL/LAMPS/LI GHTI NG - EXTERI OR/
LEFT MULTI -FUNCTI ON SWI TCH - DI AGNOSI S
AND TESTI NG).
DIAGNOSIS AND TESTING - FRONT/REAR FOG
LAMP INDICATOR
The di agnosi s found here addresses an i noperati ve
front/rear fog l amp i ndi cator condi ti on. Before begi n-
ni ng thi s test, confi rm the functi onal i ty of the front
or rear fog l amp system. I f no fog l amp system prob-
l em i s found, the fol l owi ng procedure wi l l hel p to
l ocate an open i n the front or rear fog l amp feed ci r-
cui t between the fog l amp rel ay and the i nstrument
cl uster. Refer to the appropri ate wi ri ng i nformati on.
The wi ri ng i nformati on i ncl udes wi ri ng di agrams,
proper wi re and connector repai r procedures, detai l s
of wi re harness routi ng and retenti on, connector pi n-
out i nformati on and l ocati on vi ews for the vari ous
wi re harness connectors, spl i ces and grounds.
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE SUPPLEMENTAL RESTRAINT SYS-
TEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, AIRBAG, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE BEFORE PERFORMING FURTHER DIAG-
NOSIS OR SERVICE. THIS IS THE ONLY SURE WAY
TO DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT.
(1) Di sconnect and i sol ate the battery negati ve
cabl e. Remove the i nstrument cl uster from the
i nstrument panel . Di sconnect the i nstrument panel
wi re harness connector (Connector C1) for the i nstru-
ment cl uster from the connector receptacl e on the
back of the cl uster housi ng.
(2) Reconnect the battery negati ve cabl e. Turn the
fog l amps on by pul l i ng out the control knob on the
end of the l eft-mul ti -functi on swi tch control stal k.
Check for battery vol tage at the front/rear fog l amp
feed ci rcui t cavi ty of the i nstrument panel wi re har-
ness connector (Connector C1) for the i nstrument
cl uster. I f OK, repl ace the faul ty i nstrument cl uster.
I f not OK, repai r the open front/rear fog l amp feed
ci rcui t between the fog l amp rel ay and the i nstru-
ment cl uster as requi red.
FRONT LOCK INDICATOR
DESCRIPTION
A front l ock i ndi cator i s standard equi pment on al l
i nstrument cl usters, but i s onl y functi onal on vehi -
cl es equi pped wi th the opti onal off-road package (Fi g.
14). The front l ock i ndi cator i s l ocated near the upper
edge of the i nstrument cl uster, to the ri ght of center.
The front l ock i ndi cator consi sts of a stenci l -l i ke cut-
out of the words “FRONT LOCK” i n the opaque l ayer
of the i nstrument cl uster overl ay. The dark outer
l ayer of the overl ay prevents the i ndi cator from bei ng
cl earl y vi si bl e when i t i s not i l l umi nated. A amber
Fig. 14 Front Lock Indicator
TJ INSTRUMENT CLUSTER 8J - 27
FOG LAMP INDICATOR (Continued)
Li ght Emi tti ng Di ode (LED) behi nd the cutout i n the
opaque l ayer of the overl ay causes the “FRONT
LOCK” text to appear i n amber through the transl u-
cent outer l ayer of the overl ay when the i ndi cator i s
i l l umi nated from behi nd by the LED, whi ch i s sol -
dered onto the i nstrument cl uster el ectroni c ci rcui t
board. The i l l umi nati on i ntensi ty of the front l ock
i ndi cator i s one-step di mmabl e. When the exteri or
l i ghti ng i s turned On, the i ndi cator i s di mmed; and,
when the exteri or l i ghti ng i s turned Off, the i ndi cator
i s i l l umi nated at ful l i ntensi ty. The front l ock i ndi ca-
tor i s servi ced as a uni t wi th the i nstrument cl uster.
OPERATION
The front l ock i ndi cator gi ves an i ndi cati on to the
vehi cl e operator of the status of the l ocker mecha-
ni sm i n the front axl e of vehi cl es equi pped wi th the
opti onal off-road package. The front l ock i ndi cator
can al so gi ve an i ndi cati on when certai n faul ts are
detected i n the axl e l ocker system. Thi s i ndi cator i s
control l ed by a transi stor on the i nstrument cl uster
el ectroni c ci rcui t board based upon cl uster program-
mi ng, and hard wi red i nputs to the cl uster from the
key-i n i gni ti on swi tch, the axl e l ock swi tch, and the
front l ocker i ndi cator swi tch. The front l ock i ndi cator
Li ght Emi tti ng Di ode (LED) i s compl etel y control l ed
by the i nstrument cl uster l ogi c ci rcui t, and that l ogi c
wi l l al l ow thi s i ndi cator to operate whenever the
i nstrument cl uster recei ves a battery current i nput
on the fused B(+) ci rcui t. Therefore, the LED can be
i l l umi nated regardl ess of the i gni ti on swi tch posi ti on.
The cl uster can i l l umi nate the LED sol i d, or fl ash i t
on and off at two di fferent rates, sl ow or fast. The
sl ow rate i s about one fl ash per second, whi l e the fast
rate i s about two fl ashes per second. The LED onl y
i l l umi nates when i t i s provi ded a path to ground by
the i nstrument cl uster transi stor. The i nstrument
cl uster wi l l turn on the front l ock i ndi cator for the
fol l owi ng reasons:
• Front Axle Lock Request Input - Each ti me
the cl uster detects ground on the front axl e l ock
request ci rcui t from the axl e l ock swi tch (front axl e
l ock request ci rcui t ground = front axl e l ock request
acti ve) whi l e the key i s i n the i gni ti on l ock cyl i nder,
the front l ock i ndi cator fl ashes on and off at a sl ow
rate. The i ndi cator conti nues to fl ash unti l the front
axl e l ock request i nput to the cl uster i s an open ci r-
cui t (front axl e l ock request ci rcui t open = front axl e
l ock request i nacti ve), or unti l the cl uster detects a
change i n the i nputs from the front l ocker i ndi cator
swi tch or the key-i n i gni ti on swi tch, whi chever occurs
fi rst.
• Front Locker Indicator Switch Input - Each
ti me the cl uster detects ground on the front l ocker
i ndi cator swi tch sense ci rcui t (front l ocker i ndi cator
swi tch cl osed = front axl e l ocker engaged) whi l e the
front axl e l ock request i s acti ve and the key i s i n the
i gni ti on l ock cyl i nder, the front l ock i ndi cator i s i l l u-
mi nated sol i d. The i ndi cator remai ns i l l umi nated
sol i d unti l the front l ocker i ndi cator swi tch i nput to
the cl uster i s an open ci rcui t (front l ocker i ndi cator
swi tch open = front axl e l ocker di sengaged), or unti l
the cl uster detects a change i n the i nputs from the
axl e l ock swi tch or the key-i n i gni ti on swi tch, whi ch-
ever occurs fi rst.
• Front Lock Request/Feedback Mismatch -
Each ti me the cl uster detects that the i nputs from
the axl e l ock swi tch (request) on the front axl e l ock
request ci rcui t and from the front l ocker i ndi cator
swi tch (feedback) on the front l ocker i ndi cator swi tch
sense ci rcui t are mi smatched, the front l ock i ndi cator
fl ashes on and off at a sl ow rate. Thi s condi ti on
occurs when the l ock request i s acti ve but the axl e
l ocker remai ns di sengaged, or when the l ock request
i s i nacti ve but the axl e l ocker remai ns engaged. The
i ndi cator conti nues to fl ash unti l the request and the
feedback are matchi ng.
• Key-In Ignition Switch Input - Each ti me the
cl uster detects that the key has been removed from
the i gni ti on l ock cyl i nder (key-i n i gni ti on swi tch open
= key i s not i n i gni ti on swi tch) whi l e the front axl e
l ock request i s sti l l acti ve, the front l ock i ndi cator
fl ashes at a fast rate and three chi me tones are
sounded. The i ndi cator wi l l conti nue to fl ash at thi s
rate unti l the key i s repl aced i n the i gni ti on l ock cyl -
i nder (key-i n i gni ti on swi tch cl osed = key i s i n i gni -
ti on swi tch) whi l e the front axl e l ock request i s sti l l
acti ve, or unti l the front axl e l ock request i nput i s
deacti vated, whi chever occurs fi rst.
The axl e l ock swi tch i n the accessory swi tch bezel
on the i nstrument panel provi des a hard wi red
ground i nput to the i nstrument cl uster ci rcui try
through the front axl e l ock request ci rcui t whenever
the swi tch i s enabl ed and the rear and front axl e l ock
posi ti on of the swi tch i s sel ected by the vehi cl e oper-
ator. The front l ocker i ndi cator swi tch on the front
axl e housi ng provi des a hard wi red ground i nput to
the i nstrument cl uster whenever the front axl e l ocker
mechani sm i s engaged. The key-i n i gni ti on swi tch
i ntegral to the i gni ti on swi tch provi des a hard wi red
ground i nput to the i nstrument cl uster whenever a
key i s present i n the i gni ti on l ock cyl i nder. Each of
these i nputs to the i nstrument cl uster can be di ag-
nosed usi ng conventi onal di agnosti c tool s and meth-
ods. For further di agnosi s of the i nstrument cl uster
ci rcui try that control s the front l ock i ndi cator LED,
(Refer to 8 - ELECTRI CAL/I NSTRUMENT CLUS-
TER - DI AGNOSI S AND TESTI NG).
8J - 28 INSTRUMENT CLUSTER TJ
FRONT LOCK INDICATOR (Continued)
FUEL GAUGE
DESCRIPTION
A fuel gauge i s standard equi pment on al l i nstru-
ment cl usters. The fuel gauge i s l ocated i n the l ower
l eft quadrant of the i nstrument cl uster, bel ow the
vol tage gauge. The fuel gauge consi sts of a movabl e
gauge needl e or poi nter control l ed by the i nstrument
cl uster ci rcui try and a fi xed 90 degree scal e on the
cl uster overl ay that reads l eft-to-ri ght from “E” (or
Empty) to “F” (or Ful l ). An I nternati onal Control and
Di spl ay Symbol i con for “Fuel ” i s l ocated on the cl us-
ter overl ay, i n the center of the gauge di rectl y above
the hub of the gauge needl e (Fi g. 15). An arrowhead
poi nted toward the l eft si de of the vehi cl e i s
i mpri nted on the cl uster overl ay next to the “Fuel ”
i con i n the fuel gauge to provi de the dri ver wi th a
remi nder as to the l ocati on of the fuel fi l l er access.
The fuel gauge graphi cs are whi te and bl ue agai nst a
bl ack fi el d except for a si ngl e red graduati on at the
l ow end of the gauge scal e, maki ng them cl earl y vi s-
i bl e wi thi n the i nstrument cl uster i n dayl i ght. When
i l l umi nated from behi nd by the panel l amps di mmer
control l ed cl uster i l l umi nati on l i ghti ng wi th the exte-
ri or l amps turned On, the whi te graphi cs appear
whi te, the bl ue graphi cs appear bl ue, and the red
graphi cs appear red. The orange gauge needl e i s
i nternal l y i l l umi nated. Gauge i l l umi nati on i s pro-
vi ded by repl aceabl e i ncandescent bul b and bul b
hol der uni ts l ocated on the i nstrument cl uster el ec-
troni c ci rcui t board. The fuel gauge i s servi ced as a
uni t wi th the i nstrument cl uster.
OPERATION
The fuel gauge gi ves an i ndi cati on to the vehi cl e
operator of the l evel of fuel i n the fuel tank. Thi s
gauge i s control l ed by the i nstrument cl uster ci rcui t
board based upon cl uster programmi ng and el ec-
troni c messages recei ved by the cl uster from the
Powertrai n Control Modul e (PCM) over the Program-
mabl e Communi cati ons I nterface (PCI ) data bus. The
fuel gauge i s an ai r core magneti c uni t that recei ves
battery current on the i nstrument cl uster el ectroni c
ci rcui t board through the fused i gni ti on swi tch out-
put (run-start) ci rcui t whenever the i gni ti on swi tch i s
i n the On or Start posi ti ons. The cl uster i s pro-
grammed to move the gauge needl e back to the l ow
end of the scal e after the i gni ti on swi tch i s turned to
the Off posi ti on. The i nstrument cl uster ci rcui try
control s the gauge needl e posi ti on and provi des the
fol l owi ng features:
• Percent Tank Full Message - Each ti me the
cl uster recei ves a message from the PCM i ndi cati ng
the percent tank ful l , the cl uster programmi ng
appl i es an al gori thm to cal cul ate the proper gauge
needl e posi ti on, then moves the gauge needl e to the
proper rel ati ve posi ti on on the gauge scal e. The al go-
ri thm i s used to dampen gauge needl e movement
agai nst the negati ve effect that fuel sl oshi ng wi thi n
the fuel tank can have on accurate i nputs from the
fuel tank sendi ng uni t to the PCM.
• Less Than 12.5 Percent Tank Full Message -
Each ti me the cl uster recei ves a message from the
PCM i ndi cati ng that the percent tank ful l i s l ess
than about 12.5 (one-ei ghth), the gauge needl e i s
moved to the proper posi ti on on the gauge scal e, the
l ow fuel i ndi cator i s i l l umi nated, and a si ngl e chi me
tone i s sounded. The l ow fuel i ndi cator remai ns i l l u-
mi nated unti l the cl uster recei ves messages from the
PCM for a conti nuous twenty seconds i ndi cati ng that
the percent tank ful l has i ncreased by more than
0.625 gal l ons or unti l the i gni ti on swi tch i s turned to
the Off posi ti on, whi chever occurs fi rst. The chi me
tone feature wi l l occur onl y once per i gni ti on cycl e.
• Less Than Empty Percent Tank Full Mes-
sage - Each ti me the cl uster recei ves a message from
the PCM i ndi cati ng that the percent tank ful l i s l ess
than empty, the gauge needl e i s moved to the far l eft
end of the gauge scal e and the l ow fuel i ndi cator i s
i l l umi nated i mmedi atel y. Thi s message woul d i ndi -
cate that the fuel tank sender i nput to the PCM i s a
short ci rcui t.
• More Than Full Percent Tank Full Message
- Each ti me the cl uster recei ves a message from the
PCM i ndi cati ng the percent tank ful l i s more than
ful l , the gauge needl e i s moved to the far l eft end of
the gauge scal e and the l ow fuel i ndi cator i s i l l umi -
nated i mmedi atel y. Thi s message woul d i ndi cate that
the fuel tank sender i nput to the PCM i s an open ci r-
cui t.
• Communication Error - I f the cl uster fai l s to
recei ve a percent tank ful l message, i t wi l l hol d the
gauge needl e at the l ast i ndi cati on about twel ve sec-
onds or unti l the i gni ti on swi tch i s turned to the Off
posi ti on, whi chever occurs fi rst. After twel ve seconds,
the cl uster wi l l move the gauge needl e to the l eft end
of the gauge scal e and the l ow fuel i ndi cator i s i l l u-
mi nated i mmedi atel y.
• Actuator Test - Each ti me the cl uster i s put
through the actuator test, the gauge needl e wi l l be
swept to several cal i brati on poi nts on the gauge scal e
i n a prescri bed sequence to confi rm the functi onal i ty
of the gauge and the cl uster control ci rcui try.
The PCM conti nual l y moni tors the fuel tank send-
i ng uni t to determi ne the l evel of the fuel i n the fuel
Fig. 15 Fuel Gauge Icon
TJ INSTRUMENT CLUSTER 8J - 29
tank. The PCM then sends the proper fuel l evel mes-
sages to the i nstrument cl uster. For further di agnosi s
of the fuel gauge or the i nstrument cl uster ci rcui try
that control s the gauge, (Refer to 8 - ELECTRI CAL/
I NSTRUMENT CLUSTER - DI AGNOSI S AND
TESTI NG). For proper di agnosi s of the fuel tank
sendi ng uni t, the PCM, the PCI data bus, or the el ec-
troni c message i nputs to the i nstrument cl uster that
control the fuel gauge, a DRBI I I ௡ scan tool i s
requi red. Refer to the appropri ate di agnosti c i nfor-
mati on.
HIGH BEAM INDICATOR
DESCRIPTION
A hi gh beam i ndi cator i s standard equi pment on
al l i nstrument cl usters (Fi g. 16). The hi gh beam i ndi -
cator i s l ocated near the upper edge of the i nstru-
ment cl uster, between the tachometer and the
speedometer. The hi gh beam i ndi cator consi sts of a
stenci l -l i ke cutout of the I nternati onal Control and
Di spl ay Symbol i con for “Hi gh Beam” i n the opaque
l ayer of the i nstrument cl uster overl ay. The dark
outer l ayer of the overl ay prevents the i ndi cator from
bei ng cl earl y vi si bl e when i t i s not i l l umi nated. A
bl ue l ens behi nd the cutout i n the opaque l ayer of
the overl ay causes the i con to appear i n bl ue through
the transl ucent outer l ayer of the overl ay when the
i ndi cator i s i l l umi nated from behi nd by a repl aceabl e
i ncandescent bul b and bul b hol der uni t, whi ch i s
l ocated on the i nstrument cl uster el ectroni c ci rcui t
board. The hi gh beam i ndi cator i s servi ced as a uni t
wi th the i nstrument cl uster.
OPERATION
The hi gh beam i ndi cator gi ves an i ndi cati on to the
vehi cl e operator whenever the headl amp hi gh beams
are i l l umi nated, or when the exteri or l amps are i nad-
vertentl y l eft On. Thi s i ndi cator i s control l ed by a
hard wi red i nput to the cl uster from the headl amp
beam sel ect swi tch ci rcui try of the l eft mul ti -functi on
swi tch, and by the i nstrument cl uster ci rcui t board
based upon cl uster programmi ng based upon hard
wi red i nputs from the head/park/fog l amp swi tch ci r-
cui try of the l eft mul ti -functi on swi tch, from the
dri ver door ajar swi tch, and from the i gni ti on swi tch.
The hi gh beam i ndi cator bul b i s compl etel y control l ed
by the i nstrument cl uster l ogi c ci rcui t, and that l ogi c
wi l l al l ow thi s i ndi cator to operate whenever the
i nstrument cl uster recei ves a battery current i nput
on the fused B(+) ci rcui t. Therefore, the bul b can be
i l l umi nated regardl ess of the i gni ti on swi tch posi ti on.
The bul b onl y i l l umi nates when i t i s provi ded a path
to ground by the i nstrument cl uster transi stor. The
i nstrument cl uster wi l l turn on the hi gh beam i ndi -
cator for the fol l owi ng reasons:
• Beam Select Switch Input - Each ti me the
cl uster detects battery current on the beam sel ect
swi tch sense ci rcui t (beam sel ect swi tch cl osed = hi gh
beams sel ected or opti cal horn feature acti vated) the
hi gh beam i ndi cator wi l l be i l l umi nated sol i d. Thi s
i nput can occur when the headl amp hi gh beams are
sel ected or when the opti cal horn feature i s acti vated.
The i ndi cator remai ns i l l umi nated unti l the beam
sel ect swi tch sense i nput to the cl uster i s an open ci r-
cui t (beam sel ect swi tch open = hi gh beams not
sel ected and opti cal horn feature not acti vated), or
unti l the exteri or l i ghti ng i s turned off, whi chever
occurs fi rst.
• Exterior Lamps-On Optical Warning - Each
ti me the cl uster detects battery current on the head-
l amp swi tch output ci rcui t (park or head l amp swi tch
cl osed = exteri or l i ghti ng i s On), ground on the dri ver
door ajar swi tch sense ci rcui t (dri ver door ajar swi tch
cl osed = dri ver door i s open), and the fused i gni ti on
swi tch output (run-start) i nput i s an open ci rcui t
(i gni ti on swi tch i s i n a posi ti on other than On or
Start), the hi gh beam i ndi cator wi l l be fl ashed on
and off repeatedl y. The i ndi cator wi l l conti nue to
fl ash unti l the exteri or l i ghti ng i s turned Off, unti l
the dri ver door i s cl osed, or unti l the i gni ti on swi tch
i s turned to the On or Start posi ti ons, whi chever
occurs fi rst.
• Actuator Test - Each ti me the cl uster i s put
through the actuator test, the hi gh beam i ndi cator
wi l l be turned on, then off agai n duri ng the bul b
check porti on of the test to confi rm the functi onal i ty
of the bul b and the cl uster control ci rcui try.
The i nstrument cl uster conti nual l y moni tors the
headl amp beam sel ect swi tch and ci rcui try i ntegral
to the l eft mul ti -functi on swi tch, the dri ver door ajar
swi tch, and the i gni ti on swi tch and turns the hi gh
beam i ndi cator on or off accordi ngl y. For further
di agnosi s of the hi gh beam i ndi cator or the i nstru-
ment cl uster ci rcui try that control s the i ndi cator,
(Refer to 8 - ELECTRI CAL/I NSTRUMENT CLUS-
TER - DI AGNOSI S AND TESTI NG). The l eft mul ti -
functi on swi tch, dri ver door ajar swi tch, and i gni ti on
swi tch i nputs to the i nstrument cl uster can be di ag-
nosed usi ng conventi onal di agnosti c tool s and meth-
ods.
DIAGNOSIS AND TESTING - HIGH BEAM
INDICATOR
The di agnosi s found here addresses an i noperati ve
hi gh beam i ndi cator condi ti on. Before begi nni ng thi s
test, confi rm the functi onal i ty of the hi gh beam i ndi -
Fig. 16 High Beam Indicator
8J - 30 INSTRUMENT CLUSTER TJ
FUEL GAUGE (Continued)
cator bul b and the cl uster control ci rcui try by per-
formi ng the i nstrument cl uster actuator test. (Refer
to 8 - ELECTRI CAL/I NSTRUMENT CLUSTER -
DI AGNOSI S AND TESTI NG). I f the hi gh beam i ndi -
cator fai l s to i l l umi nate duri ng the actuator test,
repl ace the i ndi cator bul b and bul b hol der wi th a
known good uni t and repeat the test. I f the i ndi cator
sti l l fai l s to i l l umi nate, repl ace the faul ty i nstrument
cl uster. I f the probl em bei ng di agnosed i s rel ated to
i noperati ve headl amp hi gh beams, be certai n to
repai r the headl amp system ci rcui ts and swi tches
before attempti ng to di agnose or repai r the hi gh
beam i ndi cator. I f no headl amp system probl ems are
found and the hi gh beam i ndi cator i l l umi nates dur-
i ng the i nstrument cl uster actuator test, the fol l ow-
i ng procedure wi l l hel p l ocate an open i n the hi gh
beam i ndi cator dri ver ci rcui t. Refer to the appropri -
ate wi ri ng i nformati on. The wi ri ng i nformati on
i ncl udes wi ri ng di agrams, proper wi re and connector
repai r procedures, detai l s of wi re harness routi ng
and retenti on, connector pi n-out i nformati on and
l ocati on vi ews for the vari ous wi re harness connec-
tors, spl i ces and grounds.
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE SUPPLEMENTAL RESTRAINT SYS-
TEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, AIRBAG, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE BEFORE PERFORMING FURTHER DIAG-
NOSIS OR SERVICE. THIS IS THE ONLY SURE WAY
TO DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT.
(1) Di sconnect and i sol ate the battery negati ve
cabl e. Remove the i nstrument cl uster from the
i nstrument panel . Di sconnect the i nstrument panel
wi re harness connector (Connector C1) for the i nstru-
ment cl uster from the connector receptacl e on the
back of the cl uster housi ng.
(2) Reconnect the battery negati ve cabl e. Turn the
headl amps On and sel ect the headl amp hi gh beams
wi th the l eft mul ti -functi on swi tch control stal k.
Check for battery vol tage at the hi gh beam i ndi cator
dri ver ci rcui t cavi ty of the i nstrument panel wi re
harness connector (Connector C1) for the i nstrument
cl uster. I f OK, repl ace the faul ty i nstrument cl uster.
I f not OK, repai r the open hi gh beam i ndi cator dri ver
ci rcui t between the i nstrument cl uster and the l eft
mul ti -functi on swi tch as requi red.
LOW FUEL INDICATOR
DESCRIPTION
A l ow fuel i ndi cator i s standard equi pment on al l
i nstrument cl usters (Fi g. 17). The l ow fuel i ndi cator
i s l ocated near the l ower edge of the i nstrument cl us-
ter, to the l eft of center. The l ow fuel i ndi cator con-
si sts of a stenci l -l i ke cutout of the I nternati onal
Control and Di spl ay Symbol i con for “Fuel ” i n the
opaque l ayer of the i nstrument cl uster overl ay. The
dark outer l ayer of the overl ay prevents the i ndi cator
from bei ng cl earl y vi si bl e when i t i s not i l l umi nated.
An amber Li ght Emi tti ng Di ode (LED) behi nd the
cutout i n the opaque l ayer of the overl ay causes the
i con to appear i n amber through the transl ucent
outer l ayer of the overl ay when the i ndi cator i s i l l u-
mi nated from behi nd by the LED, whi ch i s sol dered
onto the i nstrument cl uster el ectroni c ci rcui t board.
The l ow fuel i ndi cator i s servi ced as a uni t wi th the
i nstrument cl uster.
OPERATION
The l ow fuel i ndi cator gi ves an i ndi cati on to the
vehi cl e operator when the l evel of fuel i n the fuel
tank becomes l ow. Thi s i ndi cator i s control l ed by a
transi stor on the i nstrument cl uster ci rcui t board
based upon cl uster programmi ng and el ectroni c mes-
sages recei ved by the cl uster from the Powertrai n
Control Modul e (PCM) over the Programmabl e Com-
muni cati ons I nterface (PCI ) data bus. The l ow fuel
i ndi cator Li ght Emi tti ng Di ode (LED) i s compl etel y
control l ed by the i nstrument cl uster l ogi c ci rcui t, and
that l ogi c wi l l onl y al l ow thi s i ndi cator to operate
when the i nstrument cl uster recei ves a battery cur-
rent i nput on the fused i gni ti on swi tch output (run-
start) ci rcui t. Therefore, the LED wi l l al ways be off
when the i gni ti on swi tch i s i n any posi ti on except On
or Start. The LED onl y i l l umi nates when i t i s pro-
vi ded a path to ground by the i nstrument cl uster
transi stor. The i nstrument cl uster wi l l turn on the
l ow fuel i ndi cator for the fol l owi ng reasons:
• Bulb Test - Each ti me the i gni ti on swi tch i s
turned to the On posi ti on the i ndi cator i s i l l umi nated
for about two seconds as a bul b test.
• Less Than 12.5 Percent Tank Full Message -
Each ti me the cl uster recei ves a message from the
PCM i ndi cati ng that the percent tank ful l i s l ess
than 12.5 (one-ei ghth), the l ow fuel i ndi cator i s i l l u-
mi nated and a si ngl e chi me tone i s sounded. The l ow
fuel i ndi cator remai ns i l l umi nated unti l the cl uster
recei ves messages from the PCM for a conti nuous
twenty seconds i ndi cati ng that the percent tank ful l
Fig. 17 Low Fuel Indicator
TJ INSTRUMENT CLUSTER 8J - 31
HIGH BEAM INDICATOR (Continued)
has i ncreased by more than 0.625 gal l ons or unti l the
i gni ti on swi tch i s turned to the Off posi ti on, whi ch-
ever occurs fi rst. Thi s strategy i s i ntended to reduce
the effect that fuel sl oshi ng wi thi n the fuel tank can
have on rel i abl e i ndi cati ons. The chi me tone feature
wi l l occur onl y once per i gni ti on cycl e.
• Less Than Empty Percent Tank Full Mes-
sage - Each ti me the cl uster recei ves a message from
the PCM i ndi cati ng the percent tank ful l i s l ess than
empty, the l ow fuel i ndi cator i s i l l umi nated i mmedi -
atel y. Thi s message woul d i ndi cate that the fuel tank
sender i nput to the PCM i s a short ci rcui t.
• More Than Full Percent Tank Full Message
- Each ti me the cl uster recei ves a message from the
PCM i ndi cati ng the percent tank ful l i s more than
ful l , the l ow fuel i ndi cator i s i l l umi nated i mmedi -
atel y. Thi s message woul d i ndi cate that the fuel tank
sender i nput to the PCM i s an open ci rcui t.
• Actuator Test - Each ti me the cl uster i s put
through the actuator test, the l ow fuel i ndi cator wi l l
be turned on, then off agai n duri ng the bul b check
porti on of the test to confi rm the functi onal i ty of the
LED and the cl uster control ci rcui try.
The PCM conti nual l y moni tors the fuel tank send-
i ng uni t to determi ne the l evel of fuel i n the fuel
tank. The PCM then sends the proper fuel l evel mes-
sages to the i nstrument cl uster. For further di agnosi s
of the l ow fuel i ndi cator or the i nstrument cl uster ci r-
cui try that control s the LED, (Refer to 8 - ELECTRI -
CAL/I NSTRUMENT CLUSTER - DI AGNOSI S AND
TESTI NG). For proper di agnosi s of the fuel tank
sendi ng uni t, the PCM, the PCI data bus, or the el ec-
troni c message i nputs to the i nstrument cl uster that
control the l ow fuel i ndi cator, a DRBI I I ௡ scan tool i s
requi red. Refer to the appropri ate di agnosti c i nfor-
mati on.
MALFUNCTION INDICATOR
LAMP (MIL)
DESCRIPTION
A Mal functi on I ndi cator Lamp (MI L) i s standard
equi pment on al l i nstrument cl usters (Fi g. 18). The
MI L i s l ocated near the l ower edge of the i nstrument
cl uster, to the ri ght of center. The MI L consi sts of a
stenci l -l i ke cutout of the I nternati onal Control and
Di spl ay Symbol i con for “Engi ne” i n the opaque l ayer
of the i nstrument cl uster overl ay. The dark outer
l ayer of the overl ay prevents the i ndi cator from bei ng
cl earl y vi si bl e when i t i s not i l l umi nated. An amber
Li ght Emi tti ng Di ode (LED) behi nd the cutout i n the
opaque l ayer of the overl ay causes the i con to appear
i n amber through the transl ucent outer l ayer of the
overl ay when the i ndi cator i s i l l umi nated from
behi nd by the LED, whi ch i s sol dered onto the
i nstrument cl uster el ectroni c ci rcui t board. The MI L
i s servi ced as a uni t wi th the i nstrument cl uster.
OPERATION
The Mal functi on I ndi cator Lamp (MI L) gi ves an
i ndi cati on to the vehi cl e operator when the Power-
trai n Control Modul e (PCM) has recorded a Di agnos-
ti c Troubl e Code (DTC) for an On-Board Di agnosti cs
I I (OBDI I ) emi ssi ons-rel ated ci rcui t or component
mal functi on. The MI L i s control l ed by a transi stor on
the i nstrument cl uster ci rcui t board based upon cl us-
ter programmi ng and el ectroni c messages recei ved by
the cl uster from the PCM over the Programmabl e
Communi cati ons I nterface (PCI ) data bus. The MI L
Li ght Emi tti ng Di ode (LED) i s compl etel y control l ed
by the i nstrument cl uster l ogi c ci rcui t, and that l ogi c
wi l l onl y al l ow thi s i ndi cator to operate when the
i nstrument cl uster recei ves a battery current i nput
on the fused i gni ti on swi tch output (run-start) ci r-
cui t. Therefore, the LED wi l l al ways be off when the
i gni ti on swi tch i s i n any posi ti on except On or Start.
The LED onl y i l l umi nates when i t i s provi ded a path
to ground by the i nstrument cl uster transi stor. The
i nstrument cl uster wi l l turn on the MI L for the fol -
l owi ng reasons:
• Bulb Test - Each ti me the i gni ti on swi tch i s
turned to the On posi ti on the i ndi cator i s i l l umi nated
for about seven seconds as a bul b test. The enti re
two seven second bul b test i s a functi on of the PCM.
• MIL Lamp-On Message - Each ti me the cl us-
ter recei ves a MI L l amp-on message from the PCM,
the i ndi cator wi l l be i l l umi nated. The i ndi cator can
be fl ashed on and off, or i l l umi nated sol i d, as di c-
tated by the PCM message. For some DTC’s, i f a
probl em does not recur, the PCM wi l l send a l amp-off
message automati cal l y. Other DTC’s may requi re
that a faul t be repai red and the PCM be reset before
a l amp-off message wi l l be sent. For more i nforma-
ti on on the PCM and the DTC set and reset param-
eters, (Refer to 25 - EMI SSI ONS CONTROL -
OPERATI ON).
• Communication Error - I f the cl uster recei ves
no l amp-on or l amp-off message from the PCM for
twenty seconds, the MI L i s i l l umi nated by the i nstru-
ment cl uster and a “no BuS” message wi l l appear i n
the odometer/tri p odometer Vacuum Fl uorescent Di s-
pl ay (VFD) uni t to i ndi cate a l oss of bus communi ca-
ti on. The i ndi cator remai ns control l ed and
i l l umi nated by the cl uster unti l a val i d l amp-on or
l amp-off message i s recei ved from the PCM.
Fig. 18 Malfunction Indicator Lamp (MIL)
8J - 32 INSTRUMENT CLUSTER TJ
LOW FUEL INDICATOR (Continued)
• Actuator Test - Each ti me the cl uster i s put
through the actuator test, the MI L wi l l be turned on,
then off agai n duri ng the bul b check porti on of the
test to confi rm the functi onal i ty of the LED and the
cl uster control ci rcui try.
The PCM conti nual l y moni tors the fuel and emi s-
si ons system ci rcui ts and sensors to deci de whether
the system i s i n good operati ng condi ti on. The PCM
then sends the proper l amp-on or l amp-off messages
to the i nstrument cl uster. For further di agnosi s of
the MI L or the i nstrument cl uster ci rcui try that con-
trol s the LED, (Refer to 8 - ELECTRI CAL/I NSTRU-
MENT CLUSTER - DI AGNOSI S AND TESTI NG). I f
the i nstrument cl uster turns on the MI L after the
bul b test, i t may i ndi cate that a mal functi on has
occurred and that the fuel and emi ssi ons system may
requi re servi ce. For proper di agnosi s of the fuel and
emi ssi ons systems, the PCM, the PCI data bus, or
the el ectroni c message i nputs to the i nstrument cl us-
ter that control the MI L, a DRBI I I ௡ scan tool i s
requi red. Refer to the appropri ate di agnosti c i nfor-
mati on.
ODOMETER
DESCRIPTION
An odometer and tri p odometer are standard
equi pment i n al l i nstrument cl usters (Fi g. 19). The
odometer and tri p odometer i nformati on are di s-
pl ayed i n a common el ectroni c, bl ue-green Vacuum
Fl uorescent Di spl ay (VFD). The VFD i s sol dered onto
the cl uster el ectroni c ci rcui t board and i s vi si bl e
through a wi ndow wi th a smoked cl ear l ens l ocated
near the l ower edge of the cl uster overl ay between
the tachometer and speedometer. The dark l ens over
the VFD prevents i t from bei ng cl earl y vi si bl e when
i t i s not i l l umi nated. However, the odometer, and tri p
odometer i nformati on are not di spl ayed si mul ta-
neousl y. The tri p odometer reset swi tch on the
i nstrument cl uster ci rcui t board toggl es the di spl ay
between odometer and tri p odometer modes by
depressi ng the odometer/tri p odometer swi tch button
that extends through the l ower edge of the cl uster
l ens, just ri ght of the odometer VFD.
The odometer and tri p odometer i nformati on i s
stored i n the i nstrument cl uster memory. Thi s i nfor-
mati on can be i ncreased when the proper i nputs are
provi ded to the i nstrument cl uster, but the i nforma-
ti on cannot be decreased. The odometer can di spl ay
val ues up to 999,999 ki l ometers (999,999 mi l es). The
odometer l atches at these val ues, and wi l l not rol l
over to zero. The tri p odometer can di spl ay val ues up
to 9,999.9 ki l ometers (9,999.9 mi l es) before i t rol l s
over to zero. The odometer di spl ay does not have a
deci mal poi nt and wi l l not show val ues l ess than a
ful l uni t (ki l ometer or mi l e), whi l e the tri p odometer
di spl ay does have a deci mal poi nt and wi l l show
tenths of a uni t (ki l ometer or mi l e). The uni t of mea-
sure (ki l ometers or mi l es) for the odometer and tri p
odometer di spl ay i s not shown i n the VFD. The uni t
of measure for the i nstrument cl uster odometer/tri p
odometer i s sel ected at the ti me that i t i s manufac-
tured, and cannot be changed. I f the i nstrument cl us-
ter has a speedometer wi th a pri mary scal e i n
ki l ometers-per-hour, the l etters “KM” are pri nted on
the cl uster mask next to the VFD wi ndow to i ndi cate
the odometer uni t of measure.
The odometer has a “Rental Car” mode, whi ch wi l l
i l l umi nate the odometer i nformati on i n the VFD
whenever the dri ver si de front door i s opened wi th
the i gni ti on swi tch i n the Off or Accessory posi ti ons.
Duri ng dayl i ght hours (exteri or l amps are Off) the
VFD i s i l l umi nated at ful l bri ghtness for cl ear vi si bi l -
i ty. At ni ght (exteri or l amps are On) the VFD l i ghti ng
l evel i s adjusted wi th the other cl uster i l l umi nati on
l amps usi ng the panel l amps di mmer control ri ng on
the control stal k of the l eft mul ti -functi on swi tch.
However, a “Parade” mode posi ti on of the panel
l amps di mmer control ri ng al l ows the VFD to be i l l u-
mi nated at ful l bri ghtness i f the exteri or l amps are
turned On duri ng dayl i ght hours.
The VFD, the tri p odometer swi tch, and the tri p
odometer swi tch button are servi ced as a uni t wi th
the i nstrument cl uster. The rubber tri p odometer
reset knob boot that seal s the hol e i n the cl uster l ens
through whi ch the reset knob protrudes i s avai l abl e
for i ndi vi dual servi ce repl acement.
OPERATION
The odometer and tri p odometer gi ve an i ndi cati on
to the vehi cl e operator of the di stance the vehi cl e has
travel ed. Thi s i ndi cator i s control l ed by the i nstru-
ment cl uster ci rcui try based upon cl uster program-
mi ng and el ectroni c messages recei ved by the cl uster
from the Powertrai n Control Modul e (PCM) over the
Programmabl e Communi cati ons I nterface (PCI ) data
bus. The odometer and tri p odometer i nformati on i s
di spl ayed by the i nstrument cl uster Vacuum Fl uores-
cent Di spl ay (VFD). The VFD wi l l di spl ay the odom-
eter i nformati on whenever the dri ver door i s opened
wi th the i gni ti on swi tch i n the Off or Accessory posi -
ti ons, and wi l l di spl ay the l ast previ ousl y sel ected
odometer or tri p odometer i nformati on when the i gni -
ti on swi tch i s turned to the On or Start posi ti ons.
The i nstrument cl uster ci rcui try control s the VFD
and provi des the fol l owi ng features:
Fig. 19 Odometer Display
TJ INSTRUMENT CLUSTER 8J - 33
MALFUNCTION INDICATOR LAMP (MIL) (Continued)
• Odometer/Trip Odometer Display Toggling -
Actuati ng the tri p odometer reset swi tch button
momentari l y wi th the VFD i l l umi nated wi l l toggl e
the di spl ay between the odometer and tri p odometer
i nformati on. Each ti me the VFD i s i l l umi nated wi th
the i gni ti on swi tch i n the On or Start posi ti ons, the
di spl ay wi l l automati cal l y return to the l ast mode
previ ousl y sel ected (odometer or tri p odometer).
• Trip Odometer Reset - When the tri p odome-
ter reset swi tch button i s pressed and hel d for l onger
than about two seconds wi th the i gni ti on swi tch i n
the On or Start posi ti ons, tri p odometer wi l l be reset
to 0.0 ki l ometers (mi l es). The VFD must be di spl ay-
i ng the tri p odometer i nformati on i n order for the
tri p odometer i nformati on to be reset.
• Communication Error - I f the cl uster fai l s to
recei ve a di stance message duri ng normal operati on,
i t wi l l hol d and di spl ay the l ast data recei ved unti l
the i gni ti on swi tch i s turned to the Off posi ti on. I f
the cl uster does not recei ve a di stance message
wi thi n one second after the i gni ti on swi tch i s turned
to the On posi ti on, i t wi l l di spl ay the l ast di stance
message stored i n the cl uster memory. I f the cl uster
i s unabl e to di spl ay di stance i nformati on due to an
error i nternal to the cl uster, ei ther “888888”wi l l be
di spl ayed i n the VFD or the VFD wi l l be bl ank.
• Actuator Test - Each ti me the cl uster i s put
through the actuator test, the number “8” wi l l be
scrol l ed across the VFD from ri ght-to-l eft, then the
tri p odometer deci mal poi nt “.” wi l l be i l l umi nated i n
order to confi rm the functi onal i ty of each of the VFD
segments and the cl uster control ci rcui try.
The PCM conti nual l y moni tors the vehi cl e speed
pul se i nformati on recei ved from the vehi cl e speed
sensor, then sends the proper di stance messages to
the i nstrument cl uster. For further di agnosi s of the
odometer/tri p odometer or the i nstrument cl uster ci r-
cui try that control s these functi ons, (Refer to 8 -
ELECTRI CAL/I NSTRUMENT CLUSTER - DI AGNO-
SI S AND TESTI NG). For proper di agnosi s of the
vehi cl e speed sensor, the PCM, the PCI data bus, or
the el ectroni c message i nputs to the i nstrument cl us-
ter that control the odometer/tri p odometer, a
DRBI I I ௡ scan tool i s requi red. Refer to the appropri -
ate di agnosti c i nformati on.
OIL PRESSURE GAUGE
DESCRIPTION
An oi l pressure gauge i s standard equi pment on al l
i nstrument cl usters. The oi l pressure gauge i s l ocated
i n the upper ri ght quadrant of the i nstrument cl us-
ter, above the engi ne cool ant temperature gauge. The
oi l pressure gauge consi sts of a movabl e gauge needl e
or poi nter control l ed by the i nstrument cl uster ci r-
cui try and a fi xed 90 degree scal e on the cl uster over-
l ay that reads l eft-to-ri ght from “L” (or Low) to “H”
(or Hi gh). An I nternati onal Control and Di spl ay Sym-
bol i con for “Engi ne Oi l ” i s l ocated on the cl uster
overl ay, i n the center of the gauge di rectl y above the
hub of the gauge needl e (Fi g. 20). The oi l pressure
gauge graphi cs are whi te and bl ue agai nst a bl ack
fi el d, maki ng them cl earl y vi si bl e wi thi n the i nstru-
ment cl uster i n dayl i ght. When i l l umi nated from
behi nd by the panel l amps di mmer control l ed cl uster
i l l umi nati on l i ghti ng wi th the exteri or l amps turned
On, the whi te graphi cs appear whi te, and the bl ue
graphi cs appear bl ue. The orange gauge needl e i s
i nternal l y i l l umi nated. Gauge i l l umi nati on i s pro-
vi ded by repl aceabl e i ncandescent bul b and bul b
hol der uni ts l ocated on the i nstrument cl uster el ec-
troni c ci rcui t board. The oi l pressure gauge i s ser-
vi ced as a uni t wi th the i nstrument cl uster.
OPERATION
The oi l pressure gauge gi ves an i ndi cati on to the
vehi cl e operator of the engi ne oi l pressure. Thi s
gauge i s control l ed by the i nstrument cl uster ci rcui t
board based upon cl uster programmi ng and el ec-
troni c messages recei ved by the cl uster from the
Powertrai n Control Modul e (PCM) over the Program-
mabl e Communi cati ons I nterface (PCI ) data bus. The
oi l pressure gauge i s an ai r core magneti c uni t that
recei ves battery current on the i nstrument cl uster
el ectroni c ci rcui t board through the fused i gni ti on
swi tch output (run-start) ci rcui t whenever the i gni -
ti on swi tch i s i n the On or Start posi ti ons. The cl us-
ter i s programmed to move the gauge needl e back to
the l ow end of the scal e after the i gni ti on swi tch i s
turned to the Off posi ti on. The i nstrument cl uster
ci rcui try control s the gauge needl e posi ti on and pro-
vi des the fol l owi ng features:
• Engine Oil Pressure Message - Each ti me the
cl uster recei ves a message from the PCM i ndi cati ng
the engi ne oi l pressure of a 2.4L engi ne i s above
about 0.2 kg/cm
2
(3 psi ), or of any engi ne other than
a 2.4L i s above about 0.4 kg/cm
2
(6 psi ), the cl uster
moves the gauge needl e to the mi ddl e of the normal
range on the gauge scal e to represent the engi ne oi l
pressure. The gauge needl e wi l l conti nue to be posi -
ti oned at the mi ddl e of normal range on the gauge
scal e unti l the cl uster recei ves a message from the
PCM that i ndi cates the engi ne oi l pressure i s l ow, or
unti l the i gni ti on swi tch i s turned to the Off posi ti on,
whi chever occurs fi rst.
• Engine Oil Pressure Low Message - Each
ti me the cl uster recei ves a message from the PCM
i ndi cati ng the engi ne oi l pressure of a 2.4L engi ne i s
Fig. 20 Engine Oil Icon
8J - 34 INSTRUMENT CLUSTER TJ
ODOMETER (Continued)
bel ow about 0.2 kg/cm
2
(3 psi ), or of any engi ne other
than a 2.4L i s bel ow about 0.4 kg/cm
2
(6 psi ), the
gauge needl e i s moved to the graduati on at the far
l eft (l ow) end of the gauge scal e, the check gauges
i ndi cator i s i l l umi nated, and a si ngl e chi me tone i s
generated. The gauge needl e remai ns at the l eft end
of the gauge scal e and the check gauges i ndi cator
remai ns i l l umi nated unti l the cl uster recei ves a mes-
sage from the PCM i ndi cati ng that the engi ne oi l
pressure of a 2.4L engi ne i s above about 0.2 kg/cm
2
(3 psi ), or of any engi ne other than a 2.4L i s above
about 0.4 kg/cm
2
(6 psi ), or unti l the i gni ti on swi tch
i s turned to the Off posi ti on, whi chever occurs fi rst.
The cl uster wi l l onl y turn the check gauges i ndi cator
on i n response to an engi ne oi l pressure l ow message
i f the engi ne speed message i s 300 rpm or greater for
more than about fi ve seconds.
• Communication Error - I f the cl uster fai l s to
recei ve an engi ne oi l pressure message, i t wi l l hol d
the gauge needl e at the l ast i ndi cati on about twel ve
seconds or unti l the i gni ti on swi tch i s turned to the
Off posi ti on, whi chever occurs fi rst. After twel ve sec-
onds, the cl uster wi l l move the gauge needl e to the
l eft end of the gauge scal e.
• Actuator Test - Each ti me the cl uster i s put
through the actuator test, the gauge needl e wi l l be
swept to several cal i brati on poi nts on the gauge scal e
i n a prescri bed sequence to confi rm the functi onal i ty
of the gauge and the cl uster control ci rcui try.
The PCM conti nual l y moni tors the engi ne oi l pres-
sure sensor to determi ne the engi ne oi l pressure. The
PCM then sends the proper engi ne oi l pressure mes-
sages to the i nstrument cl uster. For further di agnosi s
of the oi l pressure gauge or the i nstrument cl uster
ci rcui try that control s the gauge, (Refer to 8 - ELEC-
TRI CAL/I NSTRUMENT CLUSTER - DI AGNOSI S
AND TESTI NG). I f the i nstrument cl uster turns on
the check gauges i ndi cator due to a l ow oi l pressure
gauge readi ng, i t may i ndi cate that the engi ne or the
engi ne oi l i ng system requi res servi ce. For proper
di agnosi s of the engi ne oi l pressure sensor, the PCM,
the PCI data bus, or the el ectroni c message i nputs to
the i nstrument cl uster that control the oi l pressure
gauge, a DRBI I I ௡ scan tool i s requi red. Refer to the
appropri ate di agnosti c i nformati on.
REAR LOCK INDICATOR
DESCRIPTION
A rear l ock i ndi cator i s standard equi pment on al l
i nstrument cl usters, but i s onl y functi onal on vehi -
cl es equi pped wi th the opti onal off-road package (Fi g.
21). The rear l ock i ndi cator i s l ocated near the upper
edge of the i nstrument cl uster, to the ri ght of center.
The rear l ock i ndi cator consi sts of a stenci l -l i ke cut-
out of the words “REAR LOCK” i n the opaque l ayer
of the i nstrument cl uster overl ay. The dark outer
l ayer of the overl ay prevents the i ndi cator from bei ng
cl earl y vi si bl e when i t i s not i l l umi nated. A amber
Li ght Emi tti ng Di ode (LED) behi nd the cutout i n the
opaque l ayer of the overl ay causes the “REAR LOCK”
text to appear i n amber through the transl ucent
outer l ayer of the overl ay when the i ndi cator i s i l l u-
mi nated from behi nd by the LED, whi ch i s sol dered
onto the i nstrument cl uster el ectroni c ci rcui t board.
The i l l umi nati on i ntensi ty of the rear l ock i ndi cator
i s one-step di mmabl e. When the exteri or l i ghti ng i s
turned On, the i ndi cator i s di mmed; and, when the
exteri or l i ghti ng i s turned Off, the i ndi cator i s i l l umi -
nated at ful l i ntensi ty. The rear l ock i ndi cator i s ser-
vi ced as a uni t wi th the i nstrument cl uster.
OPERATION
The rear l ock i ndi cator gi ves an i ndi cati on to the
vehi cl e operator of the status of the l ocker mecha-
ni sm i n the rear axl e of vehi cl es equi pped wi th the
opti onal off-road package. The rear l ock i ndi cator can
al so gi ve an i ndi cati on when certai n faul ts are
detected i n the axl e l ocker system. Thi s i ndi cator i s
control l ed by a transi stor on the i nstrument cl uster
el ectroni c ci rcui t board based upon cl uster program-
mi ng, and hard wi red i nputs to the cl uster from the
key-i n i gni ti on swi tch, the axl e l ock swi tch, and the
rear l ocker i ndi cator swi tch. The rear l ock i ndi cator
Li ght Emi tti ng Di ode (LED) i s compl etel y control l ed
by the i nstrument cl uster l ogi c ci rcui t, and that l ogi c
wi l l al l ow thi s i ndi cator to operate whenever the
i nstrument cl uster recei ves a battery current i nput
on the fused B(+) ci rcui t. Therefore, the LED can be
i l l umi nated regardl ess of the i gni ti on swi tch posi ti on.
The cl uster can i l l umi nate the LED sol i d, or fl ash i t
on and off at two di fferent rates, sl ow or fast. The
sl ow rate i s about one fl ash per second, whi l e the fast
rate i s about two fl ashes per second. The LED onl y
i l l umi nates when i t i s provi ded a path to ground by
the i nstrument cl uster transi stor. The i nstrument
Fig. 21 Rear Lock Indicator
TJ INSTRUMENT CLUSTER 8J - 35
OIL PRESSURE GAUGE (Continued)
cl uster wi l l turn on the rear l ock i ndi cator for the fol -
l owi ng reasons:
• Rear Axle Lock Request Input - Each ti me
the cl uster detects ground on the rear axl e l ock
request ci rcui t from the axl e l ock swi tch (rear axl e
l ock request ci rcui t ground = rear axl e l ock request
acti ve) whi l e the key i s i n the i gni ti on l ock cyl i nder,
the rear l ock i ndi cator fl ashes on and off at a sl ow
rate. The i ndi cator conti nues to fl ash unti l the rear
axl e l ock request i nput to the cl uster i s an open ci r-
cui t (rear axl e l ock request ci rcui t open = rear axl e
l ock request i nacti ve), or unti l the cl uster detects a
change i n the i nputs from the rear l ocker i ndi cator
swi tch or the key-i n i gni ti on swi tch, whi chever occurs
fi rst.
• Rear Locker Indicator Switch Input - Each
ti me the cl uster detects ground on the rear l ocker
i ndi cator swi tch sense ci rcui t (rear l ocker i ndi cator
swi tch cl osed = rear axl e l ocker engaged) whi l e the
rear axl e l ock request i s acti ve and the key i s i n the
i gni ti on l ock cyl i nder, the rear l ock i ndi cator i s i l l u-
mi nated sol i d. The i ndi cator remai ns i l l umi nated
sol i d unti l the rear l ocker i ndi cator swi tch i nput to
the cl uster i s an open ci rcui t (rear l ocker i ndi cator
swi tch open = rear axl e l ocker di sengaged), or unti l
the cl uster detects a change i n the i nputs from the
axl e l ock swi tch or the key-i n i gni ti on swi tch, whi ch-
ever occurs fi rst.
• Rear Lock Request/Feedback Mismatch -
Each ti me the cl uster detects that the i nputs from
the axl e l ock swi tch (request) on the rear axl e l ock
request ci rcui t and from the rear l ocker i ndi cator
swi tch (feedback) on the rear l ocker i ndi cator swi tch
sense ci rcui t are mi smatched, the rear l ock i ndi cator
fl ashes on and off at a sl ow rate. Thi s condi ti on
occurs when the l ock request i s acti ve but the axl e
l ocker remai ns di sengaged, or when the l ock request
i s i nacti ve but the axl e l ocker remai ns engaged. The
i ndi cator conti nues to fl ash unti l the request and the
feedback are matchi ng.
• Key-In Ignition Switch Input - Each ti me the
cl uster detects that the key has been removed from
the i gni ti on l ock cyl i nder (key-i n i gni ti on swi tch open
= key i s not i n i gni ti on swi tch) whi l e the rear axl e
l ock request i s sti l l acti ve, the rear l ock i ndi cator
fl ashes at a fast rate and three chi me tones are
sounded. The i ndi cator wi l l conti nue to fl ash at thi s
rate unti l the key i s repl aced i n the i gni ti on swi tch
l ock cyl i nder (key-i n i gni ti on swi tch cl osed = key i s i n
i gni ti on swi tch) whi l e the rear axl e l ock request i s
sti l l acti ve, or unti l the rear axl e l ock request i nput
i s deacti vated, whi chever occurs fi rst.
The axl e l ock swi tch i n the accessory swi tch bezel
on the i nstrument panel provi des a hard wi red
ground i nput to the i nstrument cl uster ci rcui try
through the rear axl e l ock request ci rcui t whenever
the swi tch i s enabl ed and the rear or the rear and
front axl e l ock posi ti on of the swi tch i s sel ected by
the vehi cl e operator. The rear l ocker i ndi cator swi tch
on the rear axl e housi ng provi des a hard wi red
ground i nput to the i nstrument cl uster whenever the
rear axl e l ocker mechani sm i s engaged. The key-i n
i gni ti on swi tch i ntegral to the i gni ti on swi tch pro-
vi des a hard wi red ground i nput to the i nstrument
cl uster whenever a key i s present i n the i gni ti on l ock
cyl i nder. Each of these i nputs to the i nstrument cl us-
ter can be di agnosed usi ng conventi onal di agnosti c
tool s and methods. For further di agnosi s of the
i nstrument cl uster ci rcui try that control s the rear
l ock i ndi cator LED, (Refer to 8 - ELECTRI CAL/I N-
STRUMENT CLUSTER - DI AGNOSI S AND TEST-
I NG).
SEATBELT INDICATOR
DESCRIPTION
A seatbel t i ndi cator i s standard equi pment on al l
i nstrument cl usters (Fi g. 22). The seatbel t i ndi cator
i s l ocated near the center of the i nstrument cl uster,
between the tachometer and the speedometer. The
seatbel t i ndi cator consi sts of a stenci l -l i ke cutout of
the I nternati onal Control and Di spl ay Symbol i con
for “Seat Bel t” i n the opaque l ayer of the i nstrument
cl uster overl ay. The dark outer l ayer of the overl ay
prevents the i ndi cator from bei ng cl earl y vi si bl e
when i t i s not i l l umi nated. A red Li ght Emi tti ng
Di ode (LED) behi nd the cutout i n the opaque l ayer of
the overl ay causes the i con to appear i n red through
the transl ucent outer l ayer of the overl ay when the
i ndi cator i s i l l umi nated from behi nd by the LED,
whi ch i s sol dered onto the i nstrument cl uster el ec-
troni c ci rcui t board. The seatbel t i ndi cator i s servi ced
as a uni t wi th the i nstrument cl uster.
OPERATION
The seatbel t i ndi cator gi ves an i ndi cati on to the
vehi cl e operator of the status of the dri ver si de front
seatbel t. Thi s i ndi cator i s control l ed by a transi stor
on the i nstrument cl uster ci rcui t board based upon
cl uster programmi ng and a hard wi red i nput from
the seatbel t swi tch i n the dri ver si de front seatbel t
buckl e through the seat bel t i ndi cator dri ver ci rcui t.
The seatbel t i ndi cator Li ght Emi tti ng Di ode (LED) i s
compl etel y control l ed by the i nstrument cl uster l ogi c
ci rcui t, and that l ogi c wi l l onl y al l ow thi s i ndi cator to
operate when the i nstrument cl uster recei ves a bat-
Fig. 22 Seatbelt Indicator
8J - 36 INSTRUMENT CLUSTER TJ
REAR LOCK INDICATOR (Continued)
tery current i nput on the fused i gni ti on swi tch out-
put (run-start) ci rcui t. Therefore, the LED wi l l
al ways be off when the i gni ti on swi tch i s i n any posi -
ti on except On or Start. The LED onl y i l l umi nates
when i t i s provi ded a path to ground by the i nstru-
ment cl uster transi stor. The i nstrument cl uster wi l l
turn on the seatbel t i ndi cator for the fol l owi ng rea-
sons:
• Seatbelt Reminder Function - Each ti me the
cl uster recei ves a battery current i nput on the fused
i gni ti on swi tch output (run-start) ci rcui t, the i ndi ca-
tor wi l l be i l l umi nated as a seatbel t remi nder for
about seven seconds, or unti l the i gni ti on swi tch i s
turned to the Off posi ti on, whi chever occurs fi rst.
Thi s remi nder functi on wi l l occur regardl ess of the
status of the seatbel t swi tch i nput to the cl uster.
• Driver Side Front Seatbelt Not Buckled -
Fol l owi ng the seatbel t remi nder functi on, each ti me
the cl uster detects a ground on the seat bel t swi tch
sense ci rcui t (seatbel t swi tch cl osed = seatbel t
unbuckl ed) wi th the i gni ti on swi tch i n the Start or
On posi ti ons, the i ndi cator wi l l be i l l umi nated. The
seatbel t i ndi cator remai ns i l l umi nated unti l the seat
bel t swi tch sense i nput to the cl uster i s an open ci r-
cui t (seatbel t swi tch open = seatbel t buckl ed), or
unti l the i gni ti on swi tch i s turned to the Off posi ti on,
whi chever occurs fi rst.
• Actuator Test - Each ti me the cl uster i s put
through the actuator test, the seatbel t i ndi cator wi l l
be turned on, then off agai n duri ng the bul b check
porti on of the test to confi rm the functi onal i ty of the
LED and the cl uster control ci rcui try.
The seatbel t swi tch i s connected i n seri es between
ground and the seat bel t swi tch sense i nput to the
i nstrument cl uster. The seatbel t swi tch i nput to the
i nstrument cl uster ci rcui try can be di agnosed usi ng
conventi onal di agnosti c tool s and methods. For fur-
ther di agnosi s of the seatbel t i ndi cator or the i nstru-
ment cl uster ci rcui try that control s the LED, (Refer
to 8 - ELECTRI CAL/I NSTRUMENT CLUSTER -
DI AGNOSI S AND TESTI NG).
SHIFT INDICATOR (TRANSFER
CASE)
DESCRIPTION
A four-wheel dri ve i ndi cator i s standard equi pment
on al l i nstrument cl usters (Fi g. 23). The four-wheel
dri ve i ndi cator i s l ocated near the upper edge of the
i nstrument cl uster, to the ri ght of center. The four-
wheel dri ve i ndi cator consi sts of a stenci l -l i ke cutout
of the text “4WD” i n the opaque l ayer of the i nstru-
ment cl uster overl ay. The dark outer l ayer of the
overl ay prevents the i ndi cator from bei ng cl earl y vi s-
i bl e when i t i s not i l l umi nated. A amber Li ght Emi t-
ti ng Di ode (LED) behi nd the cutout i n the opaque
l ayer of the overl ay causes the “4WD” text to appear
i n amber through the transl ucent outer l ayer of the
overl ay when the i ndi cator i s i l l umi nated from
behi nd by the LED, whi ch i s sol dered onto the
i nstrument cl uster el ectroni c ci rcui t board. The i l l u-
mi nati on i ntensi ty of the four-wheel dri ve i ndi cator i s
one-step di mmabl e. When the exteri or l i ghti ng i s
turned On, the i ndi cator i s di mmed; and, when the
exteri or l i ghti ng i s turned Off, the i ndi cator i s i l l umi -
nated at ful l i ntensi ty. The four-wheel dri ve i ndi cator
i s servi ced as a uni t wi th the i nstrument cl uster.
OPERATION
The four-wheel dri ve i ndi cator gi ves an i ndi cati on
to the vehi cl e operator that a four-wheel dri ve oper-
ati ng mode of the four-wheel dri ve transfer case i s
sel ected. The four-wheel dri ve i ndi cator l i ghts when
the transfer case i s engaged i n the 4H or 4L posi -
ti ons. Thi s i ndi cator i s control l ed by a transi stor on
the i nstrument cl uster el ectroni c ci rcui t board based
upon cl uster programmi ng. On model s not equi pped
wi th the opti onal Off-Road Package the cl uster al so
uses a hard wi red transfer case swi tch i nput. Model s
that are equi pped wi th the Off-Road Package do not
have a hard wi red transfer case swi tch i nput, so the
cl uster uses el ectroni c messages recei ved by the cl us-
ter from the Powertrai n Control Modul e (PCM) over
the Programmabl e Communi cati ons I nterface (PCI )
data bus to determi ne the transfer case operati ng
mode. The four-wheel dri ve i ndi cator Li ght Emi tti ng
Di ode (LED) i s compl etel y control l ed by the i nstru-
ment cl uster l ogi c ci rcui t, and that l ogi c wi l l onl y
al l ow thi s i ndi cator to operate when the i nstrument
cl uster recei ves a battery current i nput on the fused
i gni ti on swi tch output (run-start) ci rcui t. Therefore,
the LED wi l l al ways be off when the i gni ti on swi tch
i s i n any posi ti on except On or Start. The LED onl y
i l l umi nates when i t i s provi ded a path to ground by
the i nstrument cl uster transi stor. The i nstrument
cl uster wi l l turn on the four-wheel dri ve i ndi cator for
the fol l owi ng reasons:
• Transfer Case Switch Input - Each ti me the
cl uster detects a ground on the 4WD swi tch sense
ci rcui t (transfer case swi tch cl osed = 4WD mode
sel ected) the part ti me i ndi cator i s i l l umi nated. The
i ndi cator remai ns i l l umi nated unti l the 4WD swi tch
sense i nput to the cl uster i s an open ci rcui t (transfer
case swi tch open = 4WD mode not sel ected), or unti l
Fig. 23 4WD Indicator
TJ INSTRUMENT CLUSTER 8J - 37
SEATBELT INDICATOR (Continued)
the i gni ti on swi tch i s turned to the Off posi ti on,
whi chever occurs fi rst.
• 4WD Transfer Case Status Message - Each
ti me the cl uster recei ves a message from the PCM
i ndi cati ng that the transfer case i s operati ng i n a
four-wheel dri ve mode, the 4WD i ndi cator i s i l l umi -
nated. The 4WD i ndi cator remai ns i l l umi nated unti l
the cl uster recei ves messages from the PCM i ndi cat-
i ng that the transfer case i s not i n a four-wheel dri ve
mode or unti l the i gni ti on swi tch i s turned to the Off
posi ti on, whi chever occurs fi rst.
• Actuator Test - Each ti me the cl uster i s put
through the actuator test, the 4WD i ndi cator wi l l be
turned on, then off agai n duri ng the bul b check por-
ti on of the test to confi rm the functi onal i ty of the
LED and the cl uster control ci rcui try.
On model s wi thout the Off-Road Package, the
transfer case shi ft posi ti on swi tch i s connected i n
seri es between ground and the 4WD swi tch sense
i nput to the i nstrument cl uster. The transfer case
swi tch i nput to the i nstrument cl uster ci rcui try can
be di agnosed usi ng conventi onal di agnosti c tool s and
methods. (Refer to 21 - TRANSMI SSI ON/TRANS-
AXLE/TRANSFER CASE - DESCRI PTI ON) for more
i nformati on on the transfer case swi tch. For further
di agnosi s of the 4WD i ndi cator or the i nstrument
cl uster ci rcui try that control s the LED, (Refer to 8 -
ELECTRI CAL/I NSTRUMENT CLUSTER - DI AGNO-
SI S AND TESTI NG).
On model s equi pped wi th the Off-Road Package,
the PCM conti nual l y moni tors the transfer case shi ft
posi ti on swi tch to determi ne the operati ng mode of
the transfer case. The PCM then sends the proper
transfer case shi ft posi ti on status messages to the
i nstrument cl uster. For further di agnosi s of the 4WD
i ndi cator or the i nstrument cl uster ci rcui try that con-
trol s the LED, (Refer to 8 - ELECTRI CAL/I NSTRU-
MENT CLUSTER - DI AGNOSI S AND TESTI NG).
For proper di agnosi s of the transfer case shi ft posi -
ti on swi tch, the PCM, the PCI data bus, or the el ec-
troni c message i nputs to the i nstrument cl uster that
control the 4WD i ndi cator, a DRBI I I ௡ scan tool i s
requi red. Refer to the appropri ate di agnosti c i nfor-
mati on.
DIAGNOSIS AND TESTING - 4WD INDICATOR
The di agnosi s found here addresses an i noperati ve
four-wheel dri ve i ndi cator condi ti on onl y on model s
that are not equi pped wi th the opti onal Off-Road
Package. I f the vehi cl e i s equi pped wi th the Off-Road
Package, for proper di agnosi s of the transfer case
swi tch, the PCM, the PCI data bus, or the el ectroni c
message i nputs to the i nstrument cl uster that control
the 4WD i ndi cator, a DRBI I I ௡ scan tool i s requi red.
Refer to the appropri ate di agnosti c i nformati on.
Before begi nni ng thi s test, confi rm the functi onal i ty
of the four-wheel dri ve i ndi cator Li ght Emi tti ng
Di ode (LED) and the cl uster control ci rcui try by per-
formi ng the i nstrument cl uster actuator test. (Refer
to 8 - ELECTRI CAL/I NSTRUMENT CLUSTER -
DI AGNOSI S AND TESTI NG). I f the four-wheel dri ve
i ndi cator fai l s to i l l umi nate duri ng the actuator test,
repl ace the faul ty i nstrument cl uster. I f the probl em
bei ng di agnosed i s rel ated to i ndi cator accuracy, be
certai n to confi rm that the probl em i s wi th the i ndi -
cator or transfer case swi tch and not a mechani cal
mal functi on of the transfer case or transfer case shi ft
l i nkage. (Refer to 21 - TRANSMI SSI ON/TRANS-
AXLE/TRANSFER CASE - DI AGNOSI S AND TEST-
I NG). I f no transfer case probl em i s found, the
fol l owi ng procedure wi l l hel p to l ocate a short or open
i n the 4WD swi tch sense ci rcui t. Refer to the appro-
pri ate wi ri ng i nformati on. The wi ri ng i nformati on
i ncl udes wi ri ng di agrams, proper wi re and connector
repai r procedures, detai l s of wi re harness routi ng
and retenti on, connector pi n-out i nformati on and
l ocati on vi ews for the vari ous wi re harness connec-
tors, spl i ces and grounds.
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE SUPPLEMENTAL RESTRAINT SYS-
TEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, AIRBAG, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE BEFORE PERFORMING FURTHER DIAG-
NOSIS OR SERVICE. THIS IS THE ONLY SURE WAY
TO DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT.
INDICATOR DOES NOT ILLUMINATE WITH 4WD MODE
SELECTED
(1) Di sconnect and i sol ate the battery negati ve
cabl e. Di sconnect the engi ne wi re harness connector
for the transfer case swi tch from the transfer case
swi tch connector receptacl e. Check for conti nui ty
between the ground ci rcui t cavi ty of the engi ne wi re
harness connector for the transfer case swi tch and a
good ground. There shoul d be conti nui ty. I f OK, go to
Step 2. I f not OK, repai r the open ground ci rcui t to
ground (G105) as requi red.
(2) Reconnect the battery negati ve cabl e. Turn the
i gni ti on swi tch to the On posi ti on. I nstal l a jumper
wi re between the 4WD swi tch sense ci rcui t cavi ty of
the engi ne wi re harness connector for the transfer
case swi tch and a good ground. The 4WD i ndi cator
8J - 38 INSTRUMENT CLUSTER TJ
SHIFT INDICATOR (TRANSFER CASE) (Continued)
shoul d l i ght. I f OK, repl ace the faul ty transfer case
swi tch. I f not OK, go to Step 3.
(3) Turn the i gni ti on swi tch to the Off posi ti on.
Di sconnect and i sol ate the battery negati ve cabl e.
Remove the i nstrument cl uster from the i nstrument
panel . Di sconnect the i nstrument panel wi re harness
connector (Connector C2) for the i nstrument cl uster
from the connector receptacl e on the back of the cl us-
ter housi ng. Check for conti nui ty between the 4WD
swi tch sense ci rcui t cavi ti es of the i nstrument panel
wi re harness connector (Connector C2) for the i nstru-
ment cl uster and the engi ne wi re harness connector
for the transfer case swi tch. There shoul d be conti nu-
i ty. I f OK, repl ace the faul ty i nstrument cl uster. I f
not OK, repai r the open 4WD swi tch sense ci rcui t
between the i nstrument cl uster and the transfer case
swi tch as requi red.
INDICATOR STAYS ILLUMINATED WITH 4WD MODE NOT
SELECTED
(1) Di sconnect and i sol ate the battery negati ve
cabl e. Di sconnect the engi ne wi re harness connector
for the transfer case swi tch from the transfer case
swi tch connector receptacl e. Check for conti nui ty
between the ground ci rcui t and the 4WD swi tch
sense ci rcui t termi nal s i n the transfer case swi tch
connector receptacl e. There shoul d be no conti nui ty.
I f OK, go to Step 2. I f not OK, repl ace the faul ty
transfer case swi tch.
(2) Remove the i nstrument cl uster from the i nstru-
ment panel . Di sconnect the i nstrument panel wi re
harness connector (Connector C2) for the i nstrument
cl uster from the connector receptacl e on the back of
the cl uster housi ng. Check for conti nui ty between the
4WD swi tch sense ci rcui t cavi ty of the i nstrument
panel wi re harness connector (Connector C2) for the
i nstrument cl uster and a good ground. There shoul d
be no conti nui ty. I f OK, repl ace the faul ty i nstrument
cl uster. I f not OK, repai r the shorted 4WD swi tch
sense ci rcui t between the transfer case swi tch and
the i nstrument cl uster as requi red.
SKIS INDICATOR
DESCRIPTION
A Sentry Key I mmobi l i zer System (SKI S) i ndi cator
i s standard equi pment on al l i nstrument cl usters, but
i s onl y functi onal on vehi cl es equi pped wi th the
opti onal SKI S (Fi g. 24). The SKI S i ndi cator i s l ocated
near the upper edge of the i nstrument cl uster over-
l ay, to the l eft of center. The SKI S i ndi cator consi sts
of a stenci l -l i ke cutout of a graphi cal representati on
or i con of a key that i s ci rcl ed and crossed-out i n the
opaque l ayer of the i nstrument cl uster overl ay. The
dark outer l ayer of the overl ay prevents the i ndi cator
from bei ng cl earl y vi si bl e when i t i s not i l l umi nated.
A amber Li ght Emi tti ng Di ode (LED) behi nd the cut-
out i n the opaque l ayer of the overl ay causes the
i ndi cator to appear i n amber through the transl ucent
outer l ayer of the overl ay when the i ndi cator i s i l l u-
mi nated from behi nd by the LED, whi ch i s sol dered
onto the i nstrument cl uster el ectroni c ci rcui t board.
The SKI S i ndi cator i s servi ced as a uni t wi th the
i nstrument cl uster.
OPERATION
The Sentry Key I mmobi l i zer System (SKI S) i ndi ca-
tor gi ves an i ndi cati on to the vehi cl e operator of the
status of the SKI S. Thi s i ndi cator i s control l ed by the
i nstrument cl uster ci rcui t board based upon el ec-
troni c messages recei ved by the cl uster from the Sen-
try Key I mmobi l i zer Modul e (SKI M) over the
Programmabl e Communi cati ons I nterface (PCI ) data
bus. The SKI S i ndi cator Li ght Emi tti ng Di ode (LED)
i s compl etel y control l ed by the i nstrument cl uster
l ogi c ci rcui t, and that l ogi c wi l l onl y al l ow thi s i ndi -
cator to operate when the i nstrument cl uster recei ves
a battery current i nput on the fused i gni ti on swi tch
output (run-start) ci rcui t. Therefore, the LED wi l l
al ways be off when the i gni ti on swi tch i s i n any posi -
ti on except On or Start. The LED onl y i l l umi nates
when i t i s provi ded a path to ground by the i nstru-
ment cl uster transi stor. The i nstrument cl uster wi l l
turn on the SKI S i ndi cator for the fol l owi ng reasons:
• Bulb Test - Each ti me the i gni ti on swi tch i s
turned to the On posi ti on, the SKI M sends a message
to the cl uster to i l l umi nate the SKI S i ndi cator for
about three seconds as a bul b test.
• SKIM Lamp-On Message - Each ti me the cl us-
ter recei ves a l amp-on message from the SKI M, the
SKI S i ndi cator wi l l be i l l umi nated. The i ndi cator can
be fl ashed on and off, or i l l umi nated sol i d, as di c-
tated by the SKI M message. For more i nformati on on
the SKI S and the SKI S i ndi cator control parameters,
(Refer to 8 - ELECTRI CAL/VEHI CLE THEFT SECU-
RI TY - OPERATI ON). The i ndi cator remai ns i l l umi -
nated unti l the cl uster recei ves a l amp-off message
from the SKI M or unti l the i gni ti on swi tch i s turned
to the Off posi ti on, whi chever occurs fi rst.
• Actuator Test - Each ti me the cl uster i s put
through the actuator test, the SKI S i ndi cator wi l l be
turned on, then off agai n duri ng the bul b check por-
ti on of the test to confi rm the functi onal i ty of the
LED and the cl uster control ci rcui try.
The SKI M performs a sel f-test each ti me the i gni -
ti on swi tch i s turned to the On posi ti on to deci de
Fig. 24 SKIS Indicator
TJ INSTRUMENT CLUSTER 8J - 39
SHIFT INDICATOR (TRANSFER CASE) (Continued)
whether the system i s i n good operati ng condi ti on.
The SKI M then sends the proper SKI S l amp-on or
l amp-off messages to the i nstrument cl uster. For fur-
ther di agnosi s of the SKI S i ndi cator or the i nstru-
ment cl uster ci rcui try that control s the i ndi cator,
(Refer to 8 - ELECTRI CAL/I NSTRUMENT CLUS-
TER - DI AGNOSI S AND TESTI NG). I f the i nstru-
ment cl uster turns on the SKI S i ndi cator after the
bul b test, ei ther sol i d or fl ashi ng, i t i ndi cates that a
SKI S mal functi on has occurred or that the SKI S i s
i noperati ve. For proper di agnosi s of the SKI S, the
PCI data bus, or the el ectroni c message i nputs to the
i nstrument cl uster that control the SKI S i ndi cator, a
DRBI I I ௡ scan tool i s requi red. Refer to the appropri -
ate di agnosti c i nformati on.
SPEEDOMETER
DESCRIPTION
A speedometer i s standard equi pment on al l i nstru-
ment cl usters. The speedometer i s l ocated next to the
tachometer, just to the ri ght of center i n the i nstru-
ment cl uster. The speedometer consi sts of a movabl e
gauge needl e or poi nter control l ed by the i nstrument
cl uster ci rcui try and a fi xed 210 degree pri mary scal e
on the cl uster overl ay that reads l eft-to-ri ght ei ther
from “0” to “100” mph, from “0” to “110” mph, or from
“0” to “180” km/h, dependi ng upon the requi rements
of the market for whi ch the vehi cl e i s manufactured.
Each versi on al so has a secondary i nner scal e on the
cl uster overl ay that provi des the equi val ent opposi te
uni ts from the pri mary scal e. Text appeari ng on the
cl uster overl ay just bel ow the hub of the speedometer
needl e abbrevi ates the uni t of measure for the pri -
mary scal e (i .e.: MPH or km/h), fol l owed by the uni t
of measure for the secondary scal e (Fi g. 25). The
speedometer graphi cs are whi te (pri mary scal e) and
bl ue (secondary scal e) agai nst a bl ack fi el d, maki ng
them cl earl y vi si bl e wi thi n the i nstrument cl uster i n
dayl i ght. When i l l umi nated from behi nd by the panel
l amps di mmer control l ed cl uster i l l umi nati on l i ghti ng
wi th the exteri or l amps turned On, the whi te graph-
i cs appear whi te and the bl ue graphi cs appear bl ue.
The orange gauge needl e i s i nternal l y i l l umi nated.
Gauge i l l umi nati on i s provi ded by repl aceabl e i ncan-
descent bul b and bul b hol der uni ts l ocated on the
i nstrument cl uster el ectroni c ci rcui t board. The
speedometer i s servi ced as a uni t wi th the i nstru-
ment cl uster.
OPERATION
The speedometer gi ves an i ndi cati on to the vehi cl e
operator of the vehi cl e road speed. Thi s gauge i s con-
trol l ed by the i nstrument cl uster ci rcui t board based
upon cl uster programmi ng and el ectroni c messages
recei ved by the cl uster from the Powertrai n Control
Modul e (PCM) over the Programmabl e Communi ca-
ti ons I nterface (PCI ) data bus. The speedometer i s an
ai r core magneti c uni t that recei ves battery current
on the i nstrument cl uster el ectroni c ci rcui t board
through the fused i gni ti on swi tch output (run-start)
ci rcui t whenever the i gni ti on swi tch i s i n the On or
Start posi ti ons. The cl uster i s programmed to move
the gauge needl e back to the l ow end of the scal e
after the i gni ti on swi tch i s turned to the Off posi ti on.
The i nstrument cl uster ci rcui try control s the gauge
needl e posi ti on and provi des the fol l owi ng features:
• Vehicle Speed Message - Each ti me the cl us-
ter recei ves a vehi cl e speed message from the PCM i t
wi l l cal cul ate the correct vehi cl e speed readi ng and
posi ti on the gauge needl e at that rel ati ve speed posi -
ti on on the gauge scal e. The cl uster wi l l recei ve a
new vehi cl e speed message and reposi ti on the gauge
poi nter accordi ngl y about every 86 mi l l i seconds. The
gauge needl e wi l l conti nue to be posi ti oned at the
actual vehi cl e speed posi ti on on the gauge scal e unti l
the i gni ti on swi tch i s turned to the Off posi ti on.
• Communication Error - I f the cl uster fai l s to
recei ve a speedometer message, i t wi l l hol d the gauge
needl e at the l ast i ndi cati on for about si x seconds, or
unti l the i gni ti on swi tch i s turned to the Off posi ti on,
whi chever occurs fi rst. After si x seconds, the gauge
needl e wi l l return to the l eft end of the gauge scal e.
• Actuator Test - Each ti me the cl uster i s put
through the actuator test, the gauge needl e wi l l be
swept to several cal i brati on poi nts on the gauge scal e
i n a prescri bed sequence i n order to confi rm the func-
ti onal i ty of the gauge and the cl uster control ci r-
cui try.
The PCM conti nual l y moni tors the vehi cl e speed
sensor to determi ne the vehi cl e road speed, then
sends the proper vehi cl e speed messages to the
i nstrument cl uster. For further di agnosi s of the
speedometer or the i nstrument cl uster ci rcui try that
control s the gauge, (Refer to 8 - ELECTRI CAL/I N-
STRUMENT CLUSTER - DI AGNOSI S AND TEST-
I NG). For proper di agnosi s of the vehi cl e speed
sensor, the PCM, the PCI data bus, or the el ectroni c
message i nputs to the i nstrument cl uster that control
the speedometer, a DRBI I I ௡ scan tool i s requi red.
Refer to the appropri ate di agnosti c i nformati on.
Fig. 25 Speedometer Text
8J - 40 INSTRUMENT CLUSTER TJ
SKIS INDICATOR (Continued)
TACHOMETER
DESCRIPTION
A tachometer i s standard equi pment on al l i nstru-
ment cl usters. The tachometer i s l ocated to the l eft of
the speedometer, just to the l eft of center i n the
i nstrument cl uster. The tachometer consi sts of a
movabl e gauge needl e or poi nter control l ed by the
i nstrument cl uster ci rcui try and a fi xed 210 degree
scal e on the cl uster overl ay that reads l eft-to-ri ght
from 0 to 6. The text “X1000 RPM” i mpri nted on the
cl uster overl ay di rectl y bel ow the hub of the tachom-
eter needl e i denti fi es that each number on the
tachometer scal e i s to be mul ti pl i ed by 1000 rpm
(Fi g. 26). Red graduati ons at the ri ght (hi gh) end of
the gauge scal e desi gnate the engi ne overspeed area
of the gauge. The tachometer graphi cs are whi te
agai nst a bl ack fi el d, except for the red graduati ons,
maki ng them cl earl y vi si bl e wi thi n the i nstrument
cl uster i n dayl i ght. When i l l umi nated from behi nd by
the panel l amps di mmer control l ed cl uster i l l umi na-
ti on l i ghti ng wi th the exteri or l amps turned On, the
whi te graphi cs appear whi te and the red graphi cs
appear red. The orange gauge needl e i s i nternal l y
i l l umi nated. Gauge i l l umi nati on i s provi ded by
repl aceabl e i ncandescent bul b and bul b hol der uni ts
l ocated on the i nstrument cl uster el ectroni c ci rcui t
board. The tachometer i s servi ced as a uni t wi th the
i nstrument cl uster.
OPERATION
The tachometer gi ves an i ndi cati on to the vehi cl e
operator of the engi ne speed. Thi s gauge i s control l ed
by the i nstrument cl uster ci rcui t board based upon
cl uster programmi ng and el ectroni c messages
recei ved by the cl uster from the Powertrai n Control
Modul e (PCM) over the Programmabl e Communi ca-
ti ons I nterface (PCI ) data bus. The tachometer i s an
ai r core magneti c uni t that recei ves battery current
on the i nstrument cl uster el ectroni c ci rcui t board
through the fused i gni ti on swi tch output (run-start)
ci rcui t whenever the i gni ti on swi tch i s i n the On or
Start posi ti ons. The cl uster i s programmed to move
the gauge needl e back to the l ow end of the scal e
after the i gni ti on swi tch i s turned to the Off posi ti on.
The i nstrument cl uster el ectroni c ci rcui try control s
the gauge needl e posi ti on and provi des the fol l owi ng
features:
• Engine Speed Message - Each ti me the cl uster
recei ves an engi ne speed message from the PCM i t
wi l l cal cul ate the correct engi ne speed readi ng and
posi ti on the gauge needl e at that rel ati ve speed posi -
ti on on the gauge scal e. The cl uster wi l l recei ve a
new engi ne speed message and reposi ti on the gauge
poi nter accordi ngl y about every 86 mi l l i seconds. The
gauge needl e wi l l conti nual l y be reposi ti oned on the
gauge scal e unti l the engi ne stops runni ng, or unti l
the i gni ti on swi tch i s turned to the Off posi ti on,
whi chever occurs fi rst.
• Communication Error - I f the cl uster fai l s to
recei ve an engi ne speed message, i t wi l l hol d the
gauge needl e at the l ast i ndi cati on for about si x sec-
onds, or unti l the i gni ti on swi tch i s turned to the Off
posi ti on, whi chever occurs fi rst. After si x seconds, the
gauge needl e wi l l return to the l eft (l ow) end of the
gauge scal e.
• Actuator Test - Each ti me the cl uster i s put
through the actuator test, the gauge needl e wi l l be
swept to several cal i brati on poi nts on the gauge scal e
i n a prescri bed sequence to confi rm the functi onal i ty
of the gauge and the cl uster control ci rcui try.
The PCM conti nual l y moni tors the crankshaft posi -
ti on sensor to determi ne the engi ne speed. The PCM
then sends the proper engi ne speed messages to the
i nstrument cl uster. For further di agnosi s of the
tachometer or the i nstrument cl uster ci rcui try that
control s the gauge, (Refer to 8 - ELECTRI CAL/I N-
STRUMENT CLUSTER - DI AGNOSI S AND TEST-
I NG). For proper di agnosi s of the crankshaft posi ti on
sensor, the PCM, the PCI data bus, or the el ectroni c
message i nputs to the i nstrument cl uster that control
the tachometer, a DRBI I I ௡ scan tool i s requi red.
Refer to the appropri ate di agnosti c i nformati on.
TURN SIGNAL INDICATOR
DESCRIPTION
Two turn si gnal i ndi cators, one ri ght and one l eft,
are standard equi pment on al l i nstrument cl usters
(Fi g. 27). The turn si gnal i ndi cators are l ocated near
the upper edge of the i nstrument cl uster, between
the speedometer and the tachometer. Each turn si g-
nal i ndi cator consi sts of a stenci l -l i ke cutout of the
I nternati onal Control and Di spl ay Symbol i con for
“Turn Warni ng” i n the opaque l ayer of the i nstru-
ment cl uster overl ay. The dark outer l ayer of the
overl ay prevents these i cons from bei ng cl earl y vi si -
bl e when they are not i l l umi nated. A green Li ght
Emi tti ng Di ode (LED) behi nd each turn si gnal i ndi -
cator cutout i n the opaque l ayer of the cl uster over-
Fig. 26 Tachometer Text
Fig. 27 Turn Signal Indicators
TJ INSTRUMENT CLUSTER 8J - 41
l ay causes the i con to appear i n green through the
transl ucent outer l ayer of the overl ay when the i ndi -
cator i s i l l umi nated from behi nd the LED, whi ch i s
sol dered onto the i nstrument cl uster el ectroni c ci rcui t
board. The turn si gnal i ndi cators are servi ced as a
uni t wi th the i nstrument cl uster.
OPERATION
The turn si gnal i ndi cators gi ve an i ndi cati on to the
vehi cl e operator that the turn si gnal s (l eft or ri ght
i ndi cator fl ashi ng) or hazard warni ng (both l eft and
ri ght i ndi cators fl ashi ng) have been sel ected and are
operati ng. These i ndi cators are control l ed by two
i ndi vi dual hard wi red i nputs recei ved by the cl uster
from the turn si gnal swi tch ci rcui try and hazard
warni ng swi tch ci rcui try wi thi n the l eft mul ti -func-
ti on swi tch. Each turn si gnal i ndi cator Li ght Emi t-
ti ng Di ode (LED) i s grounded on the i nstrument
cl uster el ectroni c ci rcui t board at al l ti mes. There-
fore, these i ndi cators remai n functi onal regardl ess of
the i gni ti on swi tch posi ti on. Each LED wi l l onl y i l l u-
mi nate when i t i s provi ded battery current by the ci r-
cui try of the l eft mul ti -functi on swi tch.
The turn si gnal i ndi cators are connected i n seri es
between the output of the combi nati on fl asher on the
l eft mul ti -functi on swi tch and the l eft or ri ght turn
si gnal i nputs to the i nstrument cl uster, but i n paral -
l el wi th the other turn si gnal ci rcui ts. Thi s arrange-
ment al l ows the turn si gnal i ndi cators to remai n
functi onal , regardl ess of the condi ti on of the other
ci rcui ts i n the turn si gnal and hazard warni ng sys-
tems. The turn si gnal swi tch and hazard warni ng
swi tch i nputs to the i nstrument cl uster can be di ag-
nosed usi ng conventi onal di agnosti c tool s and meth-
ods. (Refer to 8 - ELECTRI CAL/LAMPS/LI GHTI NG -
EXTERI OR/LEFT MULTI -FUNCTI ON SWI TCH -
OPERATI ON) for more i nformati on on the turn si g-
nal swi tch and the hazard warni ng swi tch.
UPSHIFT INDICATOR
DESCRIPTION
An upshi ft i ndi cator i s standard equi pment on al l
i nstrument cl usters (Fi g. 28). However, on vehi cl es
not bui l t for North Ameri can markets and those not
equi pped wi th a manual transmi ssi on, thi s i ndi cator
i s el ectroni cal l y di sabl ed. The upshi ft i ndi cator i s
l ocated near the upper edge of the i nstrument cl us-
ter, to the ri ght of center. The upshi ft i ndi cator con-
si sts of a stenci l -l i ke cutout of an upward poi nted
arrow i con i n the opaque l ayer of the i nstrument
cl uster overl ay. The dark outer l ayer of the cl uster
overl ay prevents the i con from bei ng cl earl y vi si bl e
when the i ndi cator i s not i l l umi nated. A amber Li ght
Emi tti ng Di ode (LED) behi nd the cutout i n the
opaque l ayer of the cl uster overl ay causes the i con to
appear i n amber through the transl ucent outer l ayer
of the overl ay when the i ndi cator i s i l l umi nated from
behi nd by the LED, whi ch i s sol dered onto the
i nstrument cl uster el ectroni c ci rcui t board. The i l l u-
mi nati on i ntensi ty of the upshi ft i ndi cator i s one-step
di mmabl e. When the exteri or l i ghti ng i s turned On,
the i ndi cator i s di mmed; and, when the exteri or
l i ghti ng i s turned Off, the i ndi cator i s i l l umi nated at
ful l i ntensi ty. The upshi ft i ndi cator i s servi ced as a
uni t wi th the i nstrument cl uster.
OPERATION
The upshi ft i ndi cator gi ves an i ndi cati on to the
vehi cl e operator when the manual transmi ssi on
shoul d be shi fted to the next hi ghest gear i n order to
achi eve the best fuel economy. Thi s i ndi cator i s con-
trol l ed by a transi stor on the i nstrument cl uster ci r-
cui t board based upon cl uster programmi ng and
el ectroni c messages recei ved by the cl uster from the
Powertrai n Control Modul e (PCM) over the Program-
mabl e Communi cati ons I nterface (PCI ) data bus. The
upshi ft i ndi cator functi on of the i nstrument cl uster i s
el ectroni cal l y enabl ed or di sabl ed by a PCI data bus
message recei ved by the cl uster from the PCM. The
upshi ft i ndi cator Li ght Emi tti ng Di ode (LED) i s com-
pl etel y control l ed by the i nstrument cl uster l ogi c ci r-
cui t, and that l ogi c wi l l onl y al l ow thi s i ndi cator to
operate when the i nstrument cl uster recei ves a bat-
tery current i nput on the fused i gni ti on swi tch out-
put (run-start) ci rcui t. Therefore, the i ndi cator wi l l
al ways be off when the i gni ti on swi tch i s i n any posi -
ti on except On or Start. The LED onl y i l l umi nates
when i t i s provi ded a path to ground by the i nstru-
ment cl uster transi stor. The i nstrument cl uster wi l l
turn on the upshi ft i ndi cator for the fol l owi ng rea-
sons:
• Upshift Lamp-On Message - Each ti me the
cl uster recei ves an upshi ft l amp-on message from the
PCM i ndi cati ng the engi ne speed and l oad condi ti ons
are ri ght for a transmi ssi on upshi ft to occur, the
upshi ft i ndi cator i s i l l umi nated. The i ndi cator
remai ns i l l umi nated unti l the cl uster recei ves an
upshi ft l amp-off message from the PCM, or unti l the
i gni ti on swi tch i s turned to the Off posi ti on, whi ch-
ever occurs fi rst. The PCM wi l l normal l y send an
upshi ft l amp-off message three to fi ve seconds after a
l amp-on message, i f an upshi ft i s not performed. The
i ndi cator wi l l then remai n off unti l the vehi cl e stops
accel erati ng and i s brought back i nto the range of
i ndi cator operati on, or unti l the transmi ssi on i s
shi fted i nto another gear.
Fig. 28 Upshift Indicator
8J - 42 INSTRUMENT CLUSTER TJ
TURN SIGNAL INDICATOR (Continued)
• Actuator Test - Each ti me the cl uster i s put
through the actuator test, the upshi ft i ndi cator wi l l
be turned on, then off agai n duri ng the bul b check
porti on of the test to confi rm the functi onal i ty of the
LED and the cl uster control ci rcui try.
The PCM conti nual l y moni tors the engi ne speed
and l oad condi ti ons to determi ne the proper fuel and
i gni ti on requi rements. The PCM then sends the
proper upshi ft i ndi cator l amp-on and l amp-off mes-
sages to the i nstrument cl uster. For further di agnosi s
of the upshi ft i ndi cator or the i nstrument cl uster ci r-
cui try that control s the i ndi cator, (Refer to 8 - ELEC-
TRI CAL/I NSTRUMENT CLUSTER - DI AGNOSI S
AND TESTI NG). For proper di agnosi s of the PCM,
the PCI data bus, or the el ectroni c message i nputs to
the i nstrument cl uster that control the upshi ft i ndi -
cator, a DRBI I I ௡ scan tool i s requi red. Refer to the
appropri ate di agnosti c i nformati on.
VOLTAGE GAUGE
DESCRIPTION
A vol tage gauge i s standard equi pment on al l
i nstrument cl usters. The vol tage gauge i s l ocated i n
the upper l eft quadrant of the i nstrument cl uster,
above the fuel gauge. The vol tage gauge consi sts of a
movabl e gauge needl e or poi nter control l ed by the
i nstrument cl uster ci rcui try and a fi xed 90 degree
scal e on the cl uster overl ay that reads l eft-to-ri ght
from 9 vol ts to 19 vol ts. An I nternati onal Control and
Di spl ay Symbol i con for “Battery Chargi ng Condi -
ti on” i s l ocated on the cl uster overl ay, di rectl y above
the hub of the gauge needl e (Fi g. 29). The vol tage
gauge graphi cs are whi te and bl ue agai nst a bl ack
fi el d except for a si ngl e red graduati on at each end of
the gauge scal e, maki ng them cl earl y vi si bl e wi thi n
the i nstrument cl uster i n dayl i ght. When i l l umi nated
from behi nd by the panel l amps di mmer control l ed
cl uster i l l umi nati on l i ghti ng wi th the exteri or l amps
turned On, the whi te graphi cs appear whi te, the bl ue
graphi cs appear bl ue, and the red graphi cs appear
red. The orange gauge needl e i s i nternal l y i l l umi -
nated. Gauge i l l umi nati on i s provi ded by repl aceabl e
i ncandescent bul b and bul b hol der uni ts l ocated on
the i nstrument cl uster el ectroni c ci rcui t board. The
vol tage gauge i s servi ced as a uni t wi th the i nstru-
ment cl uster.
OPERATION
The vol tage gauge gi ves an i ndi cati on to the vehi -
cl e operator of the el ectri cal system vol tage. Thi s
gauge i s control l ed by the i nstrument cl uster ci rcui t
board based upon cl uster programmi ng and el ec-
troni c messages recei ved by the cl uster from the
Powertrai n Control Modul e (PCM) over the Program-
mabl e Communi cati ons I nterface (PCI ) data bus. The
vol tage gauge i s an ai r core magneti c uni t that
recei ves battery current on the i nstrument cl uster
el ectroni c ci rcui t board through the fused i gni ti on
swi tch output (run-start) ci rcui t whenever the i gni -
ti on swi tch i s i n the On or Start posi ti ons. The cl us-
ter i s programmed to move the gauge needl e back to
the l eft end of the scal e after the i gni ti on swi tch i s
turned to the Off posi ti on. The i nstrument cl uster
ci rcui try control s the gauge needl e posi ti on and pro-
vi des the fol l owi ng features:
• System Voltage Message - Each ti me the cl us-
ter recei ves a system vol tage message from the PCM
i ndi cati ng the system vol tage i s between about 9.5
vol ts and about 18.5 vol ts, the gauge needl e i s moved
to the rel ati ve vol tage posi ti on on the gauge scal e.
• System Voltage Low (Charge Fail) Message
- Each ti me the cl uster recei ves a message from the
PCM i ndi cati ng the el ectri cal system vol tage i s l ess
than about 9.0 vol ts (charge fai l condi ti on), the gauge
needl e i s moved to the 9 vol t graduati on on the far
l eft end of the gauge scal e and the check gauges i ndi -
cator i s i l l umi nated. The gauge needl e remai ns on
the 9 vol t graduati on and the check gauges i ndi cator
remai ns i l l umi nated unti l the cl uster recei ves a mes-
sage from the PCM i ndi cati ng the el ectri cal system
vol tage i s greater than about 12.0 vol ts (but l ess than
about 16.0 vol ts), or unti l the i gni ti on swi tch i s
turned to the Off posi ti on, whi chever occurs fi rst.
• System Voltage High Message - Each ti me
the cl uster recei ves a message from the PCM i ndi cat-
i ng the el ectri cal system vol tage i s greater than
about 19.0 vol ts, the gauge needl e i s moved to the 19
vol t graduati on on the far ri ght end of the gauge
scal e and the check gauges i ndi cator i s i l l umi nated.
The gauge needl e remai ns on the ri ght end of the
gauge scal e and the check gauges i ndi cator remai ns
i l l umi nated unti l the cl uster recei ves a message from
the PCM i ndi cati ng the el ectri cal system vol tage i s
l ess than about 16.0 (but greater than about 9.5
vol ts), or unti l the i gni ti on swi tch i s turned to the Off
posi ti on, whi chever occurs fi rst.
• Communication Error - I f the cl uster fai l s to
recei ve a system vol tage message, i t wi l l hol d the
gauge needl e at the l ast i ndi cati on about twel ve sec-
onds or unti l the i gni ti on swi tch i s turned to the Off
posi ti on, whi chever occurs fi rst. After twel ve seconds,
i t wi l l move the gauge needl e to the far l eft end of
the gauge scal e.
• Actuator Test - Each ti me the cl uster i s put
through the actuator test, the gauge needl e wi l l be
swept to several cal i brati on poi nts on the gauge scal e
Fig. 29 Battery Charging Condition Icon
TJ INSTRUMENT CLUSTER 8J - 43
UPSHIFT INDICATOR (Continued)
i n a prescri bed sequence i n order to confi rm the func-
ti onal i ty of the gauge and the cl uster control ci r-
cui try.
The PCM conti nual l y moni tors the system vol tage
to control the generator output. The PCM then sends
the proper system vol tage messages to the i nstru-
ment cl uster. For further di agnosi s of the vol tage
gauge or the i nstrument cl uster ci rcui try that con-
trol s the gauge, (Refer to 8 - ELECTRI CAL/I NSTRU-
MENT CLUSTER - DI AGNOSI S AND TESTI NG). I f
the i nstrument cl uster turns on the check gauges
i ndi cator due to a charge fai l or vol tage hi gh condi -
ti on, i t may i ndi cate that the chargi ng system
requi res servi ce. For proper di agnosi s of the chargi ng
system, the PCM, the PCI data bus, or the el ectroni c
message i nputs to the i nstrument cl uster that control
the vol tage gauge, a DRBI I I ௡ scan tool i s requi red.
Refer to the appropri ate di agnosti c i nformati on.
8J - 44 INSTRUMENT CLUSTER TJ
VOLTAGE GAUGE (Continued)
LAMPS
TABLE OF CONTENTS
page page
LAMPS/LIGHTING - EXTERIOR . . . . . . . . . . . . . . . 1 LAMPS/LIGHTING - INTERIOR. . . . . . . . . . . . . . . 32
LAMPS/LIGHTING - EXTERIOR
TABLE OF CONTENTS
page page
LAMPS/LIGHTING - EXTERIOR
DESCRIPTION - TURN SIGNAL & HAZARD
WARNING SYSTEM . . . . . . . . . . . . . . . . . . . . . 2
OPERATION - TURN SIGNAL & HAZARD
WARNING SYSTEM . . . . . . . . . . . . . . . . . . . . . 3
WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - TURN SIGNAL
& HAZARD WARNING SYSTEM. . . . . . . . . . . . 3
DIAGNOSIS AND TESTING - HEADLAMP
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . 6
SPECIFICATIONS
EXTERIOR LAMPS . . . . . . . . . . . . . . . . . . . . . 8
SPECIAL TOOLS
HEADLAMP ALIGNMENT . . . . . . . . . . . . . . . . 8
BRAKE LAMP SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
DIAGNOSIS AND TESTING - BRAKE LAMP
SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 9
ADJUSTMENTS
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . 9
CENTER HIGH MOUNTED STOP LAMP UNIT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 9
CENTER HIGH MOUNTED STOP LAMP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10
COMBINATION FLASHER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 10
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12
DAYTIME RUNNING LAMP MODULE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 12
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
DIAGNOSIS AND TESTING - DAYTIME
RUNNING LAMP SYSTEM . . . . . . . . . . . . . . . 12
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 13
FOG LAMP UNIT
DIAGNOSIS AND TESTING - FRONT FOG
LAMP SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 13
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 15
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . 15
FOG LAMP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 15
FOG LAMP RELAY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 16
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 16
FOG LAMP UNIT - REAR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 17
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
DIAGNOSIS AND TESTING - REAR FOG
LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 18
FOG LAMP - REAR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 18
FRONT PARK/TURN SIGNAL LAMP UNIT
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 19
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 19
TJ LAMPS 8L - 1
FRONT PARK/TURN SIGNAL LAMP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 19
HEADLAMP
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 19
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 20
HEADLAMP LEVELING SWITCH
REMOVAL
HEADLAMP LEVELING SWITCH . . . . . . . . . . 21
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 21
HEADLAMP LEVELING MOTOR
DIAGNOSIS AND TESTING - HEADLAMP
LEVELING SYSTEM . . . . . . . . . . . . . . . . . . . 21
LEFT MULTI-FUNCTION SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 23
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
DIAGNOSIS AND TESTING - LEFT MULTI-
FUNCTION SWITCH . . . . . . . . . . . . . . . . . . . 25
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 27
SIDE MARKER LAMP UNIT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 28
SIDE MARKER LAMP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 28
REPEATER LAMP
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 28
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
DIAGNOSIS AND TESTING - SIDE REPEATER
LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
TAIL LAMP UNIT
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 29
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 29
TAIL LAMP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 30
TURN SIGNAL CANCEL CAM
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 30
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
UNDERHOOD LAMP UNIT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 30
UNDERHOOD LAMP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 31
LAMPS/LIGHTING - EXTERIOR
DESCRIPTION - TURN SIGNAL & HAZARD
WARNING SYSTEM
A turn si gnal and hazard warni ng system i s stan-
dard factory-i nstal l ed safety equi pment. The turn si g-
nal and hazard warni ng system i ncl udes the
fol l owi ng major components, whi ch are descri bed i n
further detai l el sewhere i n thi s servi ce i nformati on:
• Combination Flasher - The el ectroni c combi -
nati on fl asher i s l ocated on the back of the l eft mul ti -
functi on swi tch, beneath the upper steeri ng col umn
shroud on the top of the steeri ng col umn.
• Front Side Marker Lamps - The front si de
marker l amps are l ocated on the outboard ends of
the two front fender fl ares.
• Turn Signal Repeater Lamps - The turn si g-
nal repeater l amps are l ocated on the outboard ends
of the two front fender fl ares.
• Hazard Warning Switch - The hazard warni ng
swi tch i s i ntegral to the l eft mul ti -functi on swi tch.
The hazard warni ng swi tch button protrudes from an
openi ng i n the shroud on the top of the steeri ng col -
umn.
• Turn Signal Cancel Cam - The turn si gnal
cancel cam i s i ntegral to the steeri ng col umn cl ock-
spri ng, whi ch i s l ocated beneath the shrouds on the
top of the steeri ng col umn.
• Turn Signal Indicators - The two turn si gnal
i ndi cators are i ntegral to the El ectroMechani cal
I nstrument Cl uster (EMI C) l ocated i n the i nstrument
panel .
• Turn Signal Lamps - The front turn si gnal
l amps are i ntegral to the front park/turn si gnal
l amps l ocated besi de each headl amp on the front
fender. The rear turn si gnal l amps are i ntegral to the
back-up/brake/rear turn si gnal /tai l l amps l ocated on
ei ther si de of the rear of the quarter panel s.
• Turn Signal Switch - The turn si gnal swi tch i s
i ntegral to the l eft mul ti -functi on swi tch. The l eft
mul ti -functi on swi tch control stal k actuates the turn
si gnal swi tch i n the steeri ng col umn.
The turn si gnal system i n thi s vehi cl e i ncl udes a
turn si gnal -on warni ng chi me feature. The EMI C
el ectroni c ci rcui try moni tors the turn si gnal i ndi ca-
tors as wel l as el ectroni c vehi cl e speed and di stance
messages recei ved from the PCM over the PCI data
bus network to provi de thi s feature. I f an i ndi cator
remai ns i l l umi nated conti nuousl y wi th the vehi cl e
speed above about 25 ki l ometers per hour (15 mi l es
per hour) for a di stance of greater than about 1.6
ki l ometers (1 mi l e), the EMI C generates a chi me
through an i ntegral chi me tone generator (The di s-
tance i s greater for export vehi cl es).
Hard wi red ci rcui try connects the turn si gnal and
hazard warni ng system components to each other
through the el ectri cal system of the vehi cl e. Refer to
the appropri ate wi ri ng i nformati on.
8L - 2 LAMPS/LIGHTING - EXTERIOR TJ
OPERATION - TURN SIGNAL & HAZARD
WARNING SYSTEM
The turn si gnal system operates on battery vol tage
recei ved on a i gni ti on swi tch output (run) ci rcui t so
that the turn si gnal s wi l l onl y operate wi th the i gni -
ti on swi tch i n the On posi ti on. The hazard warni ng
system operates on non-swi tched battery vol tage so
that the hazard warni ng remai ns operati onal regard-
l ess of the i gni ti on swi tch posi ti on. When the turn
si gnal swi tch control stal k i s moved up or down, the
turn si gnal system i s acti vated. When the turn si gnal
system i s acti vated, the ci rcui try of the turn si gnal
swi tch and the combi nati on fl asher wi l l cause the
sel ected turn si gnal i ndi cator, front park/turn si gnal
l amp, front si de marker l amp, repeater l amps, and
rear tai l /stop/turn si gnal l amp to fl ash on and off.
When the hazard warni ng system i s acti vated, the
ci rcui try of the hazard warni ng swi tch and the com-
bi nati on fl asher wi l l cause both the ri ght si de and
the l eft si de turn si gnal i ndi cators, front park/turn
si gnal l amps, front si de marker l amps, repeater
l amps and rear tai l /stop/turn si gnal l amps to fl ash on
and off.
I n order to provi de the turn si gnal -on warni ng, the
El ectroMechani cal I nstrument Cl uster (EMI C) moni -
tors vehi cl e speed and di stance messages recei ved
from the PCM over the PCI data bus and the hard
wi red turn si gnal swi tch i nput to the cl uster el ec-
troni c ci rcui t board. I f a turn si gnal remai ns i ndi -
cated for a di stance of greater than about 1.6
ki l ometers (1 mi l e) and the vehi cl e speed remai ns
greater than about 24 ki l ometers-per-hour (15 mi l es-
per-hour), the EMI C generates a repeti ti ve chi me at
a sl ow rate to provi de an audi bl e remi nder that a
turn si gnal has been l eft on (di stance i s sl i ghtl y
l onger wi th export vehi cl es). Once the warni ng chi me
begi ns to sound, i t wi l l conti nue unti l the turn si gnal
i s cancel l ed, unti l the vehi cl e speed fal l s bel ow about
24 ki l ometers-per-hour (15 mi l es-per-hour), or unti l
the i gni ti on swi tch i s turned to the Off posi ti on,
whi chever occurs fi rst. Thi s feature i s not acti vated
by a hazard warni ng i nput to the i nstrument cl uster.
Duri ng both the turn si gnal and the hazard warn-
i ng operati on, i f the exteri or l amps are turned Off,
the front park/turn si gnal l amps, repeater l amps and
the front si de marker l amps wi l l fl ash i n uni son. I f
the exteri or l amps are turned On, the front park/turn
si gnal l amps, repeater l amps and the front si de
marker l amps wi l l fl ash al ternatel y.
WARNING
WARNING:: EYE PROTECTION SHOULD BE USED
WHEN SERVICING GLASS COMPONENTS. PER-
SONAL INJURY CAN RESULT.
CAUTION: Do not touch the glass of halogen bulbs
with fingers or other possibly oily surface, reduced
bulb life will result.
CAUTION: Do not use bulbs with higher candle
power than indicated in the Bulb Application table
at the end of this group. Damage to lamp and/or
Daytime Running Lamp Module can result.
CAUTION: Do not use fuses, circuit breakers, or
relays having greater amperage values than indi-
cated on the fuse panel or in the Owner’s Manual.
NOTE: When it is necessary to remove components
to service another, it should not be necessary to
apply excessive force or bend a component to
remove it. Before damaging a trim component, ver-
ify hidden fasteners or captured edges are not hold-
ing the component in place.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - TURN SIGNAL &
HAZARD WARNING SYSTEM
Al ways begi n any di agnosi s by testi ng al l of the
fuses and ci rcui t breakers i n the system. Refer to the
appropri ate wi ri ng i nformati on.
When di agnosi ng the turn si gnal or hazard warn-
i ng ci rcui ts, remember that hi gh generator output
can burn out bul bs rapi dl y and repeatedl y. I f thi s i s a
probl em on the vehi cl e bei ng di agnosed (Refer to 8 -
ELECTRI CAL/CHARGI NG - DI AGNOSI S AND
TESTI NG). I f the probl em bei ng di agnosed i s rel ated
to a fai l ure of the turn si gnal s to automati cal l y can-
cel fol l owi ng compl eti on of a turn, i nspect the mul ti -
functi on swi tch for a faul ty or damaged cancel
actuator and i nspect the turn si gnal cancel cam l obes
on the cl ockspri ng mechani sm for damage or
i mproper i nstal l ati on. For compl ete ci rcui t di agrams,
refer to the appropri ate wi ri ng i nformati on.
TJ LAMPS/LIGHTING - EXTERIOR 8L - 3
LAMPS/LIGHTING - EXTERIOR (Continued)
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
CONDITION POSSIBLE CAUSES CORRECTION
ONE TURN SIGNAL LAMP
DOES NOT ILLUMINATE
1. Faulty or missing bulb 1. Test and replace turn signal
bulb as required.
2. Faulty ground circuit. 2. Test and repair open ground
circuit
3. Faulty signal circuit. 3. Test and repair open right or
left turn signal circuit.
ALL RIGHT SIDE AND/OR
LEFT SIDE TURN SIGNAL
LAMPS DO NOT FLASH
1. Faulty multifunction switch. 1. Test and replace the
multifunction switch as required.
2. Faulty flasher. 2. Replace the hazard
switch/combination flasher.
ALL RIGHT SIDE OR LEFT
SIDE TURN SIGNALS
FLASH RAPIDLY
1. Faulty or missing bulb. 1. Test and replace faulty bulb
as required.
2. Faulty ground circuit. 2. Test and repair open ground
circuit as required.
3. Faulty signal circuit. 3. Test and repair high
resistance or open signal circuit
as required.
4. Faulty flasher. 4. Replace flasher.
HAZARD WARNING
LAMPS DO NOT FLASH
1. Faulty or missing fuse. 2. Test and replace fuse as
required.
2. Faulty ground circuit. 2. Test and repair high
resistance or open ground
circuit.
3. Open battery positive voltage
circuit to hazard warning switch.
3. Test and repair open battery
voltage circuit to hazard
warning switch.
4. Faulty flasher 4. Replace flasher
5. Faulty multifunction switch. 5. Test and replace the
multifunction switch as required.
8L - 4 LAMPS/LIGHTING - EXTERIOR TJ
LAMPS/LIGHTING - EXTERIOR (Continued)
DIAGNOSIS AND TESTING - HEADLAMP
SYSTEM
Al ways begi n any di agnosi s by testi ng al l of the
fuses and ci rcui t breakers i n the system. Refer to the
appropri ate wi ri ng i nformati on.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
Conventi onal and hal ogen headl amps are i nter-
changeabl e. I t i s recommended that they not be
i ntermi xed.
CONDITION POSSIBLE CAUSES CORRECTION
HEADLAMPS ARE DIM
WITH ENGINE IDLING OR
IGNITION TURNED OFF
1. Loose or corroded battery cables. 1. Clean and secure battery cable clamps
and posts.
2. Loose or worn generator drive
belt.
2. Adjust or replace generator drive belt.
3. Charging system output too low. 3. Test and repair charging system. (Refer
to 8 - ELECTRICAL/CHARGING -
DIAGNOSIS AND TESTING)
4. Battery has insufficient charge. 4. Test battery state-of -charge. (Refer to 8 -
ELECTRICAL/BATTERY SYSTEM/
BATTERY - DIAGNOSIS AND TESTING)
5. Battery is sulfated or shorted. 5. Load test battery. (Refer to 8 -
ELECTRICAL/BATTERY SYSTEM/
BATTERY - DIAGNOSIS AND TESTING)
6. Poor lighting circuit ground. 6. Test for voltage drop across ground
locations.
7. Both headlamp bulbs faulty. 7. Replace both headlamp bulbs.
HEADLAMP BULBS BURN
OUT FREQUENTLY
1. Charging system output too high. 1. Test and repair charging system. (Refer
to 8 - ELECTRICAL/CHARGING -
DIAGNOSIS AND TESTING)
2. Loose or corroded terminals or
splices in headlamp circuit.
2. Inspect and repair all connectors and
splices.
HEADLAMPS ARE DIM
WITH ENGINE RUNNING
1. Charging system output too low. 1. Test and repair charging system. (Refer
to 8 - ELECTRICAL/CHARGING -
DIAGNOSIS AND TESTING)
ABOVE IDLE* 2. Poor lighting circuit ground. 2. Test for voltage drop across ground
locations.
3. High resistance in headlamp
circuit.
3. Test amperage draw of headlamp circuit.
4. Both headlamp bulbs faulty. 4. Replace both headlamp bulbs.
TJ LAMPS/LIGHTING - EXTERIOR 8L - 5
LAMPS/LIGHTING - EXTERIOR (Continued)
CONDITION POSSIBLE CAUSES CORRECTION
HEADLAMPS FLASH
RANDOMLY
1. Poor lighting circuit ground. 1. Test for voltage drop across ground
locations.
2. High resistance in headlamp
circuit.
2. Test amperage draw of headlamp circuit.
Should not exceed 30 amps.
3. Faulty headlamps switch circuit
breaker.
3. Replace headlamp switch. (Refer to 8 -
ELECTRICAL/LAMPS/LIGHTING -
EXTERIOR/HEADLAMP SWITCH -
REMOVAL)
4. Short in headlamp circuit Test headlamp circuit, repair as necessary.
4. Loose or corroded terminals or
splices in headlamp circuit.
4. Inspect and repair all connectors and
splices.
HEADLAMPS DO NOT
ILLUMINATE LOW OR
HIGH BEAM
1. No voltage to headlamps. 1. Repair open headlamp circuit.
2. No ground at headlamps. 2. Repair circuit ground.
3. Faulty headlamp switch. 3. Replace headlamp switch. (Refer to 8 -
ELECTRICAL/LAMPS/LIGHTING -
EXTERIOR/HEADLAMP SWITCH -
REMOVAL)
4. Faulty headlamp dimmer
(multi-function) switch.
4. Replace multi-function switch.
5. Broken connector terminal or wire
splice in headlamp circuit.
5. Repair connector terminal or wire splice.
6. Both headlamp bulbs faulty. 6. Replace both headlamp bulbs.
*Canada vehicles must have lamps ON.
ADJUSTMENTS
HEADLAMP ALIGNMENT PREPARATION
NOTE: If the vehicle is equipped with a headlamp
leveling system, be certain the headlamp leveling
switch is in the “0” position.
(1) Veri fy headl amps are operati onal i n al l modes
and i l l umi nated i n the l ow beam setti ng.
(2) Correct defecti ve components that coul d hi nder
proper headl amp al i gnment.
(3) Veri fy proper ti re i nfl ati on.
(4) Cl ean headl amp l enses.
(5) Veri fy that l uggage area i s not heavi l y l oaded.
(6) Fuel tank shoul d be FULL. Add 2.94 kg (6.5
l bs.) of wei ght over the fuel tank for each esti mated
gal l on of mi ssi ng fuel .
ALIGNMENT SCREEN PREPARATION
(1) Posi ti on vehi cl e on a l evel surface perpendi cu-
l ar to a fl at wal l 7.62 meters (25 ft.), export vehi cl es
use 10 meters (32.8 ft.), away from front of headl amp
l ens (Fi g. 1).
(2) I f necessary, tape a l i ne on the fl oor 7.62
meters (25 ft.), export vehi cl es use 10 meters (32.8
ft.), away from and paral l el to the wal l .
(3) Measure from the fl oor up 1.27 meters (5 ft.)
and tape a verti cal l i ne on the wal l at the centerl i ne
of the vehi cl e. Si ght al ong the centerl i ne of the vehi -
cl e (from rear of vehi cl e forward) to veri fy accuracy of
the l i ne pl acement.
(4) Rock vehi cl e si de-to-si de three ti mes to al l ow
suspensi on to stabi l i ze.
(5) Jounce front suspensi on three ti mes by pushi ng
downward on front bumper and rel easi ng.
(6) Measure the di stance from the center of head-
l amp l ens to the fl oor. Transfer measurement to the
al i gnment screen (wi th tape). Use thi s hori zontal l i ne
for up/down adjustment reference.
(7) Pl ace a tape l i ne 130 mm (5.12 i n.) bel ow par-
al l el to center of headl amp l i ne.
(8) Measure di stance from the centerl i ne of the
vehi cl e to the center of each headl amp bei ng al i gned.
Transfer measurements to screen (wi th tape) to each
si de of vehi cl e centerl i ne. Use these l i nes for l eft/
ri ght adjustment reference.
8L - 6 LAMPS/LIGHTING - EXTERIOR TJ
LAMPS/LIGHTING - EXTERIOR (Continued)
HEADLAMP ADJUSTMENT
(1) Pl ace headl amps on LOW beam.
(2) Cover front of the headl amp that i s not bei ng
adjusted.
(3) Turn the upper, outboard (up/down) adjustment
screw (Fi g. 2)unti l the headl amp beam pattern on
screen/wal l i s si mi l ar to the pattern depi cted i n (Fi g.
1)
NOTE: When using a headlamp aiming screen:
• Adjust the headl amps so that the beam hori zon-
tal posi ti on i s at 0.
• Adjust the beam verti cal posi ti on i s 25 mm (1
i n) downward from the l amp hori zontal centerl i ne.
(4) Rotate the l ower, i nboard (l eft/ri ght) adjust-
ment screw (Fi g. 2) unti l the headl amp beam pattern
on the ai mi ng screen/wal l si mi l ar to the pattern i n
(Fi g. 1).
(5) Cover front of the headl amp that has been
adjusted and adjust the other headl amp beam as
i nstructed above.
Fig. 1 Headlamp Alignment Screen -Typical
1 - CENTER OF VEHICLE TO CENTER OF HEADLAMP LENS
2 - FLOOR TO CENTER OF HEADLAMP LENS
3 - 7.62 METERS (25 FEET)
4 - FRONT OF HEADLAMP
5 - VEHICLE CENTERLINE
Fig. 2 Headlamp Adjustment Screws
1 - UP/DOWN ADJUSTMENT SCREW
2 - LEFT/RIGHT ADJUSTMENT SCREW
TJ LAMPS/LIGHTING - EXTERIOR 8L - 7
LAMPS/LIGHTING - EXTERIOR (Continued)
SPECIFICATIONS
EXTERIOR LAMPS
CAUTION: Do not use bulbs that have a higher can-
dle power than the bulb listed in the Bulb Applica-
tion Table. Damage to lamp can result. Do not touch
halogen bulbs with fingers or other oily surfaces.
Bulb life will be reduced.
The fol l owi ng Bul b Appl i cati on Tabl e l i sts the l amp
ti tl e on the l eft si de of the col umn and trade number
or part number on the ri ght for domesti c and export
vehi cl es.
LAMP BULB
Back-up lamp 1156 or P21W
Center High Mounted
Stoplamp
921 or W16W
Front Fog lamp H3
Front Position lamp T4W
Front Side Marker 168 or W3W
Headlamp/Sealed Beam H6024 or H4
License Plate lamp W5W
Export Only
Park/Turn Signal 3157 or P27/7W
Rear Fog lamp P21W
Side Repeater lamp W3W
Tail/Stop 1157 or P21/5W
Underhood lamp W5W
Underhood Retractable
Lamp
105
SPECIAL TOOLS
HEADLAMP ALIGNMENT
BRAKE LAMP SWITCH
DESCRIPTION
The brake l amp swi tch consi sts of mul ti pl e swi tch
contacts ei ther normal l y open or cl osed. The swi tch
contacts provi de brake pedal status to the vari ous
control l ers. The pri mary functi on of the swi tch i s to
i l l umi nate the brake l amps. The brake l amp swi tch
i s adjustabl e and mounted on the brake pedal mount-
i ng bracket under the i nstrument panel .
OPERATION
Vehi cl es equi pped wi th the speed control opti on use
a mul ti pl e functi on brake l amp swi tch. The PCM
moni tors the state of the brake l amp swi tch. Refer to
the Brake secti on for more i nformati on on brake
l amp swi tch servi ce and adjustment procedures.
The pri mary functi on of the brake swi tch i s to turn
on the brake l amps duri ng braki ng. The swi tch i s
al so used to send si gnal s to components that must
know when the brakes are appl i ed, such as the Pow-
ertrai n Control Modul e (PCM), whi ch uses the si gnal
to cancel speed control . The Control l er Anti l ock
Brake (CAB) uses the brake swi tch si gnal to moni tor
brake pedal appl i cati on. When the normal l y cl osed
swi tch contacts open, the CAB recei ves the brake
appl i ed si gnal . The CAB then moni tors the ABS sys-
tem to anti ci pate the need for a ABS stop.
DIAGNOSIS AND TESTING - BRAKE LAMP
SWITCH
The brake l amp swi tch operati on can be tested
wi th an ohmmeter. The ohmmeter i s used to check
conti nui ty between the pi n termi nal s (Fi g. 3).
SWITCH CIRCUIT IDENTIFICATION
• Termi nal s 1 and 2: brake sensor ci rcui t
• Termi nal s 3 and 4: speed control ci rcui t i f
equi pped
• Termi nal s 5 and 6: brake l amp ci rcui t
Headlamp Aiming Kit C-4466–A
Fig. 3 Brake Lamp Switch Terminal Identification
1 - TERMINAL PINS
2 - PLUNGER TEST POSITIONS
8L - 8 LAMPS/LIGHTING - EXTERIOR TJ
LAMPS/LIGHTING - EXTERIOR (Continued)
SWITCH CONTINUITY TEST
NOTE: Disconnect switch harness before testing
switch continuity.
Wi th the swi tch pl unger retracted, attach test
l eads to termi nal pi ns 1 and 2. Repl ace swi tch i f
meter i ndi cates no conti nui ty.
Wi th the swi tch pl unger retracted, attach test
l eads to termi nal pi ns 3 and 4. Repl ace swi tch i f
meter i ndi cates no conti nui ty.
Wi th the swi tch pl unger extended, attach test
l eads to termi nal pi ns 5 and 6. Repl ace swi tch i f
meter i ndi cates no conti nui ty.
REMOVAL
(1) Remove the steeri ng col umn cover and the
l ower tri m panel .
(2) Press the brake pedal downward to ful l y
appl i ed posi ti on.
(3) Rotate the swi tch approxi matel y 30° i n coun-
tercl ockwi se di recti on. Then pul l the swi tch rearward
and out of bracket.
(4) Di sconnect the swi tch harness and remove the
swi tch (Fi g. 4).
INSTALLATION
(1) Pul l the swi tch pl unger al l of the way out, to
ful l y extended posi ti on.
(2) Connect the harness connector to the swi tch.
(3) Press and hol d the brake pedal i n the appl i ed
posi ti on.
(4) Al i gn the tab on the swi tch wi th the notch i n
the swi tch bracket. Then i nsert the swi tch i n the
bracket and turn i t cl ockwi se about 30° to l ock i t i n
pl ace.
(5) Rel ease the brake pedal , then pul l the pedal
ful l y rearward. Pedal wi l l set the pl unger to the cor-
rect posi ti on as the pedal pushes the pl unger i nto the
swi tch body. The swi tch wi l l make ratcheti ng sound
as i t sel f adjusts.
ADJ USTMENTS
ADJUSTMENT
(1) Press and hol d brake pedal i n appl i ed posi ti on.
(2) Pul l swi tch pl unger al l the way out to ful l y
extended posi ti on.
(3) Rel ease brake pedal . Then pul l pedal l i ghtl y
rearward. Pedal wi l l set pl unger to correct posi ti on
as pedal pushes pl unger i nto swi tch body. Swi tch wi l l
make ratcheti ng sound as i t sel f adjusts.
CAUTION: Booster damage may occur if the pedal
pull exceeds 20 lbs.
CENTER HIGH MOUNTED
STOP LAMP UNIT
REMOVAL
NOTE: To remove to the CHMSL, it will be neces-
sary to remove spare tire from the spare tire carrier
bracket.
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the cover from CHMSL button contact
pl ate (Fi g. 5).
(3) Di sconnect the CHMSL wi re harness from the
CHMSL button contact termi nal s.
(4) Di sengage the CHMSL wi re harness from the
retai ni ng cl i ps.
(5) Di sengage the wi re harness grommet and route
the CHMSL wi re harness through the tai l gate.
(6) Remove the bol ts attachi ng CHMSL to the
spare ti re carri er bracket.
(7) Remove the CHMSL from the vehi cl e.
INSTALLATION
(1) Posi ti on the CHMSL to the vehi cl e.
(2) I nstal l the bol ts that secure the CHMSL to the
spare ti re carri er bracket.
(3) Route the CHMSL wi re harness through the
tai l gate and seat the wi re harness grommet.
(4) Connect the CHMSL wi re harness to the
CHMSL button contact termi nal s.
(5) Posi ti on the CHMSL wi re harness i nto the
retai ni ng cl i ps and engage the cl i ps.
(6) I nstal l the CHMSL button contact pl ate cover.
Fig. 4 Brake Lamp Switch
1 - RETAINER
2 - TERMINALS
3 - SWITCH PLUNGER
TJ LAMPS/LIGHTING - EXTERIOR 8L - 9
BRAKE LAMP SWITCH (Continued)
(7) Reconnect the battery negati ve cabl e.
CENTER HIGH MOUNTED
STOP LAMP
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the screws that secure the CHMSL
l ens to the CHMSL housi ng (Fi g. 6).
(3) Remove the CHMSL l ens from the CHMSL
housi ng.
(4) Rotate the l amp socket one-thi rd turn counter-
cl ockwi se and separate the l amp socket from the
CHMSL l ens.
(5) Pul l the l amp strai ght out of the socket.
INSTALLATION
(1) I nstal l the l amp i nto the socket by pushi ng i t
strai ght i nto the socket.
(2) I nstal l the l amp socket i nto the CHMSL l ens
by turni ng the socket one-thi rd turn cl ockwi se.
(3) Posi ti on the CHMSL l ens onto the CHMSL
housi ng.
(4) I nstal l the screws that secure the CHMSL l ens
to the CHMSL housi ng.
(5) Reconnect the battery negati ve cabl e.
COMBINATION FLASHER
DESCRIPTION
The combi nati on fl asher i s l ocated to the back of
the l eft mul ti -functi on swi tch housi ng on the top of
the steeri ng col umn, where i t i s conceal ed beneath
the upper steeri ng col umn shroud (Fi g. 7). The com-
bi nati on fl asher i s a smart rel ay that functi ons as
both the turn si gnal system and the hazard warni ng
system fl asher. The combi nati on fl asher contai ns
acti ve el ectroni c I ntegrated Ci rcui try (I C) el ements.
Thi s fl asher i s desi gned to handl e the current fl ow
requi rements of the factory-i nstal l ed l i ghti ng. I f sup-
pl emental l i ghti ng i s added to the turn si gnal l amp
ci rcui ts, such as when towi ng a trai l er wi th l i ghts,
Fig. 5 CHMSL and Contact Buttons
1 - CHMSL
2 - CHMSL BUTTON CONTACT PLATE
3 - TAILGATE
4 - CHMSL CONTACT BUTTONS
5 - BODY
6 - SPARE TIRE CARRIER BRACKET
Fig. 6 CHMSL Lamp
1 - SOCKET
2 - CHMSL LENS
3 - LAMP
Fig. 7 Combination Flasher
1 - COMBINATION FLASHER
2 - LEFT MULTI-FUNCTION SWITCH
8L - 10 LAMPS/LIGHTING - EXTERIOR TJ
CENTER HIGH MOUNTED STOP LAMP UNIT (Continued)
the combi nati on fl asher wi l l automati cal l y try to
compensate to keep the fl ash rate the same.
The combi nati on fl asher cannot be repai red or
adjusted and, i f faul ty or damaged, i t must be
repl aced.
OPERATION
Constant battery vol tage i s suppl i ed to the fl asher
so that i t can perform the hazard warni ng functi on,
and i gni ti on swi tched battery vol tage i s suppl i ed for
the turn si gnal functi on. The I ntegrated Ci rcui t (I C)
wi thi n the combi nati on fl asher contai ns the l ogi c that
control s the fl asher operati on and the fl ash rate. The
I C recei ves sense ground i nputs from the mul ti -func-
ti on swi tch for the hazard fl asher, ri ght turn si gnal ,
and l eft turn si gnal . A speci al desi gn feature of the
combi nati on fl asher al l ows i t to ЉsenseЉ that a turn
si gnal ci rcui t or bul b i s not operati ng, and provi de
the dri ver an i ndi cati on of the condi ti on by fl ashi ng
the remai ni ng bul bs i n the affected ci rcui t at a
hi gher rate.
Because of the acti ve el ements wi thi n the combi na-
ti on fl asher, i t cannot be tested wi th conventi onal
automoti ve el ectri cal test equi pment. I f the combi na-
ti on fl asher i s bel i eved to be faul ty, test the turn si g-
nal and hazard warni ng system pri or to repl acement.
Refer to (Refer to 8 - ELECTRI CAL/LAMPS/LI GHT-
I NG - EXTERI OR - DI AGNOSI S AND TESTI NG).
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the steeri ng col umn cover from the
i nstrument panel . (Refer to 23 - BODY/I NSTRU-
MENT PANEL/STEERI NG COLUMN OPENI NG
COVER - REMOVAL).
(3) Remove the screws that secure the l ower steer-
i ng col umn shroud to the upper shroud (Fi g. 8).
(4) Move the ti l t steeri ng col umn to the ful l y l ow-
ered posi ti on and l eave the ti l t rel ease l ever i n the
rel eased posi ti on.
(5) Remove the upper shroud from the steeri ng col -
umn.
(6) Grasp the combi nati on fl asher fi rml y and pul l
i t toward the dash panel to di sengage the fl asher ter-
mi nal s. (Fi g. 9).
(7) Remove the combi nati on fl asher.
Fig. 8 Steering Column Shrouds Remove/Install
1 - LEFT MULTI-FUNCTION SWITCH
2 - UPPER SHROUD
3 - RIGHT MULTI-FUNCTION SWITCH
4 - CLOCKSPRING
5 - IGNITION LOCK CYLINDER HOUSING
6 - LOWER SHROUD
7 - SCREW (2)
Fig. 9 Combination Flasher
1 - COMBINATION FLASHER
2 - LEFT MULTI-FUNCTION SWITCH
TJ LAMPS/LIGHTING - EXTERIOR 8L - 11
COMBINATION FLASHER (Continued)
INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, SEAT BELT TENSIONER, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE AIRBAG SYSTEM CAPACITOR
TO DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
(1) Al i gn the combi nati on fl asher termi nal s wi th
the termi nal s i n the connector on the back of the l eft
mul ti -functi on swi tch housi ng. (Fi g. 9).
(2) Push on the combi nati on fl asher unti l the ter-
mi nal s are ful l y seated i n the l eft mul ti -functi on
swi tch connector.
(3) Posi ti on the upper shroud onto the steeri ng col -
umn (Fi g. 27).
(4) I nstal l and ti ghten the screws that secure the
l ower steeri ng col umn shroud to the upper shroud.
Ti ghten the screws to 2 N·m (18 i n. l bs.).
(5) Move the ti l t steeri ng col umn to the ful l y
rai sed posi ti on and secure i t i n pl ace by movi ng the
ti l t rel ease l ever back to the l ocked posi ti on.
(6) Rei nstal l the steeri ng col umn openi ng cover.
(Refer to 23 - BODY/I NSTRUMENT PANEL/STEER-
I NG COLUMN OPENI NG COVER - I NSTALLA-
TI ON).
(7) Reconnect the battery negati ve cabl e.
DAYTIME RUNNING LAMP
MODULE
DESCRIPTION
The Dayti me Runni ng Li ghts (Headl amps) System
i s i nstal l ed on vehi cl es manufactured for sal e i n Can-
ada onl y. A separate modul e, mounted on the cowl ,
control s the DRL.
OPERATION
Battery posi ti ve vol tage i s suppl i ed to the Dayti me
Runni ng Lamp (DRL) modul e through a ci rcui t
breaker and a fuse i n the PDC. I gni ti on posi ti ve vol t-
age i s suppl i ed to the DRL modul e through a fuse i n
the fuse bl ock. The DRL modul e al so uti l i zes a VSS
i nput, hi gh and l ow beam sense ci rcui ts and hi gh
beam i ndi cator dri ver. The DRL modul e i s grounded
to the chassi s. Once the vehi cl e reaches a speed of 3
kph (2 mph) and travel s more than 1 meter (3 feet)
wi th the headl amp swi tch i n the off posi ti on, the
DRL modul e wi l l acti vate the HI GH beams at a
reduced i ntensi ty (36% of ful l i ntensi ty). When the
headl amp swi tch i s pl aced i n the LOW beam posi ti on
the DRL wi l l turn off. When the headl amp swi tch i s
turned to the HI GH beam posi ti on, the hi gh beams
wi l l operate normal l y (ful l i ntensi ty) and the DRL
modul e wi l l al so i l l umi nate the HI GH BEAM i ndi ca-
tor i n the i nstrument cl uster.
DIAGNOSIS AND TESTING - DAYTIME
RUNNING LAMP SYSTEM
Al ways begi n any di agnosi s by testi ng al l of the
fuses and ci rcui t breakers i n the system. Refer to the
appropri ate wi ri ng i nformati on.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
8L - 12 LAMPS/LIGHTING - EXTERIOR TJ
COMBINATION FLASHER (Continued)
CONDITION POSSIBLE CAUSES CORRECTION
DAYTIME RUNNING LAMPS (DRL)
DO NOT OPERATE
1. Headlamp switch in the on
position.
1. Turn the headlamp switch to the
off position.
2. Poor connection at DRL module. 2. Secure connector on DRL
module.
3. Open battery positive voltage
circuit to DRL module
3. Test and repair open circuit.
4. Open ignition positive circuit to
DLR module.
4. Test and repair open circuit.
5. Headlamp circuit shorted to
ground.
5. Test and repair headlamp circuit.
6. Open or high resistance in DLR
module ground circuit.
6. Test and repair ground circuit.
7. Open VSS signal circuit. 7. Test and repair VSS signal circuit.
8. Defective DRL module. 8. Replace DRL module.
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Di sconnect the wi re harness connector from the
modul e.
(3) Remove the screws that attach the modul e to
the cowl (Fi g. 10).
(4) Separate the modul e from the vehi cl e.
INSTALLATION
(1) Posi ti on the DRL modul e on the cowl .
(2) I nstal l the screws.
(3) Connect the wi re harness connector to the mod-
ul e.
(4) Connect the battery negati ve cabl e.
FOG LAMP UNIT
DIAGNOSIS AND TESTING - FRONT FOG LAMP
SYSTEM
Al ways begi n any di agnosi s by testi ng al l of the
fuses and ci rcui t breakers i n the system. Refer to the
appropri ate wi ri ng i nformati on.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
Fig. 10 DRL Module
1 - COWL
2 - DAYTIME RUNNING LAMP MODULE
TJ LAMPS/LIGHTING - EXTERIOR 8L - 13
DAYTIME RUNNING LAMP MODULE (Continued)
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 system output too low. 3. Test and repair charging system. (Refer
to 8 - ELECTRICAL/CHARGING -
DIAGNOSIS AND TESTING)
4. Battery has insufficient charge. 4. Test battery state-of -charge. (Refer to 8
- ELECTRICAL/BATTERY SYSTEM/
BATTERY - DIAGNOSIS AND TESTING)
5. Battery is sulfated or shorted. 5. Load test battery. (Refer to 8 -
ELECTRICAL/BATTERY SYSTEM/
BATTERY - DIAGNOSIS AND TESTING)
6. Poor lighting circuit ground. 6. Test for voltage drop across ground
locations.
FOG LAMP BULBS BURN
OUT FREQUENTLY
1. Charging system output too high. 1. Test and repair charging system. (Refer
to 8 - ELECTRICAL/CHARGING -
DIAGNOSIS AND TESTING)
2. Loose or corroded terminals or
splices in circuit.
2. Inspect and repair all connectors and
splices.
FOG LAMPS ARE DIM
WITH ENGINE RUNNING
ABOVE IDLE
1. Charging system output too low. 1. Test and repair charging system. (Refer
to 8 - ELECTRICAL/CHARGING -
DIAGNOSIS AND TESTING)
2. Poor lighting circuit ground. 2. Test for voltage drop across ground
locations.
3. High resistance in fog lamp circuit. 3. Test amperage draw of fog lamp circuit.
FOG LAMPS FLASH
RANDOMLY
1. Poor lighting circuit ground. 1. Test for voltage drop across ground
locations.
2. High resistance in fog lamp circuit. 2. Test amperage draw of fog lamp circuit.
3. Faulty relay 3. Replace relay
4. Faulty fog lamp switch. 4. Replace multifunction switch.
5. Loose or corroded terminals or
splices in circuit.
5. Inspect and repair all connectors and
splices.
FOG LAMPS DO NOT
ILLUMINATE
1. Blown fuse for fog lamp. 1. Replace fuse.
2. No ground at fog lamps. 2. Repair circuit ground.
3. High beam headlamps illuminated 3. Switch headlamp beam selector to low
beam.
4. Faulty relay 4. Replace relay
5. Faulty fog lamp switch. 5. Replace left multifunction switch.
6. Shorted clockspring. 6. Replace clockspring.
7. Broken connector terminal or wire
splice in fog lamp circuit.
7. Repair connector terminal or wire splice.
8. Faulty or burned out bulb. 8. Replace bulb.
8L - 14 LAMPS/LIGHTING - EXTERIOR TJ
FOG LAMP UNIT (Continued)
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Di sconnect the fog l amp wi re harness connec-
tor.
(3) Remove the nut attachi ng the fog l amp to the
front bumper.
(4) Remove the fog l amp.
INSTALLATION
(1) Posi ti on the fog l amp on the bumper.
(2) I nstal l the nut attachi ng the fog l amp to the
front bumper.
(3) Connect the fog l amp wi re harness connector.
(4) Connect the battery negati ve cabl e.
(5) Readjust fog l amps (Refer to 8 - ELECTRI CAL/
LAMPS/LI GHTI NG - EXTERI OR/FOG LAMP UNI T
- ADJUSTMENTS).
ADJUSTMENTS
Prepare an al i gnment screen. A properl y al i gned
fog l amp wi l l project a pattern on the al i gnment
screen 100 mm (4 i n.) bel ow the fog l amp centerl i ne
and strai ght ahead (Fi g. 11).
(1) For adjustment, l oosen the pi vot nut and turn
the fogl amp adjusti ng screw (rear center of l amp)
cl ockwi se for up, countercl ockwi se for down, then
reti ghten the pi vot nut (Fi g. 12).
FOG LAMP
REMOVAL
CAUTION: Do not touch the bulb glass with fingers
or other oily surfaces. Reduced bulb life will result.
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the screws that attach the l ens and
refl ector to the l amp housi ng.
(3) Separate the l ens and refl ector from the l amp
housi ng.
(4) Di sconnect the el ectri cal connector from the
bul b.
(5) Squeeze the bul b retai ner together to di sengage
i t from the refl ector.
(6) Remove the bul b from the refl ector (Fi g. 13).
INSTALLATION
CAUTION: Do not touch the bulb glass with fingers
or other oily surfaces. Reduced bulb life will result.
(1) I nstal l the bul b i nto the refl ector.
Fig. 11 Fog Lamp Alignment - Typical
1 - VEHICLE CENTERLINE
2 - CENTER OF FOG LAMP LENS
3 - HIGH - INTENSITY AREA
4 - FLOOR TO CENTER OF FOG LAMP LENS
5 - 100mm (4 in.)
6 - 7.62 METERS (25 FEET), EXPORT USE 10 METERS (32.8ft.).
7 - FRONT OF FOG LAMP
Fig. 12 FOG LAMP ADJUSTER
1 - FOG LAMP
2 - BUMPER
3 - MOUNTING BRACKET
4 - PIVOT NUT
5 - ADJUSTER
TJ LAMPS/LIGHTING - EXTERIOR 8L - 15
FOG LAMP UNIT (Continued)
(2) Posi ti on and engage the bul b retai ner onto the
refl ector.
(3) Connect the el ectri cal connector to the bul b.
(4) I nstal l the l ens and refl ector to the l amp hous-
i ng.
(5) I nstal l the screws that attach the l ens and
refl ector to the l amp housi ng.
(6) Reconnect the battery negati ve cabl e.
FOG LAMP RELAY
DESCRIPTION
The fog l amp rel ay i s l ocated i n the Power Di stri -
buti on Center (PDC) i n the engi ne compartment of
the vehi cl e. The fog l amp rel ay i s a conventi onal
I nternati onal Standards Organi zati on (I SO) mi cro
rel ay (Fi g. 14). Rel ays conformi ng to the I SO speci fi -
cati ons have common physi cal di mensi ons, current
capaci ti es, termi nal patterns, and termi nal functi ons.
The rel ay i s contai ned wi thi n a smal l , rectangul ar,
mol ded pl asti c housi ng and i s connected to al l of the
requi red i nputs and outputs by fi ve i ntegral mal e
spade-type termi nal s that extend from the bottom of
the rel ay base.
The fog l amp rel ay cannot be adjusted or repai red
and, i f faul ty or damaged, i t must be repl aced.
OPERATION
The fog l amp rel ay i s an el ectromechani cal swi tch
that uses a l ow current i nput from the mul ti -functi on
swi tch to control a hi gh current output to the fog
l amps. The movabl e common feed contact poi nt i s
hel d agai nst the fi xed normal l y cl osed contact poi nt
by spri ng pressure. When the rel ay coi l i s energi zed,
an el ectromagneti c fi el d i s produced by the coi l wi nd-
i ngs. Thi s el ectromagneti c fi el d draws the movabl e
rel ay contact poi nt away from the fi xed normal l y
cl osed contact poi nt, and hol ds i t agai nst the fi xed
normal l y open contact poi nt. When the rel ay coi l i s
de-energi zed, spri ng pressure returns the movabl e
contact poi nt back agai nst the fi xed normal l y cl osed
contact poi nt. A resi stor i s connected i n paral l el wi th
the rel ay coi l i n the rel ay, and hel ps to di ssi pate vol t-
age spi kes and el ectromagneti c i nterference that can
be generated as the el ectromagneti c fi el d of the rel ay
coi l col l apses.
The fog l amp rel ay termi nal s are connected to the
vehi cl e el ectri cal system through a connector recepta-
cl e i n the Power Di stri buti on Center (PDC).
The fog l amp rel ay can be di agnosed usi ng conven-
ti onal di agnosti c tool s and methods. Refer to the
appropri ate wi ri ng i nformati on for di agnosi s and
testi ng of the fog l amp mi cro-rel ay and for compl ete
wi ri ng di agrams.
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the cover for the Power Di stri buti on
Center (PDC).
(3) Remove the fog l amp rel ay by graspi ng i t
fi rml y and pul l i ng i t strai ght out from the receptacl e
i n the PDC.
INSTALLATION
(1) Posi ti on the fog l amp rel ay to the proper recep-
tacl e i n the Power Di stri buti on Center (PDC).
Fig. 13 Fog Lamp Bulb
1 - BULB
2 - FOG LAMP HOUSING
3 - BULB RETAINER
4 - FRONT BUMPER
5 - LENS AND REFLECTOR
Fig. 14 ISO Micro Relay
30 - COMMON FEED
85 - COIL GROUND
86 - COIL BATTERY
87 - NORMALLY OPEN
87A - NORMALLY CLOSED
8L - 16 LAMPS/LIGHTING - EXTERIOR TJ
FOG LAMP (Continued)
(2) Al i gn the fog l amp rel ay termi nal s wi th the
termi nal cavi ti es i n the PDC.
(3) Press fi rml y and evenl y on the top of the fog
l amp rel ay unti l the termi nal s are ful l y seated i n the
PDC.
(4) Reconnect the battery negati ve cabl e.
FOG LAMP UNIT - REAR
DESCRIPTION
Some vehi cl es are equi pped wi th a rear fog l amp.
The l amp uni t can be found mounted to the rear
bumper assembl y. The rear fog l amp uni t uti l i zes a
red l ens wi th a cl ear l amp for bri ghtness, and an
i l l umi nated i ndi cator i n the i nstrument cl uster.
Rear fog l amp(s) are standard equi pment i n certai n
parts of the worl d where excessi ve fog i s experi enced
on a regul ar basi s.
OPERATION
Battery posi ti ve (B+) vol tage i s suppl i ed to the l eft
mul ti functi on swi tch. Wi th the headl amp swi tch i n
the on posi ti on, battery posi ti ve vol tage i s suppl i ed to
the rear fog l amp swi tch contacts wi thi n the mul ti -
functi on swi tch. Pul l i ng the headl amp swi tch knob
outward and then rotati ng the knob one detent coun-
tercl ockwi se wi l l acti vate the rear fog l amp(s) and
i l l umi nate the rear fog l amp i ndi cator i n the i nstru-
ment cl uster. The rear fog l amp(s) can onl y be acti -
vated when ei ther the Low Beam or Hi gh Beam
headl amps are on. Refer to Wi ri ng Di agrams for a
compl ete system schemati c.
DIAGNOSIS AND TESTING - REAR FOG LAMP
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
Al ways begi n any di agnosi s by testi ng al l of the
fuses and ci rcui t breakers i n the system. Refer to the
appropri ate wi ri ng i nformati on.
REAR FOG LAMP CONDITION CHART
CONDITION POSSIBLE CAUSES CORRECTION
REAR FOG LAMP IS ON
WITH IGNITION KEY ON
1. Shorted multifunction switch. 1. Test and replace multifunction switch
2. Shorted steering column clock
spring.
2. Test and replace clock spring.
3. Shorted fog lamp switch output
circuit
3. Repair short to voltage in fog lamp
switch output circuit.
REAR FOG LAMP BULB
BURNS OUT
FREQUENTLY
1. Charging system output too high. 1. Test and repair charging system.
2. Loose or corroded terminals or
splices in circuit.
2. Inspect and repair all connectors and
splices.
REAR FOG LAMP IS DIM
WITH ENGINE RUNNING
1. Charging system output too low. 1. Test and repair charging system.
2. Poor lighting circuit ground. 2. Test for voltage drop across ground
locations.
3. High resistance in fog lamp circuit. 3. Test amperage draw of fog lamp circuit.
REAR FOG LAMP
FLASHES RANDOMLY
1. Poor lighting circuit ground. 1. Test for voltage drop across ground
locations.
2. High resistance in fog lamp circuit. 2. Test amperage draw of fog lamp circuit.
3. Faulty multifunction switch. 3. Replace multifunction switch.
4. Loose or corroded terminals or
splices in circuit.
4. Inspect and repair all connectors and
splices.
TJ LAMPS/LIGHTING - EXTERIOR 8L - 17
FOG LAMP RELAY (Continued)
CONDITION POSSIBLE CAUSES CORRECTION
REAR FOG LAMP WILL
NOT ILLUMINATE
1. Open fuse for fog lamp. 1. Test fog lamp circuitry for short to ground
and replace fuse.
2. Open battery positive voltage
circuit to multifunction switch.
2. Test and repair open battery positive
voltage circuit.
3. No ground at fog lamps. 3. Repair circuit ground.
4. Faulty multifunction switch. 4. Replace multifunction switch.
5. Broken connector terminal or wire
splice in fog lamp circuit.
5. Repair connector terminal or wire splice.
6. Faulty or burned out bulb. 6. Replace bulb.
REMOVAL
(1) Di sconnect and i sol ate the negati ve battery
cabl e.
(2) Remove the screws that secure the rear fog
l amp uni t to the rear bumper assembl y.
(3) Di sconnect the wi re harness connector from the
rear fog l amp connector (Fi g. 15).
(4) Remove the rear fog l amp uni t from the vehi -
cl e.
INSTALLATION
(1) Posi ti on the rear fog l amp uni t to the vehi cl e.
(2) Connect the wi re harness connector to the rear
fog l amp connector.
(3) I nstal l the screws that secure the rear fog l amp
uni t to the rear bumper assembl y.
(4) Reconnect the negati ve battery cabl e.
FOG LAMP - REAR
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the screws that secure the rear fog
l amp l ens to the housi ng (Fi g. 16).
(3) Push and rotate the rear fog l amp one-thi rd
turn countercl ockwi se, then pul l the l amp strai ght
out of the socket (Fi g. 17).
INSTALLATION
(1) I nstal l the rear fog l amp by pushi ng the l amp
i nto the rear fog l amp socket and turni ng i t one-thi rd
cl ockwi se.
(2) Posi ti on the rear fog l amp l ens onto the hous-
i ng.
(3) I nstal l the screws that secure the rear fog l amp
l ens onto the housi ng.
Fig. 15 Rear Fog Lamp Unit
1 - REAR FOG LAMP UNIT
2 - REAR BUMPER ASSEMBLY
Fig. 16 Rear Fog Lamp Lens
1 - REAR FOG LAMP
2 - FOG LAMP LENS SCREWS
8L - 18 LAMPS/LIGHTING - EXTERIOR TJ
FOG LAMP UNIT - REAR (Continued)
(4) Reconnect the negati ve battery cabl e.
FRONT PARK/TURN SIGNAL
LAMP UNIT
DESCRIPTION
A front turn si gnal /parki ng l amp assembl y i s
mounted to each front fender. Each front turn si gnal /
parki ng l amp assembl y consi st of a housi ng, l ens and
l amp.
OPERATION
The parki ng l i ght functi on i s control l ed by the
headl amp swi tch l ocated on the i nstrument panel .
The turn si gnal functi on i s control l ed by the mul ti -
functi on swi tch l ocated on the steeri ng col umn. Each
front turn si gnal /parki ng l amp assembl y can be ser-
vi ced separatel y.
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the screws that secure the park/turn
si gnal l amp housi ng to the front fender (Fi g. 18).
(3) Remove the park/turn si gnal l amp housi ng
from the fender.
(4) Rotate the socket one-thi rd turn countercl ock-
wi se and separate the socket and l amp from the
housi ng.
INSTALLATION
(1) I nstal l the socket and l amp i nto the housi ng
and rotate the socket one-thi rd turn cl ockwi se.
(2) Posi ti on the park/turn si gnal l amp housi ng i nto
the fender.
(3) I nstal l the screws that secure the park/turn
si gnal l amp housi ng to the fender. Ti ghten the screws
securel y.
(4) Reconnect the battery negati ve cabl e.
FRONT PARK/TURN SIGNAL
LAMP
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the park/turn si gnal l amp housi ng
from the fender (Refer to 8 - ELECTRI CAL/LAMPS/
LI GHTI NG - EXTERI OR/PARK/TURN SI GNAL
LAMP UNI T - REMOVAL).
(3) Pul l the l amp strai ght out of the socket.
INSTALLATION
(1) I nstal l the l amp by pushi ng i t i nto the socket.
(2) I nstal l the l amp housi ng i nto the fender (Refer
to 8 - ELECTRI CAL/LAMPS/LI GHTI NG - EXTERI -
OR/PARK/TURN SI GNAL LAMP UNI T - I NSTALLA-
TI ON).
(3) Reconnect the battery negati ve cabl e.
HEADLAMP
DESCRIPTION
The headl amps are seal ed beam uni ts. Each uni t
contai ns a hi gh and l ow beam fi l ament.
Fig. 17 Rear Fog Lamp
1 - REAR FOG LAMP HOUSING
2 - REAR FOG LAMP
Fig. 18 Park/Turn Signal Lamp Assembly
TJ LAMPS/LIGHTING - EXTERIOR 8L - 19
FOG LAMP - REAR (Continued)
OPERATION
The headl amps are turned on and off by the head-
l amp swi tch. The hi gh and l ow beam sel ecti on i s con-
trol l ed by the mul ti functi on swi tch. Each headl amp
can be servi ced i ndi vi dual l y.
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the screws that secure the headl amp
bezel to the gri l l e (Fi g. 19).
(3) Remove the screws that secure the headl amp
retai ni ng ri ng to the headl amp bucket (Fi g. 20).
(4) Remove the headl amp from the bucket and di s-
connect the wi re harness connector from the head-
l amp (Fi g. 21).
INSTALLATION
(1) Connect the wi re harness connector to the
headl amp and posi ti on the headl amp i nto the bucket.
NOTE: Insure the bosses on the headlamp align
with the slots in the bucket.
(2) Al i gn the headl amp bosses wi th the sl ots i n the
bucket and i nstal l the retai ni ng ri ng.
(3) I nstal l the screws that secure the headl amp
retai ni ng ri ng to the headl amp bucket. Ti ghten the
screws securel y.
(4) I nstal l the headl amp bezel .
NOTE: Do not overtighten the screws or damage to
the headlamp bezel may result.
(5) I nstal l the screws that secure the headl amp
bezel . Ti ghten the screws securel y.
(6) Reconnect the battery negati ve cabl e.
Fig. 19 Headlamp Bezel
1 - HEADLAMP BEZEL
2 - GRILLE
3 - RETAINER
Fig. 20 Headlamp Retaining Ring
1 - HEADLAMP
2 - HEADLAMP RETAINING RING
Fig. 21 Headlamp Wire Harness Connector
1 - HEADLAMP
2 - WIRE HARNESS CONNECTOR
8L - 20 LAMPS/LIGHTING - EXTERIOR TJ
HEADLAMP (Continued)
HEADLAMP LEVELING
SWITCH
REMOVAL
HEADLAMP LEVELING 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 COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Di sconnect the negati ve battery cabl e.
(2) Usi ng a fl at bl ade screwdri ver or si mi l ar tool
between the headl amp l evel i ng swi tch and the steer-
i ng col umn cover (Fi g. 22). Gentl y pry the headl amp
l evel i ng swi tch out of the steeri ng col umn cover.
(3) Di sconnect the headl amp l evel i ng swi tch el ec-
tri cal connector (Fi g. 23) and remove the headl amp
l evel i ng swi tch.
INSTALLATION
(1) Posi ti on the headl amp l evel i ng swi tch i n front
of the steeri ng col umn cover access hol e and connect
the swi tch el ectri cal connector (Fi g. 23).
(2) Properl y seat the headl amp l evel i ng swi tch i nto
the steeri ng col umn cover.
(3) Reconnect negati ve battery cabl e.
HEADLAMP LEVELING MOTOR
DIAGNOSIS AND TESTING - HEADLAMP
LEVELING SYSTEM
The fol l owi ng test i s desi gned to di agnosi s a faul ty
headl amp l evel i ng system. Refer to Wi ri ng Di agrams
for a compl ete system schemati c.
NOTE: Headlamps must be operating properly and
the battery must be completely charged (12.4v)
prior to testing. It may also be necessary to install
battery charger on the vehicles electrical system
when performing this test. Refer to the Battery sec-
tion of the service manual for detailed information.
Fig. 22 Headlamp Leveling Switch
1 - HEADLAMP LEVELING SWITCH
2 - I/P CENTER BEZEL
3 - STEERING COLUMN COVER
Fig. 23 Headlamp Leveling Switch Electrical
Connector
1 - I/P CENTER BEZEL
2 - HEADLAMP LEVELING SWITCH ELECTRICAL CONNECTOR
3 - STEERING COLUMN COVER
4 - HEADLAMP LEVELING SWITCH
TJ LAMPS/LIGHTING - EXTERIOR 8L - 21
CONDITION POSSIBLE CAUSES CORRECTION
ONE MOTOR DOES NOT
OPERATE
1. Poor electrical connection at
motor.
1. Check for proper electrical
harness connection and circuit
terminal tension at the motor.
2. Open or high resistance in the
battery positive voltage circuit to the
inoperative leveling motor.
2. Repair the open or high
resistance in the leveling motor
battery positive voltage circuit.
3. Open, high resistance in the
inoperative leveling motor ground
circuit.
3. Repair the open, high
resistance in the leveling motor
ground circuit.
4. Open, high resistance, short to
voltage or short to ground in the
inoperative leveling motor sense
circuit.
4. Repair the open, high
resistance, short to voltage or
short to ground in the motor
sense circuit.
5. Inoperative/Damaged motor. 5. Replace leveling motor.
BOTH MOTORS DO NOT
OPERATE
1. No battery positive voltage to the
headlamp leveling switch.
1. Repair the open circuit or
high resistance in the headlamp
leveling switch battery positive
voltage circuit.
2. No battery positive voltage to the
headlamp leveling motor.
2. Repair the open circuit or
high resistance in the headlamp
leveling motor battery positive
voltage circuit.
3. Open, high resistance in the
headlamp leveling switch ground
circuit.
3. Repair the open, high
resistance or short to voltage in
the headlamp leveling switch
ground circuit.
4. Open, high resistance in the
headlamp leveling motor ground
circuit.
4. Repair the open, high
resistance or short to voltage in
the headlamp leveling motor
ground circuit.
5. Open, high resistance, short to
voltage or short to ground in the
leveling motor sense circuit.
5. Repair the open, high
resistance, short to voltage or
short to ground in the motor
sense circuit.
6. Inoperative headlamp leveling
switch.
6. Replace headlamp leveling
switch.
7. Inoperative headlamp leveling
motors.
7. Replace headlamp motors.
MOTORS DO NOT
RESPOND TO ONE OR
MORE LEVELING
POSITION(S)
1. Inoperative headlamp leveling
switch.
1. Replace headlamp leveling
switch.
2. Stuck/Binding or Inoperative
motor(s).
2. Replace headlamp leveling
motor(s).
8L - 22 LAMPS/LIGHTING - EXTERIOR TJ
HEADLAMP LEVELING MOTOR (Continued)
LEFT MULTI-FUNCTION
SWITCH
DESCRIPTION
The l eft mul ti -functi on swi tch i s secured to the
upper steeri ng col umn housi ng, bel ow the steeri ng
wheel . (Fi g. 24). The hazard warni ng swi tch push
button i s l ocated on the top of the mul ti -functi on
swi tch housi ng.
A connector contai ni ng ei ghteen termi nal pi ns i s
l ocated on the back of the swi tch housi ng and con-
nects the swi tch to the vehi cl e el ectri cal system. A
second connector on the back of the swi tch housi ng
accepts the combi nati on fl asher. The ri ght and l eft
mul ti -functi on swi tchs are mounted together by two
screws, and the combi ned mul ti -functi on swi tch i s
secured to the upper steeri ng col umn housi ng.
The l eft mul ti -functi on swi tch i s the pri mary con-
trol for the i nteri or and exteri or l i ghti ng systems of
the vehi cl e. The l eft mul ti -functi on swi tch supports
the fol l owi ng functi ons:
• Hazard Warni ng Control
• Exteri or Li ghti ng Control
• Headl amp Beam Sel ecti on
• Headl amp Opti cal Horn
• I nteri or Li ghti ng Control
• Turn Si gnal Control
The l eft mul ti -functi on swi tch cannot be adjusted
or repai red. I f any functi on of the swi tch i s faul ty, or
i f the swi tch i s damaged, the enti re swi tch uni t must
be repl aced. The combi nati on fl asher and the ri ght
mul ti -functi on swi tch are avai l abl e for separate ser-
vi ce repl acement.
OPERATION
The l eft mul ti -functi on swi tch uses a combi nati on
of resi stor mul ti pl exed and conventi onal l y swi tched
outputs to control the many functi ons and features i t
provi des. The swi tch i s grounded to the l eft cowl si de
i nner panel , beneath the i nstrument panel . The
swi tch recei ves battery vol tage from a fuse i n the
Power Di stri buti on Center (PDC), a fused B(+) ci rcui t
and, when the i gni ti on swi tch i s i n the Accessory or
On posi ti ons, from a fuse i n the fuse bl ock through a
fused i gni ti on swi tch output (run-acc) ci rcui t. Fol l ow-
i ng are descri pti ons of the how the l eft mul ti -functi on
swi tch operates to control the many functi ons and
features i t provi des:
• Front Fog Lamps - The control knob on the
end of the l eft mul ti -functi on swi tch control stal k i s
pul l ed outward to acti vate the opti onal front fog
l amps. The control knob i s keyed so that i t cannot be
Fig. 24 MULTI-FUNCTION SWITCH
1 - LEFT MULTI-FUNCTION SWITCH CONTROL STALK
2 - HAZARD WARNING SWITCH BUTTON
3 - RIGHT MULTI-FUNCTION SWITCH CONTROL STALK
4 - SCREW (2)
5 - TURN SIGNAL CANCEL ACTUATOR
6 - LEFT MULTI-FUNCTION SWITCH CONTROL RING
7 - LEFT MULTI-FUNCTION SWITCH CONTROL KNOB
TJ LAMPS/LIGHTING - EXTERIOR 8L - 23
pul l ed outward unl ess the knob i s fi rst rotated to
turn on the exteri or l i ghti ng. The i nternal ci rcui try of
the l eft mul ti -functi on swi tch then provi des battery
vol tage through a fused fog l amp rel ay output ci rcui t
and the fog l amp rel ay to the fog l amps and to the
i nstrument cl uster for control of the fog l amp i ndi ca-
tor.
• Rear Fog Lamp(s) - The headl amp swi tch knob
must be rol l ed to the headl amp on posi ti on. Pul l i ng
the headl amp swi tch knob outward and then rol l i ng
the knob one more detent countercl ockwi se wi l l acti -
vate the rear fog l amp. The headl amp swi tch i s onl y
abl e to pul l outward whi l e i n the headl amp posi ti on.
The i nternal ci rcui try of the l eft mul ti -functi on
swi tch then provi des battery vol tage to the rear fog
l amp(s) and to the i nstrument cl uster for control of
the fog l amp i ndi cator.
• Hazard Warning System - The hazard warn-
i ng push button i s pushed down to unl atch the
swi tch and acti vate the hazard warni ng system, and
pushed down agai n to l atch the swi tch and turn the
system off. When the hazard warni ng swi tch i s
l atched, the push button wi l l be i n a l owered posi ti on
on the top of the steeri ng col umn shroud; and, when
the hazard warni ng swi tch i s unl atched, the push
button wi l l be i n a rai sed posi ti on. The l eft mul ti -
functi on swi tch hazard warni ng si mul taneousl y pro-
vi des a si gnal to the hazard warni ng sense of the
combi nati on fl asher to acti vate or deacti vate the
fl asher output, and di rects the output of the fl asher
to the hazard warni ng l amps.
• Headlamps - The control knob on the end of
the l eft mul ti -functi on swi tch control stal k i s rotated
forward to i ts second detent from the Off posi ti on to
acti vate the headl amps. The i nternal ci rcui try of the
l eft mul ti -functi on swi tch then provi des battery vol t-
age through the i ntegral beam sel ect swi tch and the
headl amp l ow beam or hi gh beam ci rcui ts to the
appropri ate headl amp fi l aments and to the i nstru-
ment cl uster for control of the hi gh beam i ndi cator.
• Headlamp Beam Selection - The l eft mul ti -
functi on swi tch control stal k i s pul l ed towards the
steeri ng wheel past a detent, then rel eased to actuate
the i ntegral beam sel ect swi tch ci rcui try. Each ti me
the control stal k i s actuated i n thi s manner, the
opposi te headl amp mode from what i s currentl y
sel ected wi l l be acti vated.
• Headlamp Optical Horn - The l eft mul ti -func-
ti on swi tch control stal k i s pul l ed towards the steer-
i ng wheel to just before a detent, to momentari l y
acti vate the headl amp hi gh beams. The hi gh beams
wi l l remai n i l l umi nated unti l the control stal k i s
rel eased. The i nternal beam sel ect swi tch ci rcui try
di rects battery vol tage through the headl amp hi gh
beam ci rcui t of the l eft mul ti -functi on swi tch to the
headl amp hi gh beams and to the i nstrument cl uster
for control of the hi gh beam i ndi cator.
• Interior Lamps Control - A control ri ng on the
l eft mul ti -functi on swi tch control stal k i s rotated to a
ful l forward detent to i l l umi nate al l i nteri or courtesy
l amps. The i nstrument cl uster ci rcui try moni tors the
hard wi red vari abl e resi stor output of the l eft mul ti -
functi on swi tch through the panel l amps di mmer si g-
nal ci rcui t then, based upon that i nput, provi des a
ground path to acti vate al l i nteri or courtesy l amps
through a courtesy l amp feed ci rcui t output.
• Panel Lamps Dimming - A control ri ng on the
l eft mul ti -functi on swi tch control stal k i s rotated to
one of si x i ntermedi ate detent posi ti ons to sel ect the
desi red i l l umi nati on i ntensi ty of al l adjustabl e
i nstrument panel and i nstrument cl uster l i ghti ng.
The control ri ng i s rotated forward to bri ghten, or
rearward to di m the l i ghti ng. The i nstrument cl uster
moni tors the hard wi red vari abl e resi stor output of
the l eft mul ti -functi on swi tch through the panel
l amps di mmer si gnal ci rcui t then, based upon that
i nput, provi des a pul se wi dth modul ated output, to
control the i nstrument cl uster l i ghti ng l evel s. The
i nstrument cl uster al so control s the l i ghti ng l evel s of
the other adjustabl e i nstrument panel l i ghti ng based
upon thi s panel l amps di mmer si gnal through a
panel l amps dri ver ci rcui t output.
• Parade Mode - A control ri ng on the l eft mul ti -
functi on swi tch control stal k i s rotated to an i nterme-
di ate detent that i s one detent rearward from the ful l
forward detent to i l l umi nate the Vacuum Fl uorescent
Di spl ay (VFD) i n the i nstrument cl uster and the
radi o at ful l i ntensi ty. The i nstrument cl uster moni -
tors the hard wi red vari abl e resi stor output of the
l eft mul ti -functi on swi tch through the panel l amps
di mmer si gnal ci rcui t then, based upon that i nput,
adjusts the i nstrument cl uster VFD to i ts ful l i nten-
si ty and provi des a battery vol tage si gnal to the radi o
on a park l amp rel ay output ci rcui t that si gnal s the
radi o to l i ght i ts VFD to ful l i ntensi ty.
• Park Lamps - The control knob on the end of
the l eft mul ti -functi on swi tch control stal k i s rotated
forward to i ts fi rst detent to acti vate the parki ng
l amps. The l eft mul ti -functi on swi tch then provi des
battery vol tage to the parki ng l amps and to the
i nstrument cl uster as a request for cl uster i l l umi na-
ti on and panel l amps output.
• Turn Signal Control - The l eft mul ti -functi on
swi tch control stal k actuates the turn si gnal swi tch.
The mul ti -functi on swi tch turn si gnal ci rcui try si mul -
taneousl y provi des a si gnal to the turn si gnal sense
ci rcui t of the combi nati on fl asher to acti vate the
fl asher output. The turn si gnal swi tch has a detent
posi ti on i n each di recti on that provi des turn si gnal s
wi th automati c cancel l ati on, and an i ntermedi ate,
momentary posi ti on i n each di recti on that provi des
8L - 24 LAMPS/LIGHTING - EXTERIOR TJ
LEFT MULTI-FUNCTION SWITCH (Continued)
turn si gnal s onl y unti l the l eft mul ti -functi on swi tch
control stal k i s rel eased. When the control stal k i s
moved to a turn si gnal swi tch detent posi ti on, the
cancel actuator extends toward the center of the
steeri ng col umn. A turn si gnal cancel cam that i s
i ntegral to the cl ockspri ng, rotates wi th the steeri ng
wheel and the cam l obes contact the cancel actuator
when i t i s extended from the mul ti -functi on swi tch.I f
onl y momentary si gnal i ng i s desi red, the swi tch i s
actuated to a l eft or ri ght i ntermedi ate detent posi -
ti on. I n thi s posi ti on the si gnal l amps fl ash as
descri bed above, but the swi tch returns to the Off
posi ti on as soon as the l ever i s rel eased. When the
system i s acti vated, one of two turn i ndi cators i n the
i nstrument cl uster fl ashes i n uni son wi th the turn
si gnal l amps, i ndi cati ng to the dri ver that the system
i s operati ng.
DIAGNOSIS AND TESTING - LEFT MULTI-
FUNCTION SWITCH
Refer to the appropri ate wi ri ng i nformati on.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the l eft mul ti -functi on swi tch from the
steeri ng col umn (Refer to 8 - ELECTRI CAL/LAMPS/
LI GHTI NG - EXTERI OR/LEFT MULTI -FUNCTI ON
SWI TCH - REMOVAL).
(3) Remove the combi nati on fl asher from the l eft
mul ti -functi on swi tch.
(4) Usi ng an ohmmeter, perform the conti nui ty
and resi stance tests at the termi nal s i n the l eft
mul ti -functi on swi tch connector receptacl es as shown
i n the Left Mul ti -Functi on Swi tch Test tabl e. Refer to
(Fi g. 25) and (Fi g. 26) for connector termi nal and
cavi ty i denti fi cati on.
Fig. 25 Combination Flasher Receptacle (Connector
A)
Fig. 26 Left Multi-Function Switch Connector
Receptacle (Connector B)
TJ LAMPS/LIGHTING - EXTERIOR 8L - 25
LEFT MULTI-FUNCTION SWITCH (Continued)
LEFT (LIGHTING) MULTI-FUNCTION SWITCH TEST
TURN SIGNAL AND HAZARD WARNING SWITCH TESTS
SWITCH POSITION
CONTINUITY
BETWEEN
TURN HAZARD
Neutral Off B1 & B4, B1 & B5
Left Off A2 & B2, A2 & B4, B1 & B5
Right Off A2 & B5, B1 & B4
Neutral On A2 & B2, A2 & B4, A2 & B5, A2 & B6, A3 & B7, A3 & A5
EXTERIOR LIGHTING SWITCH TESTS
SWITCH POSITION CONTINUITY BETWEEN
Park Lamps On B9 & B20
Headlamp Low Beams On B16 & B18, B16 & B19
Headlamp High Beams On B17 & B18, B17 & B19
Fog Lamps On B13 & B14
Rear Fog Lamps On B12 & B13
Optical Horn On B17 & B18, B17 & B19
INTERIOR LIGHTING SWITCH TESTS
SWITCH POSITION
RESISTANCE
BETWEEN
RESISTANCE (OHMS)
Panel Lamps Dimming Position 1 (Dimmest) B7 & B8 5653 ± 10%
Dimming Position 2 B7 & B8 3743 ± 10%
Dimming Position 3 B7 & B8 2593 ± 10%
Dimming Position 4 B7 & B8 1825 ± 10%
Dimming Position 5 B7 & B8 1221 ± 10%
Dimming Position 6 (Brightest) B7 & B8 768 ± 10%
Parade Mode On B7 & B8 412 ± 10%
Courtesy Lamps On B7 & B8 150 ± 10%
(5) I f the l eft mul ti -functi on swi tch fai l s any of the
conti nui ty or resi stance tests, repl ace the faul ty
swi tch uni t as requi red.
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the steeri ng col umn openi ng cover
from the i nstrument panel . (Refer to 23 - BODY/I N-
STRUMENT PANEL/STEERI NG COLUMN OPEN-
I NG COVER - REMOVAL).
(3) Remove the two screws that secure the l ower
steeri ng col umn shroud to the upper shroud (Fi g. 27).
(4) I f the vehi cl e i s equi pped wi th the opti onal ti l t
steeri ng col umn, move the ti l t steeri ng col umn to the
ful l y l owered posi ti on and l eave the ti l t rel ease l ever
i n the rel eased (down) posi ti on.
(5) Remove both the upper and l ower shrouds from
the steeri ng col umn.
(6) Di sconnect the cross body wi re harness connec-
tor for the l eft mul ti -functi on swi tch from the connec-
tor receptacl e on the back of the swi tch.
(7) Di sconnect the cross body wi re harness connec-
tor for the ri ght mul ti -functi on swi tch from the con-
nector receptacl e on the back of the swi tch.
8L - 26 LAMPS/LIGHTING - EXTERIOR TJ
LEFT MULTI-FUNCTION SWITCH (Continued)
(8) Remove the two screws that secure the mul ti -
functi on swi tch assembl y to the upper steeri ng col -
umn housi ng (Fi g. 28).
(9) Remove the mul ti -functi on swi tch assembl y
from the upper steeri ng col umn housi ng.
(10) Remove the two smal l screws that secure the
ri ght mul ti -functi on swi tch to the l eft mul ti -functi on
swi tch mounti ng housi ng.
(11) Grasp the ri ght mul ti -functi on swi tch control
stal k fi rml y and pul l the swi tch toward the ri ght far
enough to di sengage the al i gnment pi ns on the top
(1) and bottom (2) of the ri ght swi tch housi ng from
the al i gnment ramps on the l eft mul ti -functi on
swi tch mounti ng housi ng.
(12) Remove the ri ght mul ti -functi on swi tch from
the l eft mul ti -functi on swi tch.
(13) Remove the combi nati on fl asher from the con-
nector receptacl e on the back of the l eft mul ti -func-
ti on swi tch.
INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) I nstal l the combi nati on fl asher i nto the connec-
tor receptacl e on the back of the l eft mul ti -functi on
swi tch.
(2) Posi ti on the ri ght mul ti -functi on swi tch to the
l eft mul ti -functi on swi tch.
(3) Grasp the ri ght mul ti -functi on swi tch control
stal k fi rml y and sl i de the swi tch toward the l eft far
enough to engage the al i gnment pi ns on the top (1)
and bottom (2) of the ri ght swi tch housi ng i nto the
al i gnment ramps on the l eft mul ti -functi on swi tch
mounti ng housi ng.
(4) I nstal l and ti ghten the screws that secure the
ri ght mul ti -functi on swi tch to the l eft mul ti -functi on
swi tch mounti ng housi ng (Fi g. 28). Ti ghten the
screws to 2 N·m (17 i n. l bs.).
(5) Posi ti on the mul ti -functi on swi tch assembl y
onto the upper steeri ng col umn housi ng.
(6) I nstal l and ti ghten the screws that secure the
mul ti -functi on swi tch assembl y to the upper steeri ng
col umn housi ng. Ti ghten the screws to 2 N·m (17 i n.
l bs.).
Fig. 27 Steering Column Shrouds Remove/Install
1 - LEFT MULTI-FUNCTION SWITCH
2 - UPPER SHROUD
3 - RIGHT MULTI-FUNCTION SWITCH
4 - CLOCKSPRING
5 - IGNITION LOCK CYLINDER HOUSING
6 - LOWER SHROUD
7 - SCREW (2)
Fig. 28 Multi-Function Switch Remove/Install
1 - LEFT MULTI-FUNCTION SWITCH
2 - SCREW (2)
3 - SCREW (2)
4 - RIGHT MULTI-FUNCTION SWITCH
5 - UPPER STEERING COLUMN HOUSING
TJ LAMPS/LIGHTING - EXTERIOR 8L - 27
LEFT MULTI-FUNCTION SWITCH (Continued)
(7) Reconnect the cross body wi re harness connec-
tor for the ri ght mul ti -functi on swi tch to the connec-
tor receptacl e on the back of the swi tch.
(8) Reconnect the cross body wi re harness connec-
tor for the l eft mul ti -functi on swi tch to the connector
on the back of the swi tch.
(9) Posi ti on both the upper and l ower shrouds onto
the steeri ng col umn (Fi g. 29). Be certai n that the
l ocati ng tabs for the l eft and ri ght mul ti -functi on
swi tch control stal k watershi el ds are properl y
engaged i n the openi ngs of both the upper and l ower
shrouds.
(10) I nstal l and ti ghten the screws that secure the
l ower steeri ng col umn shroud to the upper shroud.
Ti ghten the screws to 2 N·m (17 i n. l bs.).
(11) I f the vehi cl e i s equi pped wi th the opti onal ti l t
steeri ng col umn, move the ti l t steeri ng col umn to the
ful l y rai sed posi ti on and secure i t i n pl ace by movi ng
the ti l t rel ease l ever back to the l ocked (up) posi ti on.
(12) Rei nstal l the steeri ng col umn openi ng cover
onto the i nstrument panel . (Refer to 23 - BODY/I N-
STRUMENT PANEL/STEERI NG COLUMN OPEN-
I NG COVER - I NSTALLATI ON).
(13) Reconnect the battery negati ve cabl e.
SIDE MARKER LAMP UNIT
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) From undersi de of the fender fl are, remove the
nut that secures the si de marker l amp housi ng to the
front fender fl are.
(3) Remove the l amp housi ng from the fender
fl are.
(4) Rotate the socket one-thi rd turn countercl ock-
wi se and separate the socket and l amp from the
housi ng.
INSTALLATION
(1) I nstal l the socket and l amp i nto the housi ng
and rotate the socket one-thi rd turn cl ockwi se.
(2) Posi ti on the si de marker l amp housi ng i nto the
front fender fl are.
(3) I nstal l the nut that secures the si de marker l amp
housi ng to the fender fl are. Ti ghten the nut securel y.
(4) Reconnect battery negati ve cabl e.
SIDE MARKER LAMP
REMOVAL
(1) Di sconnect and i sol ate the negati ve battery
cabl e.
(2) From undersi de of the fender fl are, rotate the
si de marker l amp socket one-thi rd turn countercl ock-
wi se and separate i t from the si de marker l amp
housi ng.
(3) Remove the l amp from the socket by pul l i ng i t
strai ght out of the socket.
INSTALLATION
(1) I nstal l the si de marker l amp i nto the socket by
pushi ng i t strai ght i nto the socket.
(2) I nstal l the socket i nto the housi ng and rotate
the socket one-thi rd turn cl ockwi se.
(3) Reconnect the battery negati ve cabl e.
REPEATER LAMP
DESCRIPTION
Some export model s are equi pped wi th si de
repeater l amps i nstead of si de marker l amps. The
si de repeater l amp operates wi th the turn si gnal s
and has an amber col ored l ens and a cl ear l amp. For
Removal and I nstal l ati on procedures, refer to Si de
Marker Lamps wi thi n thi s Group.
OPERATION
The si de repeater l amps operate i n seri es wi th the
front and rear turn si gnal l amps and are control l ed
by the steeri ng col umn mounted mul ti -functi on
swi tch.
DIAGNOSIS AND TESTING - SIDE REPEATER
LAMP
The fol l owi ng chart i s desi gned to di agnosi s a
faul ty si de repeater l amp wi th the turn si gnal s oper-
ati ng normal l y. Refer to Wi ri ng Di agrams for a com-
pl ete system schemati c.
Fig. 29 Shroud Remove/Install
1 - UPPER SHROUD
2 - LOWER SHROUD
8L - 28 LAMPS/LIGHTING - EXTERIOR TJ
LEFT MULTI-FUNCTION SWITCH (Continued)
SIDE REPEATER LAMP CONDITION CHART
CONDITION POSSIBLE CAUSES CORRECTION
TURN SIGNALS OPERATE
NORMALLY, ONE REPEATER
LAMP DOES NOT
ILLUMINATE
1. Inoperative, damaged or burned out
lamp.
4. Replace the lamp.
2. Poor electrical connection at lamp. 2. Check for proper wire harness
connection and circuit terminal
tension at the lamp.
3. Open or high resistance in the voltage
circuit to the inoperative lamp.
3. Repair the open or high
resistance in the repeater lamp
voltage circuit.
4. Open, high resistance in the ground
circuit to the inoperative lamp.
4. Repair the open, high resistance
in the repeater lamp ground circuit.
TAIL LAMP UNIT
DESCRIPTION
Each tai l l amp assembl y contai ns a l ens, housi ng
and two l amps. One l amp has two fi l aments and i s
used for tai l , stop, turn si gnal , rear si de marker and
l i cense pl ate (l eft si de onl y) l amp functi ons. The
other l amp has a si ngl e fi l ament and i s used for
back-up l i ght i l l umi nati on.
OPERATION
Each tai l l amp assembl y can be servi ced sepa-
ratel y. Each l amp can al so be servi ced separatel y.
The headl amp swi tch control s tai l l amp operati on.
The mul ti -functi on swi tch control s turn si gnal opera-
ti on. The back-up l i ght swi tch control s back-up l i ght
operati on. The brake l amp swi tch control s stop l amp
operati on.
REMOVAL
(1) Di sconnect and i sol ate the negati ve battery
cabl e.
(2) From the undersi de of the vehi cl e, remove the
push-i n fastener that secures the bottom rear edge of
the rear wheel house spl ash shi el d to the body.
(3) Pul l the rear of the wheel house spl ash shi el d
away from the body and reach upward to di sconnect
the wi re harness connector from the tai l l amp.
(4) Remove the screws that secure the tai l l amp
l ens to the tai l l amp housi ng (Fi g. 30).
(5) Remove the tai l l amp l ens and gasket from the
tai l l amp housi ng.
(6) Remove the bol ts that secure the tai l l amp
housi ng to the body.
(7) Remove the tai l l amp housi ng from the body.
INSTALLATION
(1) Posi ti on the tai l l amp housi ng to the body.
(2) I nstal l the bol ts that secure the tai l l amp hous-
i ng to the body. Ti ghten the bol ts securel y.
NOTE: Install the tail lamp lens with the clear por-
tion (back-up lens) at the top of the housing. Make
sure that the gasket is correctly in place and not
twisted or torn.
(3) I nstal l the tai l l amp l ens and gasket onto the
tai l l amp housi ng.
NOTE: Do not overtighten the screws or damage to
the tail lamp lens may result.
(4) I nstal l the screws that secure the tai l l amp
l ens to the tai l l amp housi ng. Ti ghten the screws
securel y.
(5) Connect the wi re harness connector to the tai l
l amp.
Fig. 30 Tail Lamp Housing
1 - BODY
2 - TAIL LAMP HOUSING
3 - TAIL LAMP LENS
TJ LAMPS/LIGHTING - EXTERIOR 8L - 29
REPEATER LAMP (Continued)
(6) I nstal l the push-i n fastener that secures the
bottom rear edge of the rear wheel house spl ash
shi el d to the body.
(7) Reconnect the negati ve battery cabl e.
TAIL LAMP
REMOVAL
(1) Di sconnect and i sol ate the negati ve battery
cabl e.
(2) Remove the screws that secure the tai l l amp
l ens to the tai l l amp housi ng (Fi g. 31).
(3) Remove the tai l l amp l ens and gasket from the
tai l l amp housi ng.
(4) Push and rotate the l amp(s) one-thi rd turn
countercl ockwi se, then pul l the l amp strai ght out of
the socket
INSTALLATION
(1) I nstal l the l amp(s) by pushi ng the l amp i nto
the tai l l amp socket and turni ng i t one-thi rd cl ock-
wi se.
NOTE: Install the tail lamp lens with the clear por-
tion (back-up lens) at the top of the housing. Make
sure that the gasket is correctly in place and not
twisted or torn.
(2) I nstal l the tai l l amp l ens and gasket onto the
tai l l amp housi ng.
NOTE: Do not overtighten the screws or damage to
the tail lamp lens may result.
(3) I nstal l the screws that secure the tai l l amp
l ens to the tai l l amp housi ng. Ti ghten the screws
securel y.
(4) Reconnect the negati ve battery cabl e.
TURN SIGNAL CANCEL CAM
DESCRIPTION
The turn si gnal cancel cam consi sts of two l obes
that are i ntegral to the l ower surface of the cl ock-
spri ng rotor. The cl ockspri ng mechani sm provi des
turn si gnal cancel l ati on as wel l as a constant el ectri -
cal connecti on between the dri ver ai rbag, steeri ng
wheel accessorys and the cross body wi re harness on
the steeri ng col umn. The housi ng of the cl ockspri ng
i s secured to the steeri ng col umn and remai ns sta-
ti onary. The rotor of the cl ockspri ng, i ncl udi ng the
turn si gnal cancel cam l obes rotate wi th the steeri ng
wheel .
The turn si gnal cancel cam i s i ntegral to the cl ock-
spri ng and cannot be repai red. I f faul ty or damaged,
the enti re cl ockspri ng assembl y must be repl aced.
(Refer to 8 - ELECTRI CAL/RESTRAI NTS/CLOCK-
SPRI NG - REMOVAL).
OPERATION
The turn si gnal cancel cam has two l obes mol ded
i nto the l ower surface of the cl ockspri ng rotor. When
the turn si gnal s are acti vated by movi ng the l eft
mul ti -functi on swi tch control stal k to a detent posi -
ti on, a turn si gnal cancel actuator i s extended from
the i nsi de surface of the l eft mul ti -functi on swi tch
housi ng toward the cl ockspri ng rotor. When the
steeri ng wheel i s rotated duri ng the turn, one of the
two turn si gnal cancel cam l obes wi l l contact the
turn si gnal cancel actuator, but the cancel actuator
stays l atched. When the steeri ng wheel i s rotated
back to center as the turn i s compl eted, the cancel
actuator i s unl atched and rel eases the l eft mul ti -
functi on swi tch control stal k from i ts detent, cancel -
l i ng the turn si gnal event.
UNDERHOOD LAMP UNIT
REMOVAL
(1) Di sconnect and i sol ate the negati ve battery
cabl e.
(2) Di sconnect the wi re harness connector from the
underhood l amp (Fi g. 32).
(3) Remove the screw that secures the underhood
l amp to the i nner hood panel .
(4) Remove the underhood l amp from the vehi cl e.
INSTALLATION
(1) Posi ti on the underhood l amp onto the i nner
hood panel .
(2) I nstal l the screw that secures the underhood
l amp to the i nner hood panel . Ti ghten the screw
securel y.
Fig. 31 Tail Lamp Lens
8L - 30 LAMPS/LIGHTING - EXTERIOR TJ
TAIL LAMP UNIT (Continued)
(3) Connect the wi re harness connector to the
underhood l amp.
(4) Reconnect the negati ve battery cabl e.
UNDERHOOD LAMP
REMOVAL
(1) Di sconnect and i sol ate the negati ve battery
cabl e.
(2) I nsert a smal l fl at bl ade i n the access sl ot
between the l amp housi ng and l amp l ens.
(3) Pry the l amp l ens upward and remove the
l amp l ens.
(4) Press the l amp termi nal i nward (Fi g. 33) to
rel ease the l amp.
INSTALLATION
(1) Engage the l amp wi re l oop to the termi nal cl os-
est to the l amp housi ng wi re connector.
(2) Press the opposi te termi nal i nward and engage
the remai ni ng l amp wi re l oop onto the termi nal .
(3) Posi ti on the l amp l ens onto the l amp housi ng
and press the l ens i nto pl ace.
(4) Reconnect the negati ve battery cabl e.
Fig. 32 Underhood Lamp
1 - UNDERHOOD LAMP
2 - HOOD
Fig. 33 Underhood Lamp
1 - LAMP
2 - LAMP TERMINAL
3 - LAMP WIRE LOOP
4 - LAMP HOUSING
TJ LAMPS/LIGHTING - EXTERIOR 8L - 31
UNDERHOOD LAMP UNIT (Continued)
LAMPS/LIGHTING - INTERIOR
TABLE OF CONTENTS
page page
LAMPS/LIGHTING - INTERIOR
SPECIFICATIONS
INTERIOR LAMPS . . . . . . . . . . . . . . . . . . . . . 32
DOME LAMP UNIT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 32
DOME LAMP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 33
DOOR AJAR SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 33
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
DIAGNOSIS AND TESTING - DOOR AJAR
SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 34
REAR WIPER/WASHER SWITCH
ILLUMINATION LAMP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 35
LAMPS/LIGHTING - INTERIOR
SPECIFICATIONS
INTERIOR LAMPS
CAUTION: Do not use bulbs that have a higher can-
dle power than the bulb listed in the Bulb Applica-
tion Table. Damage to lamp housing and lens can
result.
Some components have l amps that can onl y be ser-
vi ced by an Authori zed Servi ce Center (ASC) after
the component i s removed from the vehi cl e.
The fol l owi ng tabl e l i sts the vari ous l amp trade
numbers or part numbers.
LAMP BULB
Dome (Sound Bar) 912
Under Hood 561
Underpanel Courtesy 906
Instrument Cluster
Illumination
103
Instrument Cluster
Warning
74
Automatic Transmission
Indicator
658
DOME LAMP UNIT
REMOVAL
NOTE: The dome lamp removal procedure is the
same for both the right and left side dome lamps.
(1) Di sconnect the negati ve battery cabl e.
NOTE: The dome lamp lens locating tab is larger
than the lens retaining tabs.
(2) I nsert a smal l fl at bl ade between the dome
l amp housi ng and dome l amp l ens. Careful l y pry the
l amp l ens from the l amp housi ng (Fi g. 1).
(3) Remove the screws that secure the dome l amp
housi ng to the speaker housi ng.
(4) Remove the dome l amp housi ng from the
speaker housi ng and di sconnect the wi re harness
connector from the dome l amp.
INSTALLATION
NOTE: The dome lamp installation procedure is the
same for both the right and left side dome lamps.
(1) Connect the wi re harness connector to the
dome l amp.
NOTE: The dome lamp housing is equipped with a
locating tab that must be inserted into the slot in
the speaker housing.
(2) Al i gn the l ocati ng tab wi th the sl ot and posi -
ti on the dome l amp housi ng i nto the speaker housi ng
(Fi g. 2).
8L - 32 LAMPS/LIGHTING - INTERIOR TJ
(3) I nstal l the screws that secure the dome l amp
housi ng to the speaker housi ng.
NOTE: The dome lamp lens is equipped with a
locating tab that must be inserted into the slot in
the dome lamp housing.
(4) Al i gn the dome l amp l ens l ocati ng tab wi th the
sl ot i n the dome l amp housi ng and press the l ens
i nto pl ace.
(5) Reconnect the negati ve battery cabl e.
DOME LAMP
REMOVAL
(1) Di sconnect the negati ve battery cabl e.
(2) I nsert a smal l fl at bl ade between the dome
l amp housi ng and dome l amp l ens. Careful l y pry the
l amp l ens from the l amp housi ng
(3) Remove the dome l amp from the l amp termi -
nal s by pul l i ng the l amp strai ght out.
INSTALLATION
(1) I nstal l the dome l amp i nto the l amp termi nal s
by pushi ng the l amp strai ght i nto the termi nal s.
NOTE: The dome lamp lens is equipped with a
locating tab that must be inserted into the slot in
the dome lamp housing.
(2) Al i gn the dome l amp l ens l ocati ng tab wi th the
sl ot i n the dome l amp housi ng and press the l ens
i nto pl ace.
(3) Reconnect the negati ve battery cabl e.
DOOR AJ AR SWITCH
DESCRIPTION
The door ajar swi tches, l ocated i n each door pi l l ar,
are a sel f-adjusti ng, spri ng l oaded pl unger. The other
end of the swi tch i s actuated by the hi nge face of the
door. The sel f adjusti ng feature of the swi tch pl unger
i s a one-ti me feature, i t can be adjusted i nward (com-
pressed), but cannot be readjusted outward
(extended) once i t has been compressed. Thi s nor-
mal l y open swi tch onl y cl oses when the door i s open.
The door ajar swi tch cannot be repai red and, i f
faul ty or damaged, i t must be repl aced.
OPERATION
The door ajar swi tches control a path to ground
through separate dri ver and passenger door ajar
swi tch sense ci rcui t i nputs to the i nstrument cl uster
chi me warni ng ci rcui try when a door i s opened. The
Fig. 1 Dome Lamp - Typical
1 - DOME LENS GUIDE
2 - DOME LAMP HOUSING
3 - DOME LAMP
4 - SPEAKER HOUSING
5 - SCREW (2)
Fig. 2 Dome Lamp Housing
1 - WIRE HARNESS CONNECTOR
2 - SPEAKER
3 - LOCATING TAB
4 - DOME LAMP HOUSING
TJ LAMPS/LIGHTING - INTERIOR 8L - 33
DOME LAMP UNIT (Continued)
door ajar swi tch i nputs to the i nstrument cl uster can
be di agnosed usi ng conventi onal di agnosti c tool s and
methods.
DIAGNOSIS AND TESTING - DOOR AJAR
SWITCH
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Di sconnect the negati ve battery cabl e. Remove
the door ajar swi tch from the door hi nge pi l l ar. Di s-
connect the wi re harness connector from the door
ajar swi tch. Check for conti nui ty between the door
ajar swi tch output and the dri ver or passenger door
ajar swi tch sense ci rcui t i n the door ajar swi tch con-
nector. There shoul d be conti nui ty wi th the swi tch
pl unger rel eased, and no conti nui ty wi th the swi tch
pl unger depressed. I f OK, go to Step 2. I f not OK,
repl ace the faul ty door ajar swi tch.
(2) Check for conti nui ty between the door ajar
swi tch output ci rcui t of the wi re harness connector
for the dri ver or passenger door ajar swi tch and a
good ground. There shoul d be conti nui ty. I f OK, go to
Step 3. I f not OK, repai r the open door ajar swi tch
output ci rcui t to ground as requi red.
(3) Remove the i nstrument cl uster from the i nstru-
ment panel . Di sconnect the i nstrument panel wi re
harness connector from the i nstrument cl uster.
Check for conti nui ty between the dri ver or passenger
door ajar swi tch sense ci rcui t of the wi re harness
connector for the dri ver or passenger door ajar swi tch
and a good ground. There shoul d be no conti nui ty. I f
OK, go to Step 4. I f not OK, repai r the shorted dri ver
or passenger door ajar swi tch sense ci rcui t between
the door ajar swi tch and the i nstrument cl uster as
requi red.
(4) Check for conti nui ty between the dri ver or pas-
senger door ajar swi tch sense ci rcui t of the wi re har-
ness connector for the dri ver or passenger door ajar
swi tch and the wi re harness connector for the i nstru-
ment cl uster. There shoul d be conti nui ty. I f not OK,
repai r the open dri ver or passenger door ajar swi tch
sense ci rcui t between the door ajar swi tch and the
i nstrument cl uster as requi red.
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Di sconnect the negati ve battery cabl e
(2) Unl atch and open the door ful l y.
(3) Usi ng a smal l screwdri ver, pry careful l y
between the hi nge pi l l ar and the outer ci rcumference
of the door ajar swi tch housi ng to rel ease the swi tch
snap features from the mounti ng hol e i n the pi l l ar.
(4) Pul l the door ajar swi tch out through the
mounti ng hol e i n the hi nge pi l l ar far enough to
access and di sconnect the wi re harness connector
from the door ajar swi tch.
(5) Remove the door ajar swi tch from the door
hi nge pi l l ar.
INSTALLATION
(1) Posi ti on the door ajar swi tch to the door hi nge
pi l l ar.
(2) Connect the wi re harness connector to the door
ajar swi tch.
(3) Gui de the wi re harness for the door ajar swi tch
and the receptacl e end of the swi tch i nto the mount-
i ng hol e i n the door hi nge pi l l ar.
(4) Usi ng hand pressure, press the door ajar
swi tch housi ng i nto the mounti ng hol e i n the door
hi nge pi l l ar unti l the snap features of the swi tch are
ful l y engage i n the mounti ng hol e.
(5) Sl owl y cl ose the door and al l ow the door ajar
swi tch pl unger sel f-adjuster mechani sm to ratchet to
the proper posi ti on.
(6) Reconnect the negati ve battery cabl e.
(7) Open and cl ose the door to veri fy proper door
ajar swi tch operati on.
8L - 34 LAMPS/LIGHTING - INTERIOR TJ
DOOR AJ AR SWITCH (Continued)
REAR WIPER/WASHER
SWITCH ILLUMINATION LAMP
REMOVAL
The rear wi per and washer swi tch i n the accessory
swi tch bezel of the i nstrument panel i ncl udes a si n-
gl e servi ceabl e i ncandescent l amp and l amp hol der
uni t.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, DRIVER AIRBAG,
PASSENGER AIRBAG, OR INSTRUMENT PANEL
COMPONENT DIAGNOSIS OR SERVICE. DISCON-
NECT AND ISOLATE THE BATTERY NEGATIVE
(GROUND) CABLE, THEN WAIT TWO MINUTES FOR
THE SYSTEM CAPACITOR TO DISCHARGE BEFORE
PERFORMING FURTHER DIAGNOSIS OR SERVICE.
THIS IS THE ONLY SURE WAY TO DISABLE THE
SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO
TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
(1) Di sconnect and i sol ate the negati ve battery
cabl e.
(2) Remove the rear wi per and washer swi tch from
the accessory swi tch bezel (Refer to 8 - ELECTRI -
CAL/REAR WI PERS/WASHERS/REAR WI PER/
WASHER SWI TCH - REMOVAL).
(3) From the bottom of the swi tch housi ng, use a
smal l thi n-bl aded screwdri ver to rotate the l amp
hol der countercl ockwi se about 30 degrees i n the
mounti ng hol e (Fi g. 3).
(4) Pul l the rear wi per and washer swi tch l amp
hol der and l amp assembl y strai ght out of the mount-
i ng hol e.
INSTALLATION
CAUTION: Always use the correct lamp size and
type for replacement. An incorrect lamp size or type
may overheat and cause damage to the rear wiper
and washer switch.
(1) Al i gn the rear wi per and washer swi tch l amp
hol der and l amp assembl y wi th the mounti ng hol e i n
the bottom of the swi tch.
(2) I nsert the rear wi per and washer swi tch l amp
hol der and l amp assembl y strai ght i nto the mounti ng
hol e unti l i t i s fi rml y seated.
(3) Usi ng a smal l thi n-bl aded screwdri ver, rotate
the l amp hol der cl ockwi se about 30 degrees i n the
mounti ng hol e.
(4) I nstal l the rear wi per and washer swi tch i nto
the accessory swi tch bezel (Refer to 8 - ELECTRI -
CAL/REAR WI PERS/WASHERS/REAR WI PER/
WASHER SWI TCH - I NSTALLATI ON).
(5) Reconnect the negati ve battery cabl e.
Fig. 3 Rear Wiper/Washer Switch Lamp
1 - SCREW DRIVER
2 - LAMP HOLDER
3 - REAR WIPER/WASHER SWITCH
TJ LAMPS/LIGHTING - INTERIOR 8L - 35
POWER SYSTEMS
TABLE OF CONTENTS
page page
AUTOMATIC DAY / NIGHT MIRROR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DIAGNOSIS AND TESTING - AUTOMATIC
DAY/NIGHT MIRROR . . . . . . . . . . . . . . . . . . . . 2
STANDARD PROCEDURE
STANDARD PROCEDURE - COMPASS
CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . 2
STANDARD PROCEDURE - COMPASS
VARIATION ADJUSTMENT. . . . . . . . . . . . . . . . 3
AUTOMATIC DAY / NIGHT
MIRROR
DESCRIPTION
The automati c di mmi ng i nsi de day/ni ght rear vi ew
mi rror system i s a compl etel y sel f-contai ned uni t
that repl aces the standard equi pment i nsi de rear
vi ew mi rror. Thi s system wi l l automati cal l y change
the refl ectance of the i nsi de rear vi ew mi rror to pro-
tect the dri ver from the unwanted headl i ght gl are of
trai l i ng vehi cl es whi l e dri vi ng at ni ght. The auto-
mati c day/ni ght i nsi de mi rror recei ves i gni ti on
swi tched battery current through a fuse i n the junc-
ti on bl ock, and wi l l onl y operate when the i gni ti on
swi tch i s i n the On posi ti on.
Contai ned wi thi n the mi rror i s a compass/temper-
ature di spl ay as wel l as two LED readi ng l amps.
The automati c day/ni ght mi rror sensi ti vi ty cannot
be repai red or adjusted. I f any component of thi s uni t
i s i noperati ve or damaged, the enti re automati c day/
ni ght i nsi de rear vi ew mi rror uni t must be repl aced.
OPERATION
The automati c day/ni ght mi rror i s equi pped wi th
three buttons: the l eft swi tch for the l eft LED l amp,
the ri ght swi tch for the ri ght si de LED l amp and the
center swi tch for the compass/temperature functi on.
Pressi ng the l eft and ri ght swi tch si mul taneousl y wi l l
turn the auto di m functi on on or off. A green l i ght
next to the ri ght button wi l l i ndi cate when the di m-
mi ng feature i s acti vated. The mi rror al so senses the
backup l amp ci rcui t, and wi l l automati cal l y di sabl e
i ts sel f-di mmi ng feature whenever the transmi ssi on
gear sel ector i s i n the Reverse posi ti on.
The compass/temperature di spl ay provi des the out-
si de temperature and one of ei ght compass headi ngs.
Press and rel ease the center button once wi thi n 3
seconds to di spl ay compass/temperature (Fahren-
hei t). Press and rel ease the center button twi ce
wi thi n 3 seconds to di spl ay compass/temperature
(Cel si us). Press and rel ease the center button three
ti mes wi thi n 3 seconds to deacti vate the feature.
A thi n l ayer of el ectrochromati c materi al between
two pi eces of conducti ve gl ass make up the face of
the mi rror. Two photocel l sensors are used to moni tor
l i ght l evel s and adjust the refl ectance of the mi rror.
The ambi ent photocel l sensor faces forward, to detect
the outsi de l i ght l evel s. The headl amp sensor i s
l ocated on the mi rror housi ng just to the l eft of the
swi tch and faci ng rearward, to detect the l i ght l evel
recei ved at the rear wi ndow si de of the mi rror. When
the di fference between the two l i ght l evel s becomes
too great (the l i ght l evel recei ved at the rear of the
mi rror i s much hi gher than that at the front of the
mi rror), the mi rror begi ns to darken.
TJ POWER SYSTEMS 8N - 1
DIAGNOSIS AND TESTING - AUTOMATIC
DAY/NIGHT MIRROR
For compl ete ci rcui t di agrams, refer to the appro-
pri ate wi ri ng i nformati on.
(1) Check for a bl own fuse. I f OK, go to Step 2. I f
not OK, repai r the shorted ci rcui t or component as
requi red and repl ace the faul ty fuse.
(2) Turn the i gni ti on swi tch to the On posi ti on.
Check for battery vol tage at the fuse. I f OK, go to
Step 3. I f not OK, repai r the open ci rcui t to the i gni -
ti on swi tch as requi red.
(3) Turn the i gni ti on swi tch to the Off posi ti on.
Di sconnect and i sol ate the battery negati ve cabl e.
Unpl ug the wi re harness connector from the auto-
mati c day/ni ght mi rror. Connect the battery negati ve
cabl e. Turn the i gni ti on swi tch to the On posi ti on.
Check for battery vol tage at the fused i gni ti on swi tch
output (run/start) ci rcui t cavi ty of the automati c day/
ni ght mi rror wi re harness connector. I f OK, go to
Step 4. I f not OK, repai r the open ci rcui t as requi red.
(4) Turn the i gni ti on swi tch to the Off posi ti on.
Di sconnect and i sol ate the battery negati ve cabl e.
Check for conti nui ty between the ground ci rcui t cav-
i ty of the automati c day/ni ght mi rror wi re harness
connector and a good ground. There shoul d be conti -
nui ty. I f OK, go to Step 5. I f not OK, repai r the ci r-
cui t to ground as requi red.
(5) Connect the battery negati ve cabl e. Turn the
i gni ti on swi tch to the On posi ti on. Set the parki ng
brake. Pl ace the transmi ssi on gear sel ector l ever i n
the Reverse posi ti on. Check for battery vol tage at the
backup l amp swi tch output ci rcui t cavi ty of the auto-
mati c day/ni ght mi rror wi re harness connector. I f
OK, go to Step 6. I f not OK, repai r the open ci rcui t
as requi red.
(6) Turn the i gni ti on swi tch to the Off posi ti on.
Di sconnect the battery negati ve cabl e. Pl ug i n the
automati c day/ni ght mi rror wi re harness connector.
Connect the battery negati ve cabl e. Turn the i gni ti on
swi tch to the On posi ti on. Pl ace the transmi ssi on
gear sel ector l ever i n the Neutral posi ti on. Pl ace the
mi rror swi tch i n the On (the LED i n the mi rror
swi tch i s l i ghted) posi ti on. Cover the forward faci ng
ambi ent photocel l sensor to keep out any ambi ent
l i ght.
NOTE: The ambient photocell sensor must be cov-
ered completely, so that no light reaches the sen-
sor. Use a finger pressed tightly against the sensor,
or cover the sensor completely with electrical tape.
(7) Shi ne a l i ght i nto the rearward faci ng head-
l amp photocel l sensor. The mi rror gl ass shoul d
darken. I f OK, go to Step 8. I f not OK, repl ace the
faul ty automati c day/ni ght mi rror uni t.
(8) Wi th the mi rror gl ass darkened, pl ace the
transmi ssi on gear sel ector l ever i n the Reverse posi -
ti on. The mi rror shoul d return to i ts normal refl ec-
tance. I f not OK, repl ace the faul ty automati c day/
ni ght mi rror uni t.
STANDARD PROCEDURE
STANDARD PROCEDURE - COMPASS
CALIBRATION
AUTOMATIC CALIBRATION
The compass i s sel f cal i brati ng whi ch el i mi nates
the need to manual l y set the compass. When the
vehi cl e i s new, the compass may appear errati c and
CAL wi l l be di spl ayed. After compl eti ng one 360°
turn wi th the vehi cl e travel i ng l ess than 8 km/h (5
mph) i n an area free from l arge metal or metal l i c
objects, CAL wi l l turn off and the compass wi l l func-
ti on normal l y.
MANUAL CALIBRATION
I f the compass appears errati c and CAL does not
appear, you must manual l y put the compass i nto the
cal i brati on mode. To ensure proper compass cal i bra-
ti on, make sure the compass vari ance i s properl y set
before manual l y cal i brati ng the compass.
To put the compass i nto cal i brati on mode: Turn the
i gni ti on to the ON posi ti on. Press and hol d the center
button for 6 seconds to change the di spl ay between
VAR (compass vari ance) and CAL (compass cal i bra-
ti on) modes. To recal i brate the compass, CAL shoul d
di spl ay for a compl ete 1 1/2 360° turns i n a area free
from l arge metal objects or power l i nes. When the
compass has been cal i brated, the CAL symbol wi l l
turn off and the compass wi l l functi on normal l y.
8N - 2 POWER SYSTEMS TJ
AUTOMATIC DAY / NIGHT MIRROR (Continued)
STANDARD PROCEDURE - COMPASS
VARIATION ADJUSTMENT
Compass vari ance i s the di fference between mag-
neti c north and geographi c north. I n some areas of
the country, the di fference between magneti c and
geographi c north i s great enough to cause the com-
pass to gi ve fal se readi ngs. I f thi s occurs, the com-
pass vari ance must be set accordi ng to the compass
vari ance map (Fi g. 1).
To set the vari ance: Turn the i gni ti on to the ON
posi ti on. Press and hol d the center button for 3 to 6
seconds. The l ast vari ance zone number wi l l be di s-
pl ayed. Each press of the center button wi l l sel ect a
new vari ance zone. When the proper zone i s sel ected,
wai t 5 seconds to resume normal operati on.
Fig. 1 Variance Settings
TJ POWER SYSTEMS 8N - 3
AUTOMATIC DAY / NIGHT MIRROR (Continued)
RESTRAINTS
TABLE OF CONTENTS
page page
RESTRAINTS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
WARNING
WARNINGS - RESTRAINT SYSTEM . . . . . . . . 5
DIAGNOSIS AND TESTING - SUPPLEMENTAL
RESTRAINT SYSTEM . . . . . . . . . . . . . . . . . . . 6
STANDARD PROCEDURE
STANDARD PROCEDURE - HANDLING
NON-DEPLOYED SUPPLEMENTAL
RESTRAINTS . . . . . . . . . . . . . . . . . . . . . . . . . 6
STANDARD PROCEDURE - SERVICE
AFTER A SUPPLEMENTAL RESTRAINT
DEPLOYMENT. . . . . . . . . . . . . . . . . . . . . . . . . 6
STANDARD PROCEDURE - VERIFICATION
TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
AIRBAG CONTROL MODULE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11
CHILD RESTRAINT ANCHOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 12
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14
CLOCKSPRING
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 14
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
STANDARD PROCEDURE - CLOCKSPRING
CENTERING . . . . . . . . . . . . . . . . . . . . . . . . . 16
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 18
DRIVER AIRBAG
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 19
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 21
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 23
FRONT SEAT BELT & RETRACTOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 25
FRONT SEAT BELT BUCKLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 26
PASSENGER AIRBAG
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 27
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 28
PASSENGER AIRBAG DOOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 30
PASSENGER AIRBAG ON/OFF SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 31
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 32
REAR SEAT BELT & RETRACTOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 34
REAR SEAT BELT BUCKLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 35
SEAT BELT SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 35
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
DIAGNOSIS AND TESTING - SEAT BELT
SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
SEAT BELT TURNING LOOP ADJUSTER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 37
RESTRAINTS
DESCRIPTION
An occupant restrai nt system i s standard factory-
i nstal l ed safety equi pment on thi s model . Avai l abl e
occupant restrai nts for thi s model i ncl ude both acti ve
and passi ve types. Acti ve restrai nts are those whi ch
requi re the vehi cl e occupants to take some acti on to
empl oy, such as fasteni ng a seat bel t; whi l e passi ve
restrai nts requi re no acti on by the vehi cl e occupants
to be empl oyed (Fi g. 1).
ACTIVE RESTRAINTS
The acti ve restrai nts for thi s model i ncl ude:
• Front Seat Belts - Both front seati ng posi ti ons
are equi pped wi th three-poi nt seat bel t systems
empl oyi ng a l ower sport bar mounted i nerti a l atch-
type retractor, hei ght-adjustabl e upper sport bar
mounted turni ng l oops, a fi xed l ower seat bel t anchor
secured wi th the retractor to the l ower end of the
TJ RESTRAINTS 8O - 1
sport bar, and a travel i ng end-rel ease seat bel t
buckl e secured to the i nboard si de of each front seat
track. The front seat bel t buckl e for the dri ver si de of
al l model s i ncl udes an i ntegral seat bel t swi tch that
el ectri cal l y detects whether the dri ver seat bel t has
been fastened.
• Rear Seat Belts - On model s equi pped wi th a
rear seat, both rear seati ng posi ti ons are equi pped
wi th three-poi nt seat bel t systems. The rear seati ng
posi ti on bel ts empl oy a l ower sport bar mounted i ner-
ti a l atch-type retractor, fi xed upper sport bar
mounted turni ng l oops, a fi xed l ower seat bel t anchor
secured to the i nner rear wheel house panel , and a
fi xed end-rel ease seat bel t buckl e secured to the rear
fl oor panel .
• Child Restraint Anchors - Al l vehi cl es wi thout
a rear seat are equi pped wi th a si ngl e, fi xed-posi ti on,
chi l d seat upper tether anchor and two fi xed l ower
anchors for the front passenger seat. The upper
anchor i s i ntegral to the seat ri ser bracket and i s
accessed from behi nd the front seat. The two l ower
anchors are al so i ntegral to the seat ri ser bracket,
Fig. 1 Supplemental Restraint System
1 - AIRBAG CONTROL MODULE
2 - PASSENGER AIRBAG ON/OFF SWITCH (W/O REAR SEAT
ONLY)
3 - PASSENGER AIRBAG
4 - DRIVER AIRBAG
8O - 2 RESTRAINTS TJ
RESTRAINTS (Continued)
but are accessed from the front of the seat where the
seat back meets the seat cushi on. Vehi cl es equi pped
wi th a rear seat have two fi xed-posi ti on, chi l d seat
upper tether anchors on the rear fl oor panel behi nd
the rear seat just forward of the tai l gate openi ng,
and four l ower anchors that are i ntegral to the rear
seat back. The i nboard rear seat l ower anchors are
accessed from the front of the seat where the seat
back meets the seat cushi on. The outboard rear seat
l ower anchors are accessed between the seat hi nge
bracket on each outboard end of the rear seat, just
above the seat back pi vot. The chi l d seat tether and
l ower anchors for the front passenger seat are
del eted on model s equi pped wi th a rear seat.
PASSIVE RESTRAINTS
The passi ve restrai nts avai l abl e for thi s model
i ncl ude Next Generati on dri ver and front passenger
ai rbags. Thi s ai rbag system i s a passi ve, i nfl atabl e,
Suppl emental Restrai nt System (SRS) and vehi cl es
wi th thi s equi pment can be readi l y i denti fi ed by the
“SRS - AI RBAG” l ogo mol ded i nto the dri ver ai rbag
tri m cover i n the center of the steeri ng wheel and
al so i nto the passenger ai rbag door on the i nstru-
ment panel above the gl ove box (Fi g. 2). Vehi cl es
wi th the ai rbag system can al so be i denti fi ed by the
ai rbag i ndi cator, whi ch wi l l i l l umi nate i n the i nstru-
ment cl uster for about seven seconds as a bul b test
each ti me the i gni ti on swi tch i s turned to the On
posi ti on.
The suppl emental restrai nt system i ncl udes the
fol l owi ng major components, whi ch are descri bed i n
further detai l el sewhere i n thi s servi ce i nformati on:
• Airbag Control Module - The Ai rbag Control
Modul e (ACM) i s l ocated on a mount on the fl oor
panel transmi ssi on tunnel , bel ow the center of the
i nstrument panel .
• Airbag Indicator - The ai rbag i ndi cator i s i nte-
gral to the El ectroMechani cal I nstrument Cl uster
(EMI C), whi ch i s l ocated on the i nstrument panel i n
front of the dri ver.
• Clockspring - The cl ockspri ng i s l ocated near
the top of the steeri ng col umn, di rectl y beneath the
steeri ng wheel .
• Driver Airbag - The dri ver ai rbag i s l ocated i n
the center of the steeri ng wheel , beneath the dri ver
ai rbag tri m cover.
• Driver Knee Blocker - The dri ver knee bl ocker
i s a mol ded pl asti c structural uni t secured to the
back si de of and i ntegral to the i nstrument panel
steeri ng col umn openi ng cover.
• Passenger Airbag - The passenger ai rbag i s
l ocated on the i nstrument panel , beneath the passen-
ger ai rbag door on the i nstrument panel above the
gl ove box on the passenger si de of the vehi cl e.
• Passenger Airbag On/Off Switch - Model s
wi thout a rear seat are equi pped wi th a passenger
ai rbag on/off swi tch, whi ch i s l ocated i n a dedi cated
openi ng on the passenger si de of the accessory swi tch
bezel i n the l ower center stack area of the i nstru-
ment panel .
• Passenger Knee Blocker - The passenger knee
bl ocker i s a structural rei nforcement that i s i ntegral
to and conceal ed wi thi n the gl ove box door.
The ACM and the EMI C each contai n a central
processi ng uni t and programmi ng that al l ow them to
communi cate wi th each other usi ng the Programma-
bl e Communi cati on I nterface (PCI ) data bus network.
Thi s method of communi cati on i s used by the ACM
for control of the ai rbag i ndi cator on al l model s
equi pped wi th dual front ai rbags. (Refer to 8 - ELEC-
TRI CAL/ELECTRONI C CONTROL MODULES/
COMMUNI CATI ON - DESCRI PTI ON).
Hard wi red ci rcui try connects the suppl emental
restrai nt system components to each other through
the el ectri cal system of the vehi cl e. These hard wi red
ci rcui ts are i ntegral to several wi re harnesses, whi ch
are routed throughout the vehi cl e and retai ned by
many di fferent methods. These ci rcui ts may be con-
nected to each other, to the vehi cl e el ectri cal system,
and to the suppl emental restrai nt system compo-
nents through the use of a combi nati on of sol dered
spl i ces, spl i ce bl ock connectors, and many di fferent
types of wi re harness termi nal connectors and i nsu-
l ators. Refer to the appropri ate wi ri ng i nformati on.
The wi ri ng i nformati on i ncl udes wi ri ng di agrams,
proper wi re and connector repai r procedures, further
detai l s on wi re harness routi ng and retenti on, as wel l
as pi n-out and l ocati on vi ews for the vari ous wi re
harness connectors, spl i ces and grounds.
Fig. 2 SRS Logo
TJ RESTRAINTS 8O - 3
RESTRAINTS (Continued)
OPERATION
ACTIVE RESTRAINTS
The pri mary passenger restrai nts i n thi s or any
other vehi cl e are the standard equi pment factory-i n-
stal l ed seat bel ts and chi l d restrai nt anchors. Seat
bel ts and chi l d restrai nt anchors are referred to as
an acti ve restrai nt because the vehi cl e occupants are
requi red to physi cal l y fasten and properl y adjust
these restrai nts i n order to benefi t from them. See
the owner’s manual i n the vehi cl e gl ove box for more
i nformati on on the features, use and operati on of al l
of the factory-i nstal l ed acti ve restrai nts.
PASSIVE RESTRAINTS
The passi ve restrai nts are referred to as a suppl e-
mental restrai nt system because they were desi gned
and are i ntended to enhance the protecti on for the
occupants of the vehi cl e only when used i n conjunc-
ti on wi th the seat bel ts. They are referred to as pas-
si ve restrai nts because the vehi cl e occupants are not
requi red to do anythi ng to make them operate; how-
ever, the vehi cl e occupants must be weari ng thei r
seat bel ts i n order to obtai n the maxi mum safety
benefi t from the factory-i nstal l ed suppl emental
restrai nt system.
The suppl emental restrai nt system el ectri cal ci r-
cui ts are conti nuousl y moni tored and control l ed by a
mi croprocessor and software contai ned wi thi n the
Ai rbag Control Modul e (ACM). An ai rbag i ndi cator i n
the El ectroMechani cal I nstrument Cl uster (EMI C)
i l l umi nates for about seven seconds as a bul b test
each ti me the i gni ti on swi tch i s turned to the On or
Start posi ti ons. Fol l owi ng the bul b test, the ai rbag
i ndi cator i s turned on or off by the ACM to i ndi cate
the status of the suppl emental restrai nt system. I f
the ai rbag i ndi cator comes on at any ti me other than
duri ng the bul b test, i t i ndi cates that there i s a prob-
l em i n the suppl emental restrai nt system el ectri cal
ci rcui ts. Such a probl em may cause ai rbags not to
depl oy when requi red, or to depl oy when not
requi red.
Depl oyment of the suppl emental restrai nts
depends upon the angl e and severi ty of an i mpact.
Depl oyment i s not based upon vehi cl e speed; rather,
depl oyment i s based upon the rate of decel erati on as
measured by the forces of gravi ty (G force) upon the
i mpact sensors. When an i mpact i s severe enough,
the mi croprocessor i n the ACM si gnal s the i nfl ator of
the appropri ate ai rbag uni ts to depl oy thei r ai rbag
cushi ons. Duri ng a frontal vehi cl e i mpact, the knee
bl ockers work i n concert wi th properl y fastened and
adjusted seat bel ts to restrai n both the dri ver and
the front seat passenger i n the proper posi ti on for an
ai rbag depl oyment. The knee bl ockers al so absorb
and di stri bute the crash energy from the dri ver and
the front seat passenger to the structure of the
i nstrument panel .
Typi cal l y, the vehi cl e occupants recal l more about
the events precedi ng and fol l owi ng a col l i si on than
they do of an ai rbag depl oyment i tsel f. Thi s i s
because the ai rbag depl oyment and defl ati on occur
very rapi dl y. I n a typi cal 48 ki l ometer-per-hour (30
mi l e-per-hour) barri er i mpact, from the moment of
i mpact unti l the ai rbags are ful l y i nfl ated takes
about 40 mi l l i seconds. Wi thi n one to two seconds
from the moment of i mpact, the ai rbags are al most
enti rel y defl ated. The ti mes ci ted for these events are
approxi mati ons, whi ch appl y onl y to a barri er i mpact
at the gi ven speed. Actual ti mes wi l l vary somewhat,
dependi ng upon the vehi cl e speed, i mpact angl e,
severi ty of the i mpact, and the type of col l i si on.
When the ACM moni tors a probl em i n any of the
suppl emental restrai nt system ci rcui ts or compo-
nents, i t stores a faul t code or Di agnosti c Troubl e
Code (DTC) i n i ts memory ci rcui t and sends an el ec-
troni c message to the EMI C to turn on the ai rbag
i ndi cator. Proper testi ng of the suppl emental
restrai nt system components, the Programmabl e
Communi cati on I nterface (PCI ) data bus, the el ec-
troni c message i nputs to and outputs from the EMI C
or the ACM, as wel l as the retri eval or erasure of a
DTC from the ACM or EMI C requi res the use of a
DRBI I I ௡ scan tool . Refer to the appropri ate di agnos-
ti c i nformati on.
See the owner’s manual i n the vehi cl e gl ove box for
more i nformati on on the features, use and operati on
of al l of the factory-i nstal l ed passi ve restrai nts.
8O - 4 RESTRAINTS TJ
RESTRAINTS (Continued)
WARNING
WARNINGS - RESTRAINT SYSTEM
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, DURING AND FOLLOWING ANY SEAT BELT
OR CHILD RESTRAINT ANCHOR SERVICE, CARE-
FULLY INSPECT ALL SEAT BELTS, BUCKLES,
MOUNTING HARDWARE, RETRACTORS, TETHER
STRAPS, AND ANCHORS FOR PROPER INSTALLA-
TION, OPERATION, OR DAMAGE. REPLACE ANY
BELT THAT IS CUT, FRAYED, OR TORN.
STRAIGHTEN ANY BELT THAT IS TWISTED.
TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY
BELT THAT HAS A DAMAGED OR INOPERATIVE
BUCKLE OR RETRACTOR. REPLACE ANY BELT
THAT HAS A BENT OR DAMAGED LATCH PLATE
OR ANCHOR PLATE. REPLACE ANY CHILD
RESTRAINT ANCHOR OR THE UNIT TO WHICH THE
ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR
DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT
BELT OR CHILD RESTRAINT COMPONENT.
ALWAYS REPLACE DAMAGED OR FAULTY SEAT
BELT AND CHILD RESTRAINT COMPONENTS WITH
THE CORRECT, NEW AND UNUSED REPLACEMENT
PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR
PARTS CATALOG.
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE SUPPLEMENTAL RESTRAINT SYS-
TEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, AIRBAG, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE BEFORE PERFORMING FURTHER DIAG-
NOSIS OR SERVICE. THIS IS THE ONLY SURE WAY
TO DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT.
WARNING: TO AVOID PERSONAL INJURY OR
DEATH ON VEHICLES EQUIPPED WITH AIRBAGS,
BEFORE PERFORMING ANY WELDING OPERA-
TIONS DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE AND DISCONNECT
ALL WIRE HARNESS CONNECTORS FROM THE
AIRBAG CONTROL MODULE (ACM). FAILURE TO
TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND OTHER POSSIBLE DAMAGE TO THE SUPPLE-
MENTAL RESTRAINT SYSTEM CIRCUITS AND COM-
PONENTS.
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, DO NOT ATTEMPT TO DISMANTLE AN AIR-
BAG UNIT OR TAMPER WITH ITS INFLATOR. DO
NOT PUNCTURE, INCINERATE, OR BRING INTO
CONTACT WITH ELECTRICITY. DO NOT STORE AT
TEMPERATURES EXCEEDING 93° C (200° F). AN
AIRBAG INFLATOR UNIT MAY CONTAIN SODIUM
AZIDE AND POTASSIUM NITRATE. THESE MATERI-
ALS ARE POISONOUS AND EXTREMELY FLAMMA-
BLE. CONTACT WITH ACID, WATER, OR HEAVY
METALS MAY PRODUCE HARMFUL AND IRRITAT-
ING GASES (SODIUM HYDROXIDE IS FORMED IN
THE PRESENCE OF MOISTURE) OR COMBUSTIBLE
COMPOUNDS. AN AIRBAG INFLATOR UNIT MAY
ALSO CONTAIN A GAS CANISTER PRESSURIZED
TO OVER 2500 PSI.
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, REPLACE ALL RESTRAINT SYSTEM COM-
PONENTS ONLY WITH PARTS SPECIFIED IN THE
DAIMLERCHRYSLER MOPAR PARTS CATALOG.
SUBSTITUTE PARTS MAY APPEAR INTERCHANGE-
ABLE, BUT INTERNAL DIFFERENCES MAY RESULT
IN INFERIOR OCCUPANT PROTECTION.
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, THE FASTENERS, SCREWS, AND BOLTS
ORIGINALLY USED FOR THE RESTRAINT SYSTEM
COMPONENTS MUST NEVER BE REPLACED WITH
ANY SUBSTITUTES. THESE FASTENERS HAVE
SPECIAL COATINGS AND ARE SPECIFICALLY
DESIGNED FOR THE RESTRAINT SYSTEM. ANY
TIME A NEW FASTENER IS NEEDED, REPLACE IT
WITH THE CORRECT FASTENERS PROVIDED IN
THE SERVICE PACKAGE OR SPECIFIED IN THE
DAIMLERCHRYSLER MOPAR PARTS CATALOG.
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, WHEN A STEERING COLUMN HAS AN AIR-
BAG UNIT ATTACHED, NEVER PLACE THE COL-
UMN ON THE FLOOR OR ANY OTHER SURFACE
WITH THE STEERING WHEEL OR AIRBAG UNIT
FACE DOWN.
TJ RESTRAINTS 8O - 5
RESTRAINTS (Continued)
DIAGNOSIS AND TESTING - SUPPLEMENTAL
RESTRAINT SYSTEM
Proper di agnosi s and testi ng of the suppl emental
restrai nt system components, the PCI data bus, the
data bus el ectroni c message i nputs to and outputs
from the El ectroMechani cal I nstrument Cl uster
(EMI C), or the Ai rbag Control Modul e (ACM) as wel l
as the retri eval or erasure of a Di agnosti c Troubl e
Code (DTC) from the ACM requi res the use of a
DRBI I I ௡ scan tool . Refer to the appropri ate di agnos-
ti c i nformati on.
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE SUPPLEMENTAL RESTRAINT SYS-
TEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, AIRBAG, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE BEFORE PERFORMING FURTHER DIAG-
NOSIS OR SERVICE. THIS IS THE ONLY SURE WAY
TO DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT.
STANDARD PROCEDURE
STANDARD PROCEDURE - HANDLING
NON-DEPLOYED SUPPLEMENTAL RESTRAINTS
At no ti me shoul d any source of el ectri ci ty be per-
mi tted near the i nfl ator on the back of a non-de-
pl oyed ai rbag. When carryi ng a non-depl oyed ai rbag,
the tri m cover or ai rbag cushi on si de of the uni t
shoul d be poi nted away from the body to mi ni mi ze
i njury i n the event of an acci dental depl oyment. I f
the ai rbag uni t i s pl aced on a bench or any other sur-
face, the tri m cover or ai rbag cushi on si de of the uni t
shoul d be face up to mi ni mi ze movement i n the event
of an acci dental depl oyment. I n addi ti on, the suppl e-
mental restrai nt system shoul d be di sarmed when-
ever any steeri ng wheel , steeri ng col umn, dri ver
ai rbag, passenger ai rbag, or i nstrument panel compo-
nents requi re di agnosi s or servi ce. Fai l ure to observe
thi s warni ng coul d resul t i n acci dental ai rbag depl oy-
ment and possi bl e personal i njury.
Al l damaged, faul ty, or non-depl oyed ai rbags whi ch
are repl aced on vehi cl es are to be handl ed and di s-
posed of properl y. I f an ai rbag uni t i s faul ty or dam-
aged and non-depl oyed, refer to the Hazardous
Substance Control System for proper di sposal . Di s-
pose of al l non-depl oyed and depl oyed ai rbags i n a
manner consi stent wi th state, provi nci al , l ocal and
federal regul ati ons.
SUPPLEMENTAL RESTRAINT STORAGE
Ai rbags must be stored i n thei r ori gi nal , speci al
contai ner unti l they are used for servi ce. Al so, they
must be stored i n a cl ean, dry envi ronment; away
from sources of extreme heat, sparks, and hi gh el ec-
tri cal energy. Al ways pl ace or store any ai rbag on a
surface wi th i ts tri m cover or ai rbag cushi on si de fac-
i ng up, to mi ni mi ze movement i n case of an acci den-
tal depl oyment.
STANDARD PROCEDURE - SERVICE AFTER A
SUPPLEMENTAL RESTRAINT DEPLOYMENT
Any vehi cl e whi ch i s to be returned to use fol l ow-
i ng a suppl emental restrai nt depl oyment, must have
the depl oyed restrai nts repl aced. I n addi ti on, i f the
dri ver ai rbag has been depl oyed, the cl ockspri ng
must be repl aced. I f the passenger ai rbag i s
depl oyed, the passenger ai rbag door must be
repl aced. These components are not i ntended for
reuse and wi l l be damaged or weakened as a resul t
of a suppl emental restrai nt depl oyment, whi ch may
or may not be obvi ous duri ng a vi sual i nspecti on.
I t i s al so cri ti cal that the mounti ng surfaces and/or
mounti ng bracket for the Ai rbag Control Modul e
(ACM) be cl osel y i nspected and restored to i ts ori gi -
nal condi ti on fol l owi ng any vehi cl e i mpact damage.
Because the ACM contai ns i mpact sensors that are
used by the suppl emental restrai nt system to moni -
tor or confi rm the di recti on and severi ty of a vehi cl e
i mpact, i mproper ori entati on or i nsecure fasteni ng of
thi s component may cause ai rbags not to depl oy
when requi red, or to depl oy when not requi red. Al l
other vehi cl e components shoul d be cl osel y i nspected
fol l owi ng any suppl emental restrai nt depl oyment, but
are to be repl aced onl y as requi red by the extent of
the vi si bl e damage i ncurred.
CLEANUP PROCEDURE
Fol l owi ng a suppl emental restrai nt depl oyment,
the vehi cl e i nteri or wi l l contai n a powdery resi due.
Thi s resi due consi sts pri mari l y of harml ess parti cu-
l ate by-products of the smal l pyrotechni c charge that
i ni ti ates the propel l ant used to depl oy a suppl emen-
tal restrai nt. However, thi s resi due may al so contai n
traces of sodi um hydroxi de powder, a chemi cal
by-product of the propel l ant materi al that i s used to
generate the i nert gas that i nfl ates the ai rbag. Si nce
sodi um hydroxi de powder can i rri tate the ski n, eyes,
nose, or throat, be certai n to wear safety gl asses,
rubber gl oves, and a l ong-sl eeved shi rt duri ng
cl eanup (Fi g. 3).
8O - 6 RESTRAINTS TJ
RESTRAINTS (Continued)
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, IF YOU EXPERIENCE SKIN IRRITATION
DURING CLEANUP, RUN COOL WATER OVER THE
AFFECTED AREA. ALSO, IF YOU EXPERIENCE
IRRITATION OF THE NOSE OR THROAT, EXIT THE
VEHICLE FOR FRESH AIR UNTIL THE IRRITATION
CEASES. IF IRRITATION CONTINUES, SEE A PHYSI-
CIAN.
(1) Begi n the cl eanup by usi ng a vacuum cl eaner
to remove any resi dual powder from the vehi cl e i nte-
ri or. Cl ean from outsi de the vehi cl e and work your
way i nsi de, so that you avoi d kneel i ng or si tti ng on a
non-cl eaned area.
(2) Be certai n to vacuum the heater and ai r condi -
ti oni ng outl ets as wel l (Fi g. 4). Run the heater and
ai r condi ti oner bl ower on the l owest speed setti ng
and vacuum any powder expel l ed from the outl ets.
CAUTION: All damaged, faulty, or non-deployed
supplemental restraints which are replaced on vehi-
cles are to be handled and disposed of properly. If
an airbag unit is faulty or damaged and non-de-
ployed, refer to the Hazardous Substance Control
System for proper disposal. Be certain to dispose
of all non-deployed and deployed supplemental
restraints in a manner consistent with state, provin-
cial, local and federal regulations.
(3) Next, remove the depl oyed suppl emental
restrai nts from the vehi cl e. Refer to the appropri ate
servi ce removal procedures.
(4) You may need to vacuum the i nteri or of the
vehi cl e a second ti me to recover al l of the powder.
STANDARD PROCEDURE - VERIFICATION TEST
The fol l owi ng procedure shoul d be performed usi ng
a DRBI I I ௡ scan tool to veri fy proper suppl emental
restrai nt system operati on fol l owi ng the servi ce or
repl acement of any suppl emental restrai nt system
component.
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE SUPPLEMENTAL RESTRAINT SYS-
TEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, AIRBAG, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE BEFORE PERFORMING FURTHER DIAG-
NOSIS OR SERVICE. THIS IS THE ONLY SURE WAY
TO DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT.
(1) Duri ng the fol l owi ng test, the battery negati ve
cabl e remai ns di sconnected and i sol ated, as i t was
duri ng the suppl emental restrai nt system component
removal and i nstal l ati on procedures.
(2) Be certai n that the DRBI I I ௡ scan tool contai ns
the l atest versi on of the proper DRBI I I ௡ software.
Connect the DRBI I I ௡ to the 16-way Data Li nk Con-
nector (DLC). The DLC i s l ocated on the dri ver si de
l ower edge of the i nstrument panel , outboard of the
steeri ng col umn (Fi g. 5).
(3) Turn the i gni ti on swi tch to the On posi ti on and
exi t the vehi cl e wi th the DRBI I I ௡ scan tool .
(4) Check to be certai n that nobody i s i n the vehi -
cl e, then reconnect the battery negati ve cabl e.
(5) Usi ng the DRBI I I ௡, read and record the acti ve
(current) Di agnosti c Troubl e Code (DTC) data.
(6) Next, use the DRBI I I ௡ to read and record any
stored (hi stori cal ) DTC data.
(7) I f any DTC i s found i n Step 5 or Step 6, refer
to the appropri ate di agnosti c i nformati on.
(8) Use the DRBI I I ௡ to erase the stored DTC data.
I f any probl ems remai n, the stored DTC data wi l l not
Fig. 3 Wear Safety Glasses and Rubber Gloves -
Typical
Fig. 4 Vacuum Heater and A/C Outlets - Typical
TJ RESTRAINTS 8O - 7
RESTRAINTS (Continued)
erase. Refer to the appropri ate di agnosti c i nforma-
ti on to di agnose any stored DTC that wi l l not erase.
I f the stored DTC i nformati on i s successful l y erased,
go to Step 9.
(9) Turn the i gni ti on swi tch to the Off posi ti on for
about fi fteen seconds, and then back to the On posi -
ti on. Observe the ai rbag i ndi cator i n the i nstrument
cl uster. I t shoul d i l l umi nate for si x to ei ght seconds,
and then go out. Thi s i ndi cates that the suppl emen-
tal restrai nt system i s functi oni ng normal l y and that
the repai rs are compl ete. I f the ai rbag i ndi cator fai l s
to l i ght, or l i ghts and stays on, there i s sti l l an acti ve
suppl emental restrai nt system faul t or mal functi on.
Refer to the appropri ate di agnosti c i nformati on to
di agnose the probl em.
AIRBAG CONTROL MODULE
DESCRIPTION
The Ai rbag Control Modul e (ACM) i s secured wi th
four screws to the top mounti ng surface of a stamped
steel bracket wel ded onto the top of the fl oor panel
transmi ssi on tunnel bel ow the i nstrument panel and
forward of the center fl oor consol e i n the passenger
compartment of the vehi cl e (Fi g. 6). Conceal ed wi thi n
a hol l ow i n the center of the di e cast al umi num ACM
housi ng i s the el ectroni c ci rcui try of the ACM whi ch
i ncl udes a mi croprocessor, an el ectroni c i mpact sen-
sor, an el ectromechani cal safi ng sensor, and an
energy storage capaci tor. A stamped metal cover
pl ate i s secured to the bottom of the ACM housi ng
wi th four screws to encl ose and protect the i nternal
el ectroni c ci rcui try and components.
The ACM housi ng has an i ntegral mounti ng fl ange
on each si de. Each mounti ng fl ange has an i ntegral
l ocati ng pi n on i ts l ower surface and two round
mounti ng hol es. An arrow cast i nto the top of the
ACM housi ng near the rear provi des a vi sual veri fi -
cati on of the proper ori entati on of the uni t, and
shoul d al ways be poi nted toward the front of the
vehi cl e. A mol ded pl asti c el ectri cal connector recepta-
cl e contai ni ng twenty-three termi nal pi ns exi ts the
forward faci ng si de of the ACM housi ng. These ter-
mi nal pi ns connect the ACM to the vehi cl e el ectri cal
system through a dedi cated take out and connector of
the body wi re harness.
The i mpact sensor and safi ng sensor i nternal to
the ACM are cal i brated for the speci fi c vehi cl e, and
are onl y servi ced as a uni t wi th the ACM. The ACM
cannot be repai red or adjusted and, i f damaged or
faul ty, i t must be repl aced.
OPERATION
The mi croprocessor i n the Ai rbag Control Modul e
(ACM) contai ns the front suppl emental restrai nt sys-
tem l ogi c ci rcui ts and control s al l of the suppl emental
restrai nt system components. The ACM uses
On-Board Di agnosti cs (OBD) and can communi cate
wi th other el ectroni c modul es i n the vehi cl e as wel l
as wi th the DRBI I I ௡ scan tool usi ng the Programma-
bl e Communi cati ons I nterface (PCI ) data bus net-
work. Thi s method of communi cati on i s used for
control of the ai rbag i ndi cator i n the El ectroMechani -
cal I nstrument Cl uster (EMI C) and for suppl emental
Fig. 5 16-Way Data Link Connector - Typical
1 - 16–WAY DATA LINK CONNECTOR
2 - BOTTOM OF INSTRUMENT PANEL
Fig. 6 Airbag Control Module
1 - SCREW (4)
2 - AIRBAG CONTROL MODULE
3 - WIRE HARNESS CONNECTOR
4 - MOUNTING BRACKET
5 - FRONT FLOOR PANEL
8O - 8 RESTRAINTS TJ
RESTRAINTS (Continued)
restrai nt system di agnosi s and testi ng through the
16-way data l i nk connector l ocated on the dri ver si de
l ower edge of the i nstrument panel . (Refer to 8 -
ELECTRI CAL/I NSTRUMENT CLUSTER/AI RBAG
I NDI CATOR - OPERATI ON).
The ACM mi croprocessor conti nuousl y moni tors al l
of the front suppl emental restrai nt system el ectri cal
ci rcui ts to determi ne the system readi ness. I f the
ACM detects a moni tored system faul t, i t sets an
acti ve and stored Di agnosti c Troubl e Code (DTC) and
sends el ectroni c messages to the EMI C over the PCI
data bus to turn on the ai rbag i ndi cator. An acti ve
faul t onl y remai ns for the durati on of the faul t, or i n
some cases, the durati on of the current i gni ti on
swi tch cycl e, whi l e a stored faul t causes a DTC to be
stored i n memory by the ACM. For some DTCs, i f a
faul t does not recur for a number of i gni ti on cycl es,
the ACM wi l l automati cal l y erase the stored DTC.
For other i nternal faul ts, the stored DTC i s l atched
forever.
I n model s not equi pped wi th a rear seat, the ACM
al so moni tors a resi stor mul ti pl exed i nput from the
passenger ai rbag on/off swi tch and provi des a control
output for the Off i ndi cator i n the swi tch through a
passenger ai rbag i ndi cator dri ver ci rcui t. I f the pas-
senger ai rbag on/off swi tch i s set to the Off posi ti on,
the ACM turns on the passenger ai rbag on/off swi tch
Off i ndi cator and wi l l i nternal l y di sabl e the passen-
ger ai rbag from bei ng depl oyed i f an i mpact i s
detected that i s suffi ci ent for an ai rbag depl oyment.
The ACM al so turns on the on/off swi tch Off i ndi ca-
tor for about seven seconds each ti me the i gni ti on
swi tch i s turned to the On posi ti on as a bul b test.
Fol l owi ng the bul b test, the ACM control s the status
of the Off i ndi cator based upon the resi stance of the
i nput from the on/off swi tch. The ACM wi l l al so set
and/or store a DTC for faul ts i t detects i n the passen-
ger ai rbag on/off swi tch ci rcui ts, and wi l l turn on the
ai rbag i ndi cator i n the EMI C i f a faul t has been
detected.
The ACM recei ves battery current through two ci r-
cui ts; a fused i gni ti on swi tch output (run) ci rcui t
through a fuse i n the fuse bl ock, and a fused i gni ti on
swi tch output (run-start) ci rcui t through a second
fuse i n the fuse bl ock. The ACM recei ves ground
through a ground ci rcui t and take out of the body
wi re harness. Thi s take out has a si ngl e eyel et ter-
mi nal connector that i s secured by a ground screw to
the ri ght cowl si de i nner panel bel ow the i nstrument
panel . These connecti ons al l ow the ACM to be opera-
ti onal whenever the i gni ti on swi tch i s i n the Start or
On posi ti ons. The ACM al so contai ns an energy-stor-
age capaci tor. When the i gni ti on swi tch i s i n the
Start or On posi ti ons, thi s capaci tor i s conti nual l y
bei ng charged wi th enough el ectri cal energy to
depl oy the front suppl emental restrai nt components
for up to one second fol l owi ng a battery di sconnect or
fai l ure. The purpose of the capaci tor i s to provi de
backup suppl emental restrai nt system protecti on i n
case there i s a l oss of battery current suppl y to the
ACM duri ng an i mpact.
Two sensors are contai ned wi thi n the ACM; an
el ectroni c i mpact sensor, and a safi ng sensor. The
el ectroni c i mpact sensor i s an accel erometer that
senses the rate of vehi cl e decel erati on, whi ch pro-
vi des veri fi cati on of the di recti on and severi ty of an
i mpact. The safi ng sensor i s an el ectromechani cal
sensor wi thi n the ACM that provi des an addi ti onal
l ogi c i nput to the ACM mi croprocessor. The safi ng
sensor i s a normal l y open swi tch that i s used to ver-
i fy the need for a front suppl emental restrai nt
depl oyment by detecti ng i mpact energy of a l esser
magni tude than that of the el ectroni c i mpact sensor,
and must be cl osed i n order for the front ai rbags to
depl oy. A pre-programmed deci si on al gori thm i n the
ACM mi croprocessor determi nes when the decel era-
ti on rate as si gnal ed by the i mpact sensor and the
safi ng sensor i ndi cate an i mpact that i s severe
enough to requi re front suppl emental restrai nt sys-
tem protecti on and, based upon the status of the pas-
senger ai rbag on/off swi tch i nput and the severi ty of
the moni tored i mpact, determi nes what combi nati on
of front ai rbag depl oyment i s requi red for each front
seati ng posi ti on. When the programmed condi ti ons
are met, the ACM sends the proper el ectri cal si gnal s
to depl oy the dual front ai rbags.
The hard wi red i nputs and outputs for the ACM
may be di agnosed and tested usi ng conventi onal
di agnosti c tool s and procedures. However, conven-
ti onal di agnosti c methods wi l l not prove concl usi ve i n
the di agnosi s of the ACM, the PCI data bus network,
or the el ectroni c message i nputs to and outputs from
the ACM. The most rel i abl e, effi ci ent, and accurate
means to di agnose the ACM, the PCI data bus net-
work, and the el ectroni c message i nputs to and out-
puts from the ACM requi res the use of a DRBI I I ௡
scan tool . Refer to the appropri ate di agnosti c i nfor-
mati on.
TJ RESTRAINTS 8O - 9
AIRBAG CONTROL MODULE (Continued)
REMOVAL
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE SUPPLEMENTAL RESTRAINT SYS-
TEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, AIRBAG, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE BEFORE PERFORMING FURTHER DIAG-
NOSIS OR SERVICE. THIS IS THE ONLY SURE WAY
TO DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT.
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, NEVER STRIKE OR DROP THE AIRBAG
CONTROL MODULE, AS IT CAN DAMAGE THE
IMPACT SENSOR OR AFFECT ITS CALIBRATION.
THE AIRBAG CONTROL MODULE CONTAINS THE
IMPACT SENSOR, WHICH ENABLES THE SYSTEM
TO DEPLOY THE SUPPLEMENTAL RESTRAINTS. IF
AN AIRBAG CONTROL MODULE IS ACCIDENTALLY
DROPPED DURING SERVICE, THE MODULE MUST
BE SCRAPPED AND REPLACED WITH A NEW UNIT.
FAILURE TO OBSERVE THIS WARNING COULD
RESULT IN ACCIDENTAL, INCOMPLETE, OR
IMPROPER SUPPLEMENTAL RESTRAINT DEPLOY-
MENT.
(1) Di sconnect and i sol ate the battery negati ve
cabl e. Wai t two mi nutes for the system capaci tor to
di scharge before further servi ce.
(2) Pul l the carpet on the ri ght and l eft si des of
the fl oor panel transmi ssi on tunnel rearward far
enough to access the Ai rbag Control Modul e (ACM),
whi ch i s forward of the fl oor consol e.
(3) On model s equi pped wi th the opti onal Anti -l ock
Brake System (ABS), remove the accel erati on swi tch
from the l eft si de of the mounti ng bracket on the
fl oor panel transmi ssi on tunnel . (Refer to 5 -
BRAKES/ELECTRI CAL/G-SWI TCH - REMOVAL).
(4) Remove the four screws that secure the Ai rbag
Control Modul e (ACM) to the mounti ng bracket on
the fl oor panel transmi ssi on tunnel (Fi g. 7).
(5) Li ft the ACM upward far enough to di sengage
the l ocator pi ns on the bottom of the ACM mounti ng
fl anges from the l ocati ng hol es i n the mounti ng
bracket, then sl i de the ACM out from under the
i nstrument panel far enough to access the wi re har-
ness connector.
(6) Di sconnect the body wi re harness connector for
the ACM from the ACM connector receptacl e l ocated
on the forward faci ng si de of the modul e. To di scon-
nect the body wi re harness connector from the ACM
(Fi g. 8):
(a) Pul l the whi te Connector Posi ti ve Assurance
(CPA) l ocks on each si de of the connector out about
3 mi l l i meters (0.125 i nch).
(b) Squeeze the l atch tabs on each si de of the
connector between the thumb and forefi nger and
pul l the connector strai ght away from the ACM
connector receptacl e.
(7) Remove the ACM from beneath the i nstrument
panel .
Fig. 7 Airbag Control Module Remove/Install
1 - SCREW (4)
2 - AIRBAG CONTROL MODULE
3 - WIRE HARNESS CONNECTOR
4 - MOUNTING BRACKET
5 - FRONT FLOOR PANEL
8O - 10 RESTRAINTS TJ
AIRBAG CONTROL MODULE (Continued)
INSTALLATION
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE SUPPLEMENTAL RESTRAINT SYS-
TEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, AIRBAG, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE BEFORE PERFORMING FURTHER DIAG-
NOSIS OR SERVICE. THIS IS THE ONLY SURE WAY
TO DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT.
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, NEVER STRIKE OR DROP THE AIRBAG
CONTROL MODULE, AS IT CAN DAMAGE THE
IMPACT SENSOR OR AFFECT ITS CALIBRATION.
THE AIRBAG CONTROL MODULE CONTAINS THE
IMPACT SENSOR, WHICH ENABLES THE SYSTEM
TO DEPLOY THE SUPPLEMENTAL RESTRAINTS. IF
AN AIRBAG CONTROL MODULE IS ACCIDENTALLY
DROPPED DURING SERVICE, THE MODULE MUST
BE SCRAPPED AND REPLACED WITH A NEW UNIT.
FAILURE TO OBSERVE THIS WARNING COULD
RESULT IN ACCIDENTAL, INCOMPLETE, OR
IMPROPER SUPPLEMENTAL RESTRAINT DEPLOY-
MENT.
(1) Posi ti on the Ai rbag Control Modul e (ACM)
beneath the i nstrument panel .
(2) Reconnect the body wi re harness connector for
the ACM to the ACM connector receptacl e l ocated on
the forward faci ng si de of the modul e (Fi g. 8). Be cer-
tai n that both connector l atches and the whi te Con-
nector Posi ti ve Assurance (CPA) l ocks are ful l y
engaged.
(3) Posi ti on the ACM to the mounti ng bracket on
the fl oor panel transmi ssi on tunnel (Fi g. 7). When
the ACM i s correctl y posi ti oned, the l ocator pi ns on
the bottom of the ACM mounti ng fl anges wi l l be
engaged i n the l ocati ng hol es i n the mounti ng
bracket, and the arrow on the ACM l abel wi l l be
poi nted forward i n the vehi cl e.
(4) I nstal l and ti ghten the four screws that secure
the ACM to the mounti ng bracket on the fl oor panel
transmi ssi on tunnel . Ti ghten the screws to 14 N·m
(125 i n. l bs.).
(5) On model s equi pped wi th the opti onal ABS
brakes, rei nstal l the accel erati on swi tch onto the l eft
si de of the mounti ng bracket on the fl oor panel trans-
mi ssi on tunnel . (Refer to 5 - BRAKES/ELECTRI CAL/
G-SWI TCH - I NSTALLATI ON).
(6) Restore the carpet on the ri ght and l eft si des of
the fl oor panel transmi ssi on tunnel to i ts proper posi -
ti on beneath the i nstrument panel .
(7) Do not reconnect the battery negati ve cabl e at
thi s ti me. The suppl emental restrai nt system veri fi -
cati on test procedure shoul d be performed fol l owi ng
servi ce of any suppl emental restrai nt system compo-
nent (Refer to 8 - ELECTRI CAL/RESTRAI NTS -
STANDARD PROCEDURE - VERI FI CATI ON TEST).
Fig. 8 Airbag Control Module Connector Removal
1 - AIRBAG CONTROL MODULE
2 - PULL TWO LOCKS OUT
3 - SQUEEZE LATCHES
4 - PULL
5 - PULL
6 - SQUEEZE LATCHES
7 - WIRE HARNESS CONNECTOR
TJ RESTRAINTS 8O - 11
AIRBAG CONTROL MODULE (Continued)
CHILD RESTRAINT ANCHOR
DESCRIPTION
Thi s model i s equi pped wi th a Lower Anchors and
Tether for CHi l dren, or LATCH chi l d restrai nt
anchorage system (Fi g. 9). The LATCH system pro-
vi des for the i nstal l ati on of sui tabl e chi l d restrai nts
i n certai n seati ng posi ti ons wi thout usi ng the stan-
dard equi pment seat bel t provi ded for that seati ng
posi ti on. Al l vehi cl es wi thout a rear seat are
equi pped wi th a fi xed-posi ti on chi l d restrai nt upper
tether anchor (Fi g. 10) and two chi l d restrai nt l ower
anchors (Fi g. 11) for the front passenger seati ng posi -
ti on. Vehi cl es wi th an opti onal rear seat are equi pped
wi th fi xed-posi ti on chi l d restrai nt upper tether
anchors (Fi g. 12) and two chi l d restrai nt l ower
anchors (Fi g. 13) for each rear outboard seati ng posi -
ti on. Al l front passenger seat chi l d restrai nt anchors
are del eted on model s equi pped wi th the opti onal
rear seat.
The upper tether anchor and both l ower anchors
for the front passenger seat are i ntegral to the front
passenger seat ri ser bracket. The upper tether
anchor i s accessed from behi nd the front seat. The
l ower anchors for the front passenger seat are formed
from round steel bar stock that i s formed i nto a
U-shape, then securel y wel ded to the seat ri ser
bracket. They are accessed from the front of the seat,
at each si de where the seat back meets the seat
cushi on. The upper and l ower front seat chi l d
restrai nt anchors cannot be adjusted or repai red and,
i f faul ty or damaged, they must be repl aced as a uni t
wi th the seat ri ser bracket.
The upper tether anchors for the rear seat are
stamped steel brackets that are secured by screws to
the rear cargo fl oor panel just forward of the tai l gate
Fig. 9 Child Restraint Anchor Locations
1 - LOWER ANCHOR (MODELS WITHOUT A REAR SEAT ONLY)
2 - TETHER ANCHOR (MODELS WITHOUT A REAR SEAT ONLY)
3 - LOWER ANCHOR (PROVIDED FOR REAR OUTBOARD
SEATING POSITIONS ONLY)
4 - TETHER ANCHOR (PROVIDED FOR REAR OUTBOARD
SEATING POSITIONS ONLY)
Fig. 10 Front Passenger Seat Upper Anchor
1 - SEAT BACK
2 - UPPER ANCHOR
3 - SEAT CUSHION
8O - 12 RESTRAINTS TJ
openi ng, and are accessed from behi nd the rear seat.
The upper tether anchors for the rear seat are avai l -
abl e for i ndi vi dual servi ce repl acement. The four
fi xed l ower anchors are i ntegral to the rear seat back
frame and are accessed from the front of the rear
seat, where the seat back meets the seat cushi on.
The two i nboard l ower anchors are constructed from
round steel bar stock that i s formed i nto a U-shape,
then securel y wel ded at each end to the rear seat
back frame. The two outboard l ower anchors are
machi ned steel pi ns that are secured between the
two seat back hi nge pl ates above the pi vot pi n on
each outboard si de of the rear seat back frame. These
l ower anchors cannot be adjusted or repai red and, i f
faul ty or damaged, they must be repl aced as a uni t
wi th the rear seat back frame.
WARNING: DURING AND FOLLOWING ANY SEAT
BELT OR CHILD RESTRAINT ANCHOR SERVICE,
CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES,
MOUNTING HARDWARE, RETRACTORS, TETHER
STRAPS, AND ANCHORS FOR PROPER INSTALLA-
TION, OPERATION, OR DAMAGE. REPLACE ANY
BELT THAT IS CUT, FRAYED, OR TORN.
STRAIGHTEN ANY BELT THAT IS TWISTED.
TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY
BELT THAT HAS A DAMAGED OR INOPERATIVE
BUCKLE OR RETRACTOR. REPLACE ANY BELT
THAT HAS A BENT OR DAMAGED LATCH PLATE
OR ANCHOR PLATE. REPLACE ANY CHILD
RESTRAINT ANCHOR OR THE UNIT TO WHICH THE
ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR
DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT
BELT OR CHILD RESTRAINT COMPONENT.
ALWAYS REPLACE DAMAGED OR FAULTY SEAT
BELT AND CHILD RESTRAINT COMPONENTS WITH
THE CORRECT, NEW AND UNUSED REPLACEMENT
PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR
PARTS CATALOG.
OPERATION
See the owner’s manual i n the vehi cl e gl ove box for
more i nformati on on the proper use of al l of the fac-
tory-i nstal l ed chi l d restrai nt anchors.
REMOVAL
The fol l owi ng procedure appl i es onl y to the rear
seat upper chi l d tether anchors used on model s
equi pped wi th an opti onal rear seat. The chi l d
Fig. 11 Front Passenger Seat Lower Anchors
1 - SEAT BACK
2 - LOWER ANCHOR (2)
3 - SEAT CUSHION
Fig. 12 Rear Seat Upper Anchors
1 - REAR SEAT
2 - REAR CARGO FLOOR
3 - UPPER ANCHOR (2)
4 - TAILGATE OPENING SILL
Fig. 13 Rear Seat Lower Anchors
1 - SEAT BACK
2 - LOWER ANCHOR (4)
3 - SEAT CUSHION
TJ RESTRAINTS 8O - 13
CHILD RESTRAINT ANCHOR (Continued)
restrai nt anchors used i n thi s model i n al l other l oca-
ti ons are i ntegral to other components and cannot be
servi ced separatel y.
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, DURING AND FOLLOWING ANY SEAT BELT
OR CHILD RESTRAINT ANCHOR SERVICE, CARE-
FULLY INSPECT ALL SEAT BELTS, BUCKLES,
MOUNTING HARDWARE, RETRACTORS, TETHER
STRAPS, AND ANCHORS FOR PROPER INSTALLA-
TION, OPERATION, OR DAMAGE. REPLACE ANY
BELT THAT IS CUT, FRAYED, OR TORN.
STRAIGHTEN ANY BELT THAT IS TWISTED.
TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY
BELT THAT HAS A DAMAGED OR INOPERATIVE
BUCKLE OR RETRACTOR. REPLACE ANY BELT
THAT HAS A BENT OR DAMAGED LATCH PLATE
OR ANCHOR PLATE. REPLACE ANY CHILD
RESTRAINT ANCHOR OR THE UNIT TO WHICH THE
ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR
DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT
BELT OR CHILD RESTRAINT COMPONENT.
ALWAYS REPLACE DAMAGED OR FAULTY SEAT
BELT AND CHILD RESTRAINT COMPONENTS WITH
THE CORRECT, NEW AND UNUSED REPLACEMENT
PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR
PARTS CATALOG.
(1) Remove the screw that secures the upper chi l d
restrai nt tether anchor to the rear cargo fl oor panel
just forward of the tai l gate openi ng si l l (Fi g. 14).
(2) Remove the upper tether anchor from the rear
cargo fl oor panel .
INSTALLATION
The fol l owi ng procedure appl i es onl y to the rear
seat upper chi l d tether anchors used on model s
equi pped wi th an opti onal rear seat. The chi l d
restrai nt anchors used i n thi s model i n al l other l oca-
ti ons are i ntegral to other components and cannot be
servi ced separatel y.
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, DURING AND FOLLOWING ANY SEAT BELT
OR CHILD RESTRAINT ANCHOR SERVICE, CARE-
FULLY INSPECT ALL SEAT BELTS, BUCKLES,
MOUNTING HARDWARE, RETRACTORS, TETHER
STRAPS, AND ANCHORS FOR PROPER INSTALLA-
TION, OPERATION, OR DAMAGE. REPLACE ANY
BELT THAT IS CUT, FRAYED, OR TORN.
STRAIGHTEN ANY BELT THAT IS TWISTED.
TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY
BELT THAT HAS A DAMAGED OR INOPERATIVE
BUCKLE OR RETRACTOR. REPLACE ANY BELT
THAT HAS A BENT OR DAMAGED LATCH PLATE
OR ANCHOR PLATE. REPLACE ANY CHILD
RESTRAINT ANCHOR OR THE UNIT TO WHICH THE
ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR
DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT
BELT OR CHILD RESTRAINT COMPONENT.
ALWAYS REPLACE DAMAGED OR FAULTY SEAT
BELT AND CHILD RESTRAINT COMPONENTS WITH
THE CORRECT, NEW AND UNUSED REPLACEMENT
PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR
PARTS CATALOG.
(1) Posi ti on the upper tether anchor onto the rear
cargo fl oor panel (Fi g. 14).
(2) I nstal l and ti ghten the screw that secures the
upper tether anchor to the rear cargo fl oor panel just
forward of the tai l gate openi ng si l l . Ti ghten the
screw to 26 N·m (19 ft. l bs.).
CLOCKSPRING
DESCRIPTION
The cl ockspri ng assembl y i s secured wi th two i nte-
gral pl asti c l atches onto the steeri ng col umn l ock
housi ng near the top of the steeri ng col umn behi nd
the steeri ng wheel (Fi g. 15). The cl ockspri ng consi sts
of a fl at, round mol ded pl asti c case wi th a stubby tai l
that hangs bel ow the steeri ng col umn (Fi g. 16). The
tai l contai ns two connector receptacl es that face
toward the i nstrument panel . Wi thi n the pl asti c case
i s a spool -l i ke mol ded pl asti c rotor wi th a l arge
exposed hub. The upper surface of the rotor hub has
a l arge center hol e, two l arge fl ats, and four short
Fig. 14 Rear Upper Tether Anchor Remove/Install
1 - SCREW (2)
2 - FLOOR PANEL
3 - ANCHOR (2)
8O - 14 RESTRAINTS TJ
CHILD RESTRAINT ANCHOR (Continued)
pi gtai l wi res wi th connectors that face toward the
steeri ng wheel .
The l ower surface of the rotor hub has a mol ded
pl asti c turn si gnal cancel cam consi sti ng of two l obes
that are mol ded i nto the rotor. Wi thi n the pl asti c
case and wound around the rotor spool i s a l ong ri b-
bon-l i ke tape that consi sts of several thi n copper wi re
l eads sandwi ched between two thi n pl asti c mem-
branes. The outer end of the tape termi nates at the
connector receptacl es that face the i nstrument panel ,
whi l e the i nner end of the tape termi nates at the pi g-
tai l wi res on the hub of the cl ockspri ng rotor that
face the steeri ng wheel .
Servi ce repl acement cl ockspri ngs are shi pped pre-
centered and wi th a mol ded pl asti c l ocki ng pi n that
snaps i nto a receptacl e i n the rotor and has a tab
that i s engaged between two ri bs on the upper sur-
face of the cl ockspri ng case. The l ocki ng pi n secures
the centered cl ockspri ng rotor to the cl ockspri ng case
duri ng shi pment, but the l ocki ng pi n must be
removed from the cl ockspri ng after i t i s i nstal l ed on
the steeri ng col umn. (Refer to 8 - ELECTRI CAL/RE-
STRAI NTS/CLOCKSPRI NG - STANDARD PROCE-
DURE - CLOCKSPRI NG CENTERI NG).
The cl ockspri ng cannot be repai red. I f the cl ock-
spri ng i s faul ty, damaged, or i f the dri ver ai rbag has
been depl oyed, the cl ockspri ng must be repl aced.
OPERATION
The cl ockspri ng i s a mechani cal el ectri cal ci rcui t
component that i s used to provi de conti nuous el ectri -
cal conti nui ty between the fi xed body wi re harness
on the steeri ng col umn and the el ectri cal components
mounted on or i n the rotati ng steeri ng wheel . On thi s
model the rotati ng el ectri cal components i ncl ude the
dri ver ai rbag, the horn swi tch, and the speed control
swi tches i f the vehi cl e i s so equi pped. The cl ock-
spri ng case i s posi ti oned and secured to the upper
steeri ng col umn housi ng near the top of the steeri ng
col umn. The connector receptacl es on the tai l of the
fi xed cl ockspri ng case connect the cl ockspri ng to the
vehi cl e el ectri cal system through two take outs wi th
connectors from the body wi re harness.
The cl ockspri ng rotor i s movabl e and i s keyed by
two fl ats mol ded i nto the rotor hub to two fl ats that
are cast i nto the l ower surface of the steeri ng wheel
armature. The two l obes on the turn si gnal cancel
cam on the l ower surface of the cl ockspri ng rotor hub
contact a turn si gnal cancel actuator of the mul ti -
functi on swi tch to provi de automati c turn si gnal can-
cel l ati on. The pi gtai l wi res on the upper surface of
the cl ockspri ng rotor connect the cl ockspri ng to the
dri ver ai rbag, the horn swi tch, and the two speed
control swi tches i f the vehi cl e i s so equi pped.
Li ke the cl ockspri ng i n a ti mepi ece, the cl ockspri ng
tape has travel l i mi ts and can be damaged by bei ng
wound too ti ghtl y duri ng ful l stop-to-stop steeri ng
wheel rotati on. To prevent thi s from occurri ng, the
cl ockspri ng i s centered when i t i s i nstal l ed on the
steeri ng col umn. Centeri ng the cl ockspri ng i ndexes
the cl ockspri ng tape to the movabl e steeri ng compo-
nents so that the tape can operate wi thi n i ts
desi gned travel l i mi ts. However, i f the cl ockspri ng i s
removed from the steeri ng col umn or i f the steeri ng
shaft i s di sconnected from the steeri ng gear, the
cl ockspri ng spool can change posi ti on rel ati ve to the
Fig. 15 Clockspring
1 - CASE
2 - LOCKING PIN
3 - ROTOR
4 - ROTOR FLAT (2)
5 - CLOCKSPRING PIGTAIL WIRES (NOT SHOWN)
Fig. 16 Turn Signal Cancel Cam
1 - AIRBAG PIGTAIL
2 - LOCKING PIN
3 - LATCH (2)
4 - CANCEL CAM
5 - LOWER CONNECTOR RECEPTACLE (2)
6 - HORN SWITCH FEED PIGTAIL
7 - SPEED CONTROL SWITCH PIGTAIL (2)
TJ RESTRAINTS 8O - 15
CLOCKSPRING (Continued)
movabl e steeri ng components. The cl ockspri ng must
be re-centered fol l owi ng compl eti on of thi s servi ce or
the tape may be damaged.
Servi ce repl acement cl ockspri ngs are shi pped pre-
centered and wi th a pl asti c l ocki ng pi n i nstal l ed.
Thi s l ocki ng pi n shoul d not be di sengaged unti l the
cl ockspri ng has been i nstal l ed on the steeri ng col -
umn. I f the l ocki ng pi n i s removed or damaged before
the cl ockspri ng i s i nstal l ed on a steeri ng col umn, the
cl ockspri ng centeri ng procedure must be performed.
(Refer to 8 - ELECTRI CAL/RESTRAI NTS/CLOCK-
SPRI NG - STANDARD PROCEDURE - CLOCK-
SPRI NG CENTERI NG).
STANDARD PROCEDURE - CLOCKSPRING
CENTERING
The cl ockspri ng i s desi gned to wi nd and unwi nd
when the steeri ng wheel i s rotated, but i s onl y
desi gned to rotate the same number of turns (about
fi ve compl ete rotati ons) as the steeri ng wheel can be
turned from stop to stop. Centeri ng the cl ockspri ng
i ndexes the cl ockspri ng tape to other steeri ng compo-
nents so that i t can operate wi thi n i ts desi gned
travel l i mi ts. The rotor of a centered cl ockspri ng can
be rotated two and one-hal f turns i n ei ther di recti on
from the centered posi ti on, wi thout damagi ng the
cl ockspri ng tape.
However, i f the cl ockspri ng i s removed for servi ce
or i f the steeri ng col umn i s di sconnected from the
steeri ng gear, the cl ockspri ng tape can change posi -
ti on rel ati ve to the other steeri ng components. The
cl ockspri ng must then be re-centered fol l owi ng com-
pl eti on of such servi ce or the cl ockspri ng tape may be
damaged. Servi ce repl acement cl ockspri ngs are
shi pped pre-centered, wi th a pl asti c l ocki ng pi n
i nstal l ed (Fi g. 17). Thi s l ocki ng pi n shoul d not be
removed unti l the cl ockspri ng has been i nstal l ed on
the steeri ng col umn. I f the l ocki ng pi n i s removed
before the cl ockspri ng i s i nstal l ed on a steeri ng col -
umn, the cl ockspri ng centeri ng procedure must be
performed.
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE SUPPLEMENTAL RESTRAINT SYS-
TEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, AIRBAG, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE BEFORE PERFORMING FURTHER DIAG-
NOSIS OR SERVICE. THIS IS THE ONLY SURE WAY
TO DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT.
NOTE: Before starting this procedure, be certain to
turn the steering wheel until the front wheels are in
the straight-ahead position.
(1) Pl ace the front wheel s i n the strai ght-ahead
posi ti on.
(2) Remove the cl ockspri ng from the steeri ng col -
umn. (Refer to 8 - ELECTRI CAL/RESTRAI NTS/
CLOCKSPRI NG - REMOVAL).
(3) Rotate the cl ockspri ng rotor cl ockwi se to the
end of i ts travel . Do not apply excessive torque.
(4) From the end of the cl ockwi se travel , rotate the
rotor about two and one-hal f turns countercl ockwi se,
unti l the rotor fl ats are hori zontal . I f the cl ockspri ng
pi gtai l wi res are not ori ented towards the bottom of
the cl ockspri ng, rotate the rotor another one-hal f
turn i n the countercl ockwi se di recti on. The cl ock-
spri ng i s now centered.
(5) Lock the cl ockspri ng rotor to the cl ockspri ng
case to mai ntai n cl ockspri ng centeri ng unti l i t i s
rei nstal l ed on the steeri ng col umn.
(6) The front wheel s shoul d sti l l be i n the strai ght-
ahead posi ti on. Rei nstal l the cl ockspri ng onto the
steeri ng col umn. (Refer to 8 - ELECTRI CAL/RE-
STRAI NTS/CLOCKSPRI NG - I NSTALLATI ON).
REMOVAL
The cl ockspri ng cannot be repai red. I t must be
repl aced i f faul ty or damaged, or i f the dri ver ai rbag
has been depl oyed.
Fig. 17 Clockspring
1 - CASE
2 - LOCKING PIN
3 - ROTOR
4 - ROTOR FLAT (2)
5 - CLOCKSPRING PIGTAIL WIRES (NOT SHOWN)
8O - 16 RESTRAINTS TJ
CLOCKSPRING (Continued)
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE SUPPLEMENTAL RESTRAINT SYS-
TEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, AIRBAG, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE BEFORE PERFORMING FURTHER DIAG-
NOSIS OR SERVICE. THIS IS THE ONLY SURE WAY
TO DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT.
NOTE: Before starting this procedure, be certain to
turn the steering wheel until the front wheels are in
the straight-ahead position.
(1) Pl ace the front wheel s i n the strai ght ahead
posi ti on.
(2) Remove the dri ver ai rbag from the steeri ng
wheel . (Refer to 8 - ELECTRI CAL/RESTRAI NTS/
DRI VER AI RBAG - REMOVAL).
(3) Di sconnect the two upper cl ockspri ng pi gtai l
wi re connectors from the two speed control swi tches
or the two tri m bezel s l ocated wi thi n the two spoke
cavi ti es of the steeri ng wheel .
CAUTION: Be certain that the screws that secure
the steering wheel puller to the steering wheel are
fully engaged in the steering wheel armature with-
out passing through the steering wheel and damag-
ing the clockspring.
(4) Remove the steeri ng wheel from the steeri ng
col umn. (Refer to 19 - STEERI NG/COLUMN/STEER-
I NG WHEEL - REMOVAL).
(5) Remove the steeri ng col umn openi ng cover
from the i nstrument panel . (Refer to 23 - BODY/I N-
STRUMENT PANEL/STEERI NG COLUMN OPEN-
I NG COVER - REMOVAL).
(6) From bel ow the steeri ng col umn, remove the
two screws that secure the l ower steeri ng col umn
shroud to the upper shroud (Fi g. 18).
(7) I f the vehi cl e i s equi pped wi th the opti onal ti l t
steeri ng col umn, move the ti l t steeri ng col umn to the
ful l y l owered posi ti on and l eave the ti l t rel ease l ever
i n the rel eased (down) posi ti on.
(8) Usi ng hand pressure, push gentl y i nward on
both si des of the upper shroud near the parti ng l i ne
between the upper and l ower shrouds to rel ease the
snap features that secure i t to the l ower shroud.
(9) Remove both the upper and l ower shrouds from
the steeri ng col umn.
(10) Di sconnect the two body wi re harness connec-
tors for the cl ockspri ng from the two connector recep-
tacl es bel ow the steeri ng col umn on the back of the
cl ockspri ng housi ng (Fi g. 19).
(11) Usi ng a smal l screwdri ver, gentl y pry both
pl asti c l atches that secure the cl ockspri ng away from
the steeri ng col umn upper housi ng far enough to pul l
the cl ockspri ng away from the upper housi ng.
NOTE: If the clockspring plastic latches are broken,
be certain to remove the broken pieces from the
steering column upper housing.
(12) Remove the cl ockspri ng from the steeri ng col -
umn upper housi ng. The cl ockspri ng cannot be
repai red. I t must be repl aced i f faul ty or damaged, or
i f the dri ver ai rbag has been depl oyed.
(13) I f the removed cl ockspri ng i s to be reused, be
certai n to secure the cl ockspri ng rotor to the cl ock-
spri ng case to mai ntai n cl ockspri ng centeri ng unti l i t
i s rei nstal l ed on the steeri ng col umn. I f cl ockspri ng
centeri ng i s not mai ntai ned, the cl ockspri ng must be
centered agai n before i t i s rei nstal l ed. (Refer to 8 -
ELECTRI CAL/RESTRAI NTS/CLOCKSPRI NG -
STANDARD PROCEDURE - CLOCKSPRI NG CEN-
TERI NG).
Fig. 18 Steering Column Shrouds Remove/Install
1 - LEFT MULTI-FUNCTION SWITCH
2 - UPPER SHROUD
3 - RIGHT MULTI-FUNCTION SWITCH
4 - CLOCKSPRING
5 - IGNITION LOCK CYLINDER HOUSING
6 - LOWER SHROUD
7 - SCREW (2)
TJ RESTRAINTS 8O - 17
CLOCKSPRING (Continued)
INSTALLATION
The cl ockspri ng cannot be repai red. I t must be
repl aced i f faul ty or damaged, or i f the dri ver ai rbag
has been depl oyed.
I f the cl ockspri ng i s not properl y centered i n rel a-
ti on to the steeri ng wheel , steeri ng shaft and steer-
i ng gear, i t may be damaged. (Refer to 8 -
ELECTRI CAL/RESTRAI NTS/CLOCKSPRI NG -
STANDARD PROCEDURE - CLOCKSPRI NG CEN-
TERI NG). Servi ce repl acement cl ockspri ngs are
shi pped pre-centered and wi th a pl asti c l ocki ng pi n
i nstal l ed. Thi s l ocki ng pi n shoul d not be removed
unti l the cl ockspri ng has been i nstal l ed on the steer-
i ng col umn. I f the l ocki ng pi n i s removed before the
cl ockspri ng i s i nstal l ed on a steeri ng col umn, the
cl ockspri ng centeri ng procedure must be performed.
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE SUPPLEMENTAL RESTRAINT SYS-
TEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, AIRBAG, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE BEFORE PERFORMING FURTHER DIAG-
NOSIS OR SERVICE. THIS IS THE ONLY SURE WAY
TO DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT.
NOTE: Before starting this procedure, be certain
that the front wheels are still in the straight-ahead
position.
(1) Be certai n that the l eft mul ti -functi on swi tch
control stal k i s i n the neutral posi ti on, then careful l y
sl i de the centered cl ockspri ng down over the steeri ng
col umn upper shaft unti l both the upper and l ower
cl ockspri ng l atches engage the steeri ng col umn upper
housi ng (Fi g. 19).
(2) Reconnect the two body wi re harness connec-
tors for the cl ockspri ng to the two connector recepta-
cl es bel ow the steeri ng col umn on the back of the
cl ockspri ng housi ng.
(3) Posi ti on both the upper and l ower shrouds onto
the steeri ng col umn (Fi g. 18). Be certai n that the
l ocati ng tabs for the l eft and ri ght mul ti -functi on
swi tch control stal k watershi el ds are properl y
engaged i n the openi ngs of both the upper and l ower
shrouds.
(4) Al i gn the snap features on the upper shroud
wi th the receptacl es on the l ower shroud and appl y
hand pressure to snap them together.
(5) From bel ow the steeri ng col umn, i nstal l and
ti ghten the two screws that secure the l ower steeri ng
col umn shroud to the upper shroud. Ti ghten the
screws to 2 N·m (18 i n. l bs.).
(6) I f the vehi cl e i s equi pped wi th the opti onal ti l t
steeri ng col umn, move the ti l t steeri ng col umn to the
ful l y rai sed posi ti on and secure i t i n pl ace by movi ng
the ti l t rel ease l ever back to the l ocked (up) posi ti on.
(7) Rei nstal l the steeri ng col umn openi ng cover
onto the i nstrument panel . (Refer to 23 - BODY/I N-
STRUMENT PANEL/STEERI NG COLUMN OPEN-
I NG COVER - I NSTALLATI ON).
(8) I f a new cl ockspri ng has been i nstal l ed, remove
the l ocki ng pi n that i s securi ng the cl ockspri ng rotor
to the cl ockspri ng case to mai ntai n cl ockspri ng cen-
teri ng.
(9) Rei nstal l the steeri ng wheel onto the steeri ng
col umn. (Refer to 19 - STEERI NG/COLUMN/STEER-
I NG WHEEL - I NSTALLATI ON).
(10) Reconnect the two upper cl ockspri ng pi gtai l
wi re connectors to the two speed control swi tches or
the two tri m bezel s l ocated wi thi n the two spoke cav-
i ti es of the steeri ng wheel .
(11) Rei nstal l the dri ver ai rbag onto the steeri ng
wheel . (Refer to 8 - ELECTRI CAL/RESTRAI NTS/
DRI VER AI RBAG - I NSTALLATI ON).
Fig. 19 Clockspring Remove/Install - Typical
1 - CLOCKSPRING
2 - LATCHES
3 - BODY WIRE HARNESS
4 - LEFT MULTI-FUNCTION SWITCH
5 - SWITCH HOUSING
6 - STEERING COLUMN
7 - RIGHT MULTI-FUNCTION SWITCH
8O - 18 RESTRAINTS TJ
CLOCKSPRING (Continued)
DRIVER AIRBAG
DESCRIPTION
The col or-keyed, i njecti on mol ded, thermopl asti c
dri ver ai rbag protecti ve tri m cover i s the most vi si bl e
part of the dri ver ai rbag (Fi g. 20). The dri ver ai rbag
i s l ocated i n the center of the steeri ng wheel , where
i t i s secured wi th two screws to the two hori zontal
spokes of the four-spoke steeri ng wheel armature. Al l
model s have a Jeep l ogo embossed i n the center of
the tri m cover. Conceal ed beneath the dri ver ai rbag
tri m cover are the horn swi tch, the fol ded ai rbag
cushi on, the ai rbag cushi on retai ner, the ai rbag hous-
i ng, the ai rbag i nfl ator, and the retai ners that secure
the i nfl ator to the ai rbag housi ng.
The ai rbag cushi on, housi ng, and i nfl ator uni t i s
secured wi thi n an i ntegral receptacl e on the back of
the tri m cover (Fi g. 21). The dri ver ai rbag tri m cover
has l ocki ng bl ocks mol ded i nto the back si de of i t
that engage a l i p formed around the peri meter of the
ai rbag housi ng. Two stamped metal retai ners then fi t
over the i nfl ator mounti ng studs on the back of the
ai rbag housi ng and tabs on the retai ners are engaged
i n sl ots wi thi n the upper and l ower tri m cover l ock-
i ng bl ocks, securel y l ocki ng the cover i nto pl ace. The
stamped metal retai ners are secured to the four ai r-
bag i nfl ator mounti ng studs wi th nuts.
The resi sti ve membrane-type horn swi tch i s
secured wi thi n a pl asti c tray that i s i nserted i nto a
pocket or pouch sewn onto the ai rbag cushi on
retai ner strap, between the tri m cover and the fol ded
ai rbag cushi on. The horn swi tch ground pi gtai l wi re
has an eyel et termi nal connector that i s captured on
the upper ri ght i nfl ator mounti ng stud between the
i nfl ator and the upper tri m cover retai ner. The horn
swi tch feed pi gtai l wi re has a whi te, mol ded pl asti c
i nsul ator that i s secured by an i ntegral retai ner to a
mounti ng hol e l ocated i n the upper tri m cover
retai ner near the upper l eft corner on the back of the
ai rbag housi ng, and i s connected to the vehi cl e el ec-
tri cal system through a dedi cated pi gtai l wi re and
connector from the cl ockspri ng.
The ai rbag used i n thi s model i s a Next Genera-
ti on-type that compl i es wi th revi sed federal ai rbag
standards to depl oy wi th l ess force than those used
i n some pri or model s. A radi al depl oyi ng fabri c cush-
i on wi th i nternal tethers i s used. The ai rbag i nfl ator
i s a conventi onal pyrotechni c-type uni t that i s
secured by four hex nuts to four studs that extend
through the back of the stamped metal ai rbag hous-
i ng from the ai rbag cushi on retai ner ri ng. A keyed
connector receptacl e on the dri ver ai rbag i nfl ator con-
nects the i nfl ator i ni ti ator to the vehi cl e el ectri cal
system through a yel l ow-jacketed, two-wi re pi gtai l
harness of the cl ockspri ng. The dri ver ai rbag cannot
be repai red, and must be repl aced i f depl oyed or i n
any way damaged. The dri ver ai rbag tri m cover and
the horn swi tch are avai l abl e i ndi vi dual l y, and may
be di sassembl ed from the dri ver ai rbag for servi ce
repl acement.
OPERATION
The dri ver ai rbag i s depl oyed by el ectri cal si gnal s
generated by the Ai rbag Control Modul e (ACM)
through the dri ver ai rbag squi b ci rcui t to the i ni ti a-
tor i n the ai rbag i nfl ator. When the ACM sends the
Fig. 20 Driver Airbag Trim Cover
1 - STEERING WHEEL
2 - TRIM COVER
Fig. 21 Driver Airbag Trim Cover
1 - UPPER RETAINER
2 - AIRBAG HOUSING
3 - TRIM COVER
4 - NUT (4)
5 - LOWER RETAINER
6 - INFLATOR
7 - STUD (4)
TJ RESTRAINTS 8O - 19
proper el ectri cal si gnal to the i ni ti ator the el ectri cal
energy generates enough heat to i ni ti ate a smal l
pyrotechni c charge whi ch, i n turn i gni tes chemi cal
pel l ets wi thi n the i nfl ator. Once i gni ted, these chem-
i cal pel l ets burn rapi dl y and produce a l arge quanti ty
of i nert gas. The i nfl ator i s seal ed to the back of the
ai rbag housi ng and a di ffuser i n the i nfl ator di rects
al l of the i nert gas i nto the ai rbag cushi on, causi ng
the cushi on to i nfl ate. As the cushi on i nfl ates, the
dri ver ai rbag tri m cover wi l l spl i t at predetermi ned
breakout l i nes, then fol d back out of the way al ong
wi th the horn swi tch uni t. Fol l owi ng an ai rbag
depl oyment, the ai rbag cushi on qui ckl y defl ates by
venti ng the i nert gas towards the i nstrument panel
through the porous fabri c materi al used to construct
the back (steeri ng wheel si de) panel of the ai rbag
cushi on.
Some of the chemi cal s used to create the i nert gas
may be consi dered hazardous whi l e i n thei r sol i d
state before they are burned, but they are securel y
seal ed wi thi n the ai rbag i nfl ator. Typi cal l y, al l poten-
ti al l y hazardous chemi cal s are burned duri ng an ai r-
bag depl oyment event. The i nert gas that i s produced
when the chemi cal s are burned i s harml ess. How-
ever, a smal l amount of resi due from the burned
chemi cal s may cause some temporary di scomfort i f i t
contacts the ski n, eyes, or breathi ng passages. I f ski n
or eye i rri tati on i s noted, ri nse the affected area wi th
pl enty of cool , cl ean water. I f breathi ng passages are
i rri tated, move to another area where there i s pl enty
of cl ean, fresh ai r to breath. I f the i rri tati on i s not
al l evi ated by these acti ons, contact a physi ci an.
REMOVAL
The fol l owi ng procedure i s for repl acement of a
faul ty or damaged dri ver ai rbag. I f the ai rbag i s
faul ty or damaged, but not depl oyed, revi ew the rec-
ommended procedures for handl i ng non-depl oyed
suppl emental restrai nts. (Refer to 8 - ELECTRI CAL/
RESTRAI NTS - STANDARD PROCEDURE - HAN-
DLI NG NON-DEPLOYED SUPPLEMENTAL
RESTRAI NTS). I f the dri ver ai rbag has been
depl oyed, revi ew the recommended procedures for
servi ce after a suppl emental restrai nt depl oyment
before removi ng the ai rbag from the vehi cl e. (Refer to
8 - ELECTRI CAL/RESTRAI NTS - STANDARD PRO-
CEDURE - SERVI CE AFTER A SUPPLEMENTAL
RESTRAI NT DEPLOYMENT).
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE SUPPLEMENTAL RESTRAINT SYS-
TEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, AIRBAG, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE BEFORE PERFORMING FURTHER DIAG-
NOSIS OR SERVICE. THIS IS THE ONLY SURE WAY
TO DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT.
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, WHEN REMOVING A DEPLOYED AIRBAG,
RUBBER GLOVES, EYE PROTECTION, AND A
LONG-SLEEVED SHIRT SHOULD BE WORN. THERE
MAY BE DEPOSITS ON THE AIRBAG CUSHION AND
OTHER INTERIOR SURFACES. IN LARGE DOSES,
THESE DEPOSITS MAY CAUSE IRRITATION TO THE
SKIN AND EYES.
(1) Di sconnect and i sol ate the battery negati ve
cabl e. Wai t two mi nutes for the system capaci tor to
di scharge before further servi ce.
(2) From the undersi de of the steeri ng wheel ,
remove the two screws that secure the dri ver ai rbag
to the steeri ng wheel armature (Fi g. 22).
(3) Pul l the dri ver ai rbag away from the steeri ng
wheel far enough to access the two el ectri cal connec-
ti ons at the back of the ai rbag housi ng.
(4) Di sconnect the cl ockspri ng pi gtai l wi re connec-
tor for the horn swi tch from the horn swi tch feed pi g-
tai l wi re connector l ocated on the back of the dri ver
ai rbag.
Fig. 22 Driver Airbag Remove/Install
1 - STEERING WHEEL
2 - CLOCKSPRING PIGTAIL WIRE (HORN SWITCH)
3 - DRIVER AIRBAG
4 - CLOCKSPRING PIGTAIL WIRE (AIRBAG)
5 - SCREW (2)
8O - 20 RESTRAINTS TJ
DRIVER AIRBAG (Continued)
CAUTION: Do not pull on the clockspring pigtail
wires to disengage the connector from the driver
airbag inflator connector receptacle. Improper
removal of these pigtail wires and their connector
insulators can result in damage to the airbag cir-
cuits or connector insulators.
(5) The cl ockspri ng dri ver ai rbag pi gtai l wi re con-
nector i s secured by a ti ght snap fi t i nto the ai rbag
i nfl ator connector receptacl e, whi ch i s l ocated on the
back of the dri ver ai rbag housi ng. Fi rml y grasp and
pul l or gentl y pry on the cl ockspri ng dri ver ai rbag
pi gtai l wi re connector i nsul ator and pul l the i nsul a-
tor strai ght out from the ai rbag i nfl ator to di sconnect
i t from the connector receptacl e.
(6) Remove the dri ver ai rbag from the steeri ng
wheel .
(7) I f the dri ver ai rbag has been depl oyed, the
cl ockspri ng must be repl aced. (Refer to 8 - ELECTRI -
CAL/RESTRAI NTS/CLOCKSPRI NG - REMOVAL).
DISASSEMBLY
The fol l owi ng procedures can be used to repl ace
the dri ver ai rbag tri m cover and/or to access the horn
swi tch uni t for servi ce. I f the dri ver ai rbag i s faul ty
or depl oyed, the enti re dri ver ai rbag, tri m cover, and
horn swi tch must be repl aced as a uni t.
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE SUPPLEMENTAL RESTRAINT SYS-
TEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, AIRBAG, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE BEFORE PERFORMING FURTHER DIAG-
NOSIS OR SERVICE. THIS IS THE ONLY SURE WAY
TO DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT.
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, SERVICE OF THIS UNIT SHOULD BE PER-
FORMED ONLY BY DAIMLERCHRYSLER-TRAINED
AND AUTHORIZED DEALER SERVICE TECHNI-
CIANS. FAILURE TO TAKE THE PROPER PRECAU-
TIONS OR TO FOLLOW THE PROPER
PROCEDURES COULD RESULT IN ACCIDENTAL,
INCOMPLETE, OR IMPROPER AIRBAG DEPLOY-
MENT AND POSSIBLE OCCUPANT INJURIES.
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, USE EXTREME CARE TO PREVENT ANY
FOREIGN MATERIAL FROM ENTERING THE DRIVER
AIRBAG, OR BECOMING ENTRAPPED BETWEEN
THE DRIVER AIRBAG CUSHION AND THE DRIVER
AIRBAG TRIM COVER. FAILURE TO OBSERVE THIS
WARNING COULD RESULT IN OCCUPANT INJURIES
UPON AIRBAG DEPLOYMENT.
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, THE DRIVER AIRBAG TRIM COVER MUST
NEVER BE PAINTED. REPLACEMENT TRIM COV-
ERS ARE SERVICED IN THE ORIGINAL COLORS.
PAINT MAY CHANGE THE WAY IN WHICH THE
MATERIAL OF THE TRIM COVER RESPONDS TO AN
AIRBAG DEPLOYMENT. FAILURE TO OBSERVE
THIS WARNING COULD RESULT IN OCCUPANT
INJURIES UPON AIRBAG DEPLOYMENT.
(1) Di sconnect and i sol ate the battery negati ve
cabl e. Wai t two mi nutes for the system capaci tor to
di scharge before further servi ce.
(2) Remove the dri ver ai rbag from the steeri ng
wheel . (Refer to 8 - ELECTRI CAL/RESTRAI NTS/
DRI VER AI RBAG - REMOVAL).
(3) Pl ace the dri ver ai rbag on a sui tabl e work sur-
face wi th the tri m cover faci ng down. I f the tri m
cover wi l l be reused, be certai n to take the proper
precauti ons to prevent the tri m cover from recei vi ng
cosmeti c damage duri ng the fol l owi ng procedures.
(4) Remove the four nuts that secure the upper
and l ower tri m cover retai ners to the studs on the
back of the dri ver ai rbag housi ng (Fi g. 23).
Fig. 23 Horn Switch Feed Wire Remove/Install
1 - HORN SWITCH GROUND PIGTAIL WIRE
2 - NUT (4)
3 - HORN SWITCH FEED PIGTAIL WIRE
TJ RESTRAINTS 8O - 21
DRIVER AIRBAG (Continued)
(5) Remove the upper and l ower tri m cover retai n-
ers from the ai rbag housi ng studs (Fi g. 24).
(6) Di sengage the horn swi tch feed pi gtai l wi re
connector retai ner from the mounti ng hol e i n the
upper tri m cover retai ner.
(7) Remove the horn swi tch ground pi gtai l wi re
eyel et termi nal from the upper ri ght i nfl ator stud on
the back of the dri ver ai rbag housi ng.
(8) Di sengage the four tri m cover l ocki ng bl ocks
from the l i p around the outsi de edge of the dri ver
ai rbag housi ng and remove the housi ng from the
tri m cover receptacl e (Fi g. 25).
ASSEMBLY
The fol l owi ng procedures can be used to repl ace
the dri ver ai rbag tri m cover and/or to access the horn
swi tch uni t for servi ce. I f the dri ver ai rbag i s faul ty
or depl oyed, the enti re dri ver ai rbag, tri m cover, and
horn swi tch must be repl aced as a uni t.
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE SUPPLEMENTAL RESTRAINT SYS-
TEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, AIRBAG, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE BEFORE PERFORMING FURTHER DIAG-
NOSIS OR SERVICE. THIS IS THE ONLY SURE WAY
TO DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT.
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, SERVICE OF THIS UNIT SHOULD BE PER-
FORMED ONLY BY DAIMLERCHRYSLER-TRAINED
AND AUTHORIZED DEALER SERVICE TECHNI-
CIANS. FAILURE TO TAKE THE PROPER PRECAU-
TIONS OR TO FOLLOW THE PROPER
PROCEDURES COULD RESULT IN ACCIDENTAL,
INCOMPLETE, OR IMPROPER AIRBAG DEPLOY-
MENT AND POSSIBLE OCCUPANT INJURIES.
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, USE EXTREME CARE TO PREVENT ANY
FOREIGN MATERIAL FROM ENTERING THE DRIVER
AIRBAG, OR BECOMING ENTRAPPED BETWEEN
THE DRIVER AIRBAG CUSHION AND THE DRIVER
AIRBAG TRIM COVER. FAILURE TO OBSERVE THIS
WARNING COULD RESULT IN OCCUPANT INJURIES
UPON AIRBAG DEPLOYMENT.
Fig. 24 Driver Airbag Trim Cover
1 - UPPER RETAINER
2 - AIRBAG HOUSING
3 - TRIM COVER
4 - NUT (4)
5 - LOWER RETAINER
6 - INFLATOR
7 - STUD (4)
Fig. 25 Driver Airbag Trim Cover Remove/Install
1 - UPPER RETAINER SLOT (2)
2 - LOCKING BLOCK (4)
3 - LOWER RETAINER SLOT (2)
8O - 22 RESTRAINTS TJ
DRIVER AIRBAG (Continued)
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, THE DRIVER AIRBAG TRIM COVER MUST
NEVER BE PAINTED. REPLACEMENT TRIM COV-
ERS ARE SERVICED IN THE ORIGINAL COLORS.
PAINT MAY CHANGE THE WAY IN WHICH THE
MATERIAL OF THE TRIM COVER RESPONDS TO AN
AIRBAG DEPLOYMENT. FAILURE TO OBSERVE
THIS WARNING COULD RESULT IN OCCUPANT
INJURIES UPON AIRBAG DEPLOYMENT.
NOTE: If the horn switch and tray have been
removed from the sewn pouch in the airbag cush-
ion retaining strap, be certain that they are properly
reinstalled with the horn switch feed and ground
pigtail wires properly oriented before assembling
the trim cover onto the airbag housing. (Refer to 8 -
ELECTRICAL/HORN/HORN SWITCH - INSTALLA-
TION).
(1) Pl ace the new dri ver ai rbag tri m cover on a
sui tabl e work surface wi th the ai rbag receptacl e fac-
i ng up. Be certai n to take the proper precauti ons to
prevent the tri m cover from recei vi ng cosmeti c dam-
age duri ng the fol l owi ng procedures.
(2) Careful l y posi ti on the dri ver ai rbag i nto the
tri m cover receptacl e. Be certai n that the horn swi tch
feed and ground pi gtai l wi res are not pi nched
between the ai rbag housi ng and the tri m cover l ock-
i ng bl ocks.
(3) Engage the upper and l ower tri m cover l ocki ng
bl ocks wi th the l i p of the dri ver ai rbag housi ng, then
engage the l ocki ng bl ocks on each si de of the tri m
cover wi th the l i p of the housi ng. Be certai n that
each of the l ocki ng bl ocks i s ful l y engaged on the l i p
of the ai rbag housi ng (Fi g. 26).
(4) Rei nstal l the horn swi tch ground pi gtai l wi re
eyel et termi nal over the upper ri ght i nfl ator stud on
the back of the dri ver ai rbag housi ng.
(5) Rei nstal l the upper and l ower ai rbag tri m cover
retai ners over the i nfl ator studs on the back of the
dri ver ai rbag housi ng. Be certai n that the tabs on
each retai ner are engaged i n the sl ots of the upper
and l ower tri m cover l ocki ng bl ocks (Fi g. 25).
(6) I nstal l and ti ghten the four nuts that secure
the tri m cover retai ners to the i nfl ator studs on the
back of the dri ver ai rbag housi ng. Ti ghten the nuts
to 7 N·m (60 i n. l bs.).
(7) Engage the horn swi tch feed pi gtai l wi re con-
nector retai ner i n the mounti ng hol e i n the upper
tri m cover retai ner.
(8) Rei nstal l the dri ver ai rbag onto the steeri ng
wheel . (Refer to 8 - ELECTRI CAL/RESTRAI NTS/
DRI VER AI RBAG - I NSTALLATI ON).
INSTALLATION
The fol l owi ng procedure i s for repl acement of a
faul ty or damaged dri ver ai rbag. I f the ai rbag i s
faul ty or damaged, but not depl oyed, revi ew the rec-
ommended procedures for handl i ng non-depl oyed
suppl emental restrai nts. (Refer to 8 - ELECTRI CAL/
RESTRAI NTS - STANDARD PROCEDURE - HAN-
DLI NG NON-DEPLOYED SUPPLEMENTAL
RESTRAI NTS). I f the dri ver ai rbag has been
depl oyed, revi ew the recommended procedures for
servi ce after a suppl emental restrai nt depl oyment
before removi ng the ai rbag from the vehi cl e. (Refer to
8 - ELECTRI CAL/RESTRAI NTS - STANDARD PRO-
CEDURE - SERVI CE AFTER A SUPPLEMENTAL
RESTRAI NT DEPLOYMENT).
Fig. 26 Driver Airbag Trim Cover Locking Blocks
Engaged
1 - LIP
2 - TRIM COVER
3 - HORN SWITCH
4 - AIRBAG HOUSING
5 - LOCKING BLOCK
TJ RESTRAINTS 8O - 23
DRIVER AIRBAG (Continued)
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE SUPPLEMENTAL RESTRAINT SYS-
TEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, AIRBAG, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE BEFORE PERFORMING FURTHER DIAG-
NOSIS OR SERVICE. THIS IS THE ONLY SURE WAY
TO DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT.
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, USE EXTREME CARE TO PREVENT ANY
FOREIGN MATERIAL FROM ENTERING THE DRIVER
AIRBAG, OR BECOMING ENTRAPPED BETWEEN
THE DRIVER AIRBAG CUSHION AND THE DRIVER
AIRBAG TRIM COVER. FAILURE TO OBSERVE THIS
WARNING COULD RESULT IN OCCUPANT INJURIES
UPON AIRBAG DEPLOYMENT.
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, THE DRIVER AIRBAG TRIM COVER MUST
NEVER BE PAINTED. REPLACEMENT AIRBAGS
ARE SERVICED WITH TRIM COVERS IN THE ORIG-
INAL COLORS. PAINT MAY CHANGE THE WAY IN
WHICH THE MATERIAL OF THE TRIM COVER
RESPONDS TO AN AIRBAG DEPLOYMENT. FAIL-
URE TO OBSERVE THIS WARNING COULD RESULT
IN OCCUPANT INJURIES UPON AIRBAG DEPLOY-
MENT.
(1) Posi ti on the dri ver ai rbag cl ose enough to the
steeri ng wheel to reconnect the two el ectri cal connec-
ti ons at the back of the ai rbag housi ng.
(2) When i nstal l i ng the dri ver ai rbag, reconnect
the cl ockspri ng dri ver ai rbag pi gtai l wi re connector
to the ai rbag i nfl ator connector receptacl e by press-
i ng strai ght i n on the connector (Fi g. 22). You can be
certai n that the connector i s ful l y engaged i n i ts
receptacl e by l i steni ng careful l y for a di sti nct, audi -
bl e cl i ck as the connector snaps i nto pl ace.
(3) Reconnect the cl ockspri ng horn swi tch pi gtai l
wi re connector to the horn swi tch feed pi gtai l wi re
connector l ocated on the back of the dri ver ai rbag
housi ng.
(4) Careful l y posi ti on the dri ver ai rbag i n the
steeri ng wheel . Be certai n that the cl ockspri ng pi g-
tai l wi res and the steeri ng wheel wi re harness i n the
steeri ng wheel hub area are not pi nched between the
dri ver ai rbag and the steeri ng wheel armature.
(5) From the undersi de of the steeri ng wheel ,
i nstal l and ti ghten the two screws that secure the
dri ver ai rbag to the steeri ng wheel armature.
Ti ghten the screws to 10 N·m (90 i n. l bs.).
(6) Do not reconnect the battery negati ve cabl e at
thi s ti me. The suppl emental restrai nt system veri fi -
cati on test procedure shoul d be performed fol l owi ng
servi ce of any suppl emental restrai nt system compo-
nent. (Refer to 8 - ELECTRI CAL/RESTRAI NTS -
STANDARD PROCEDURE - VERI FI CATI ON TEST).
FRONT SEAT BELT &
RETRACTOR
REMOVAL
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, DURING AND FOLLOWING ANY SEAT BELT
OR CHILD RESTRAINT ANCHOR SERVICE, CARE-
FULLY INSPECT ALL SEAT BELTS, BUCKLES,
MOUNTING HARDWARE, RETRACTORS, TETHER
STRAPS, AND ANCHORS FOR PROPER INSTALLA-
TION, OPERATION, OR DAMAGE. REPLACE ANY
BELT THAT IS CUT, FRAYED, OR TORN.
STRAIGHTEN ANY BELT THAT IS TWISTED.
TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY
BELT THAT HAS A DAMAGED OR INOPERATIVE
BUCKLE OR RETRACTOR. REPLACE ANY BELT
THAT HAS A BENT OR DAMAGED LATCH PLATE
OR ANCHOR PLATE. REPLACE ANY CHILD
RESTRAINT ANCHOR OR THE UNIT TO WHICH THE
ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR
DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT
BELT OR CHILD RESTRAINT COMPONENT.
ALWAYS REPLACE DAMAGED OR FAULTY SEAT
BELT AND CHILD RESTRAINT COMPONENTS WITH
THE CORRECT, NEW AND UNUSED REPLACEMENT
PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR
PARTS CATALOG.
(1) Move the front seat to i ts most forward posi ti on
for easi est access to the l ower seat bel t anchor screw
and retractor and the l ower sport bar.
(2) Unsnap and l i ft the tri m cover from the front
seat bel t turni ng l oop to access the screw that
secures the turni ng l oop to the hei ght adjuster near
the top on the upper sport bar (Fi g. 27).
(3) Remove the screw that secures the shoul der
bel t turni ng l oop to the adjuster.
(4) Remove the shoul der bel t turni ng l oop and the
support/gui de washer from the adjuster.
(5) Remove the screw that secures the retractor
and l ower seat bel t anchor to the l ower sport bar
(Fi g. 28).
8O - 24 RESTRAINTS TJ
DRIVER AIRBAG (Continued)
(6) Remove the front seat bel t and retractor from
the l ower sport bar.
INSTALLATION
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, DURING AND FOLLOWING ANY SEAT BELT
OR CHILD RESTRAINT ANCHOR SERVICE, CARE-
FULLY INSPECT ALL SEAT BELTS, BUCKLES,
MOUNTING HARDWARE, RETRACTORS, TETHER
STRAPS, AND ANCHORS FOR PROPER INSTALLA-
TION, OPERATION, OR DAMAGE. REPLACE ANY
BELT THAT IS CUT, FRAYED, OR TORN.
STRAIGHTEN ANY BELT THAT IS TWISTED.
TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY
BELT THAT HAS A DAMAGED OR INOPERATIVE
BUCKLE OR RETRACTOR. REPLACE ANY BELT
THAT HAS A BENT OR DAMAGED LATCH PLATE
OR ANCHOR PLATE. REPLACE ANY CHILD
RESTRAINT ANCHOR OR THE UNIT TO WHICH THE
ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR
DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT
BELT OR CHILD RESTRAINT COMPONENT.
ALWAYS REPLACE DAMAGED OR FAULTY SEAT
BELT AND CHILD RESTRAINT COMPONENTS WITH
THE CORRECT, NEW AND UNUSED REPLACEMENT
PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR
PARTS CATALOG.
(1) Posi ti on the front seat bel t and retractor and
the l ower seat bel t anchor to the l ower sport bar (Fi g.
28). Be certai n to engage the l ocator tab on the
retractor i n the l ocator hol e on the sport bar.
(2) I nstal l and ti ghten the screw that secures the
front seat bel t retractor and l ower seat bel t anchor to
the l ower sport bar. Ti ghten the screw to 43 N·m (32
ft. l bs.).
(3) Posi ti on the support/gui de washer and the
front seat bel t turni ng l oop onto the hei ght adjuster
on the upper sport bar (Fi g. 27).
(4) I nstal l and ti ghten the screw that secures the
front seat bel t turni ng l oop to the hei ght adjuster.
Ti ghten the screw to 43 N·m (32 ft. l bs.).
(5) Fol d and snap the tri m cover back i nto pl ace
over the screw that secures the front seat bel t turn-
i ng l oop to the adjuster.
Fig. 27 Front Seat Belt Turning Loop
1 - ADJUSTER
2 - SPORT BAR
3 - TRIM COVER
4 - TURNING LOOP
Fig. 28 Front Seat Belt and Retractor - Typical
1 - SPORT BAR
2 - RETRACTOR
TJ RESTRAINTS 8O - 25
FRONT SEAT BELT & RETRACTOR (Continued)
FRONT SEAT BELT BUCKLE
REMOVAL
The seat bel t buckl e on the dri ver’s si de front seat
for al l model s al so i ncl udes a seat bel t swi tch. (Refer
to 8 - ELECTRI CAL/RESTRAI NTS/SEAT BELT
SWI TCH - DESCRI PTI ON).
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, DURING AND FOLLOWING ANY SEAT BELT
OR CHILD RESTRAINT ANCHOR SERVICE, CARE-
FULLY INSPECT ALL SEAT BELTS, BUCKLES,
MOUNTING HARDWARE, RETRACTORS, TETHER
STRAPS, AND ANCHORS FOR PROPER INSTALLA-
TION, OPERATION, OR DAMAGE. REPLACE ANY
BELT THAT IS CUT, FRAYED, OR TORN.
STRAIGHTEN ANY BELT THAT IS TWISTED.
TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY
BELT THAT HAS A DAMAGED OR INOPERATIVE
BUCKLE OR RETRACTOR. REPLACE ANY BELT
THAT HAS A BENT OR DAMAGED LATCH PLATE
OR ANCHOR PLATE. REPLACE ANY CHILD
RESTRAINT ANCHOR OR THE UNIT TO WHICH THE
ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR
DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT
BELT OR CHILD RESTRAINT COMPONENT.
ALWAYS REPLACE DAMAGED OR FAULTY SEAT
BELT AND CHILD RESTRAINT COMPONENTS WITH
THE CORRECT, NEW AND UNUSED REPLACEMENT
PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR
PARTS CATALOG.
(1) On the dri ver si de onl y, di sconnect the seat bel t
swi tch pi gtai l wi re connector from the body wi re har-
ness connector for the seat bel t swi tch (Fi g. 29).
(2) Remove the screw that secures the seat bel t
buckl e l ower anchor to the bracket on the rear of the
upper i nner front seat track (Fi g. 30).
(3) Remove the front seat bel t buckl e from the
front seat track bracket.
INSTALLATION
The seat bel t buckl e on the dri ver’s si de front seat
for al l model s al so i ncl udes a seat bel t swi tch. The
seat bel t buckl e on the dri ver’s si de front seat for al l
model s al so i ncl udes a seat bel t swi tch. (Refer to 8 -
ELECTRI CAL/RESTRAI NTS/SEAT BELT SWI TCH -
DESCRI PTI ON).
Fig. 29 Seat Belt Switch
1 - WIRE HARNESS CONNECTOR
2 - DRIVER SEAT RISER
4 - FLOOR PANEL
Fig. 30 Seat Belt Buckle
1 - SEAT CUSHION
2 - SEAT BACK
3 - TRIM ATTACHMENT WIRES
4 - SEAT TRACK
5 - SEAT RISER
6 - SEATBELT BUCKLE
8O - 26 RESTRAINTS TJ
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, DURING AND FOLLOWING ANY SEAT BELT
OR CHILD RESTRAINT ANCHOR SERVICE, CARE-
FULLY INSPECT ALL SEAT BELTS, BUCKLES,
MOUNTING HARDWARE, RETRACTORS, TETHER
STRAPS, AND ANCHORS FOR PROPER INSTALLA-
TION, OPERATION, OR DAMAGE. REPLACE ANY
BELT THAT IS CUT, FRAYED, OR TORN.
STRAIGHTEN ANY BELT THAT IS TWISTED.
TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY
BELT THAT HAS A DAMAGED OR INOPERATIVE
BUCKLE OR RETRACTOR. REPLACE ANY BELT
THAT HAS A BENT OR DAMAGED LATCH PLATE
OR ANCHOR PLATE. REPLACE ANY CHILD
RESTRAINT ANCHOR OR THE UNIT TO WHICH THE
ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR
DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT
BELT OR CHILD RESTRAINT COMPONENT.
ALWAYS REPLACE DAMAGED OR FAULTY SEAT
BELT AND CHILD RESTRAINT COMPONENTS WITH
THE CORRECT, NEW AND UNUSED REPLACEMENT
PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR
PARTS CATALOG.
(1) Posi ti on the front seat bel t buckl e l ower anchor
to the bracket on the rear of the upper i nner front
seat track.
(2) I nstal l and ti ghten the screw that secures the
front seat bel t buckl e l ower anchor to the front seat
track bracket (Fi g. 30). Ti ghten the screw to 43 N·m
(32 ft. l bs.).
(3) On the dri ver si de onl y, reconnect the seat bel t
swi tch pi gtai l wi re connector to the body wi re har-
ness connector for the seat bel t swi tch (Fi g. 29).
PASSENGER AIRBAG
DESCRIPTION
The rearward faci ng surface of the i njecti on
mol ded, thermopl asti c passenger ai rbag door i s the
most vi si bl e part of the passenger ai rbag (Fi g. 31).
The passenger ai rbag door i s l ocated above the gl ove
box openi ng on the i nstrument panel i n front of the
front seat passenger seati ng posi ti on. The passenger
ai rbag door al so serves as a tri m cover and has two
fl anges and a stamped metal bracket that secure i t to
the i nstrument panel structural support. The upper
fl ange i s secured wi th screws to the top of the i nstru-
ment panel structural support and the l ower fl ange
to the upper gl ove box openi ng rei nforcement. A
stamped metal passenger ai rbag door hi nge bracket
i s secured to the back of the i nstrument panel struc-
tural support wi th two screws.
Located behi nd the passenger ai rbag door wi thi n
the i nstrument panel i s the passenger ai rbag uni t.
The passenger ai rbag uni t has an upper rear bracket
and a l ower rear bracket that are secured by nuts to
three wel d studs on the i nstrument panel structural
support, one stud at the top and two at the bottom.
Two nuts secure a front l ower bracket on the passen-
ger ai rbag housi ng to two wel d studs on the dash
panel above the heater and ai r condi ti oner housi ng.
The front l ower bracket mounts are accessed through
the i nstrument panel gl ove box openi ng.
The passenger ai rbag uni t used i n thi s model i s a
Next Generati on-type that compl i es wi th revi sed fed-
eral ai rbag standards to depl oy wi th l ess force than
those used i n some pri or model s. The passenger ai r-
bag uni t consi sts of a stamped and wel ded metal
housi ng or retai ner, the ai rbag cushi on, and the ai r-
bag i nfl ator. The ai rbag housi ng contai ns the ai rbag
i nfl ator and the fol ded ai rbag cushi on. A rectangul ar
fabri c cushi on i s used. The ai rbag i nfl ator i s a
hybri d-type uni t that i s secured to and seal ed wi thi n
the stamped metal ai rbag housi ng beneath the fol ded
ai rbag cushi on. The i nfl ator i ni ti ator i s connected to
the vehi cl e el ectri cal system through a yel l ow connec-
tor on the end of a short, two-wi re pi gtai l harness
and a take out of the body wi re harness.
The passenger ai rbag and the passenger ai rbag
door are avai l abl e as separate servi ce i tems. The pas-
senger ai rbag cannot be repai red, and must be
repl aced i f depl oyed, faul ty, or i n any way damaged.
The passenger ai rbag door wi l l be damaged and must
be repl aced fol l owi ng an ai rbag depl oyment.
OPERATION
The passenger ai rbag i s depl oyed by an el ectri cal
si gnal generated by the Ai rbag Control Modul e
(ACM) through the passenger ai rbag squi b ci rcui ts to
the i ni ti ator i n the ai rbag i nfl ator. The hybri d-type
i nfl ator assembl y i ncl udes a smal l cani ster of hi ghl y
Fig. 31 Passenger Airbag Door
1 - PASSENGER AIRBAG DOOR
2 - GRAB HANDLE
3 - GLOVE BOX DOOR
TJ RESTRAINTS 8O - 27
FRONT SEAT BELT BUCKLE (Continued)
compressed i nert gas. When the ACM sends the
proper el ectri cal si gnal to the ai rbag i nfl ator, the
el ectri cal energy generates enough heat to i gni te
chemi cal pel l ets wi thi n the i nfl ator. Once i gni ted,
these chemi cal pel l ets burn rapi dl y and produce the
pressure necessary to rupture a burst di sk i n the
i nert gas cani ster.
The i nfl ator i s seal ed to the ai rbag cushi on so that
al l of the rel eased i nert gas i s di rected i nto the ai r-
bag cushi on, causi ng the cushi on to i nfl ate. As the
cushi on i nfl ates, the passenger ai rbag door wi l l spl i t
at predetermi ned tear seam l i nes i ntegral to the door,
then the door wi l l fol d up over the top of the i nstru-
ment panel and out of the way. Fol l owi ng a passen-
ger ai rbag depl oyment, the ai rbag cushi on qui ckl y
defl ates by venti ng the i nert gas through the porous
fabri c materi al used to construct each end panel of
the ai rbag cushi on.
REMOVAL
The fol l owi ng procedure i s for repl acement of a
faul ty or damaged passenger ai rbag. I f the ai rbag i s
faul ty or damaged, but not depl oyed, revi ew the rec-
ommended procedures for handl i ng non-depl oyed
suppl emental restrai nts. (Refer to 8 - ELECTRI CAL/
RESTRAI NTS - STANDARD PROCEDURE - HAN-
DLI NG NON-DEPLOYED SUPPLEMENTAL
RESTRAI NTS). I f the passenger ai rbag has been
depl oyed, revi ew the recommended procedures for
servi ce after a suppl emental restrai nt depl oyment
before removi ng the ai rbag from the vehi cl e. (Refer to
8 - ELECTRI CAL/RESTRAI NTS - STANDARD PRO-
CEDURE - SERVI CE AFTER A SUPPLEMENTAL
RESTRAI NT DEPLOYMENT).
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE SUPPLEMENTAL RESTRAINT SYS-
TEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, AIRBAG, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE BEFORE PERFORMING FURTHER DIAG-
NOSIS OR SERVICE. THIS IS THE ONLY SURE WAY
TO DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT.
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, WHEN REMOVING A DEPLOYED AIRBAG,
RUBBER GLOVES, EYE PROTECTION, AND A
LONG-SLEEVED SHIRT SHOULD BE WORN. THERE
MAY BE DEPOSITS ON THE AIRBAG UNIT AND
OTHER INTERIOR SURFACES. IN LARGE DOSES,
THESE DEPOSITS MAY CAUSE IRRITATION TO THE
SKIN AND EYES.
(1) Di sconnect and i sol ate the battery negati ve
cabl e. Wai t two mi nutes for the system capaci tor to
di scharge before further servi ce.
(2) Remove the i nstrument panel from the passen-
ger compartment of the vehi cl e. (Refer to 23 - BODY/
I NSTRUMENT PANEL - REMOVAL).
(3) Pl ace the i nstrument panel on a sui tabl e work
surface. Be certai n to take the proper precauti ons to
protect the i nstrument panel from any possi bl e cos-
meti c damage.
(4) Remove the three nuts that secure the passen-
ger ai rbag to the wel d studs on the i nstrument panel
structural support (Fi g. 32).
(5) Remove the passenger ai rbag from the i nstru-
ment panel structural support.
INSTALLATION
The fol l owi ng procedure i s for repl acement of a
faul ty or damaged passenger ai rbag. I f the ai rbag i s
faul ty or damaged, but not depl oyed, revi ew the rec-
ommended procedures for handl i ng non-depl oyed
suppl emental restrai nts. (Refer to 8 - ELECTRI CAL/
RESTRAI NTS - STANDARD PROCEDURE - HAN-
DLI NG NON-DEPLOYED SUPPLEMENTAL
RESTRAI NTS). I f the passenger ai rbag has been
depl oyed, revi ew the recommended procedures for
servi ce after a suppl emental restrai nt depl oyment
before removi ng the ai rbag from the vehi cl e. (Refer to
8 - ELECTRI CAL/RESTRAI NTS - STANDARD PRO-
CEDURE - SERVI CE AFTER A SUPPLEMENTAL
RESTRAI NT DEPLOYMENT).
Fig. 32 Passenger Airbag Remove/Install
1 - STRUCTURAL SUPPORT
2 - NUT (3)
3 - PASSENGER AIRBAG
8O - 28 RESTRAINTS TJ
PASSENGER AIRBAG (Continued)
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE SUPPLEMENTAL RESTRAINT SYS-
TEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, AIRBAG, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE BEFORE PERFORMING FURTHER DIAG-
NOSIS OR SERVICE. THIS IS THE ONLY SURE WAY
TO DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT.
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, WHEN REMOVING A DEPLOYED AIRBAG,
RUBBER GLOVES, EYE PROTECTION, AND A
LONG-SLEEVED SHIRT SHOULD BE WORN. THERE
MAY BE DEPOSITS ON THE AIRBAG UNIT AND
OTHER INTERIOR SURFACES. IN LARGE DOSES,
THESE DEPOSITS MAY CAUSE IRRITATION TO THE
SKIN AND EYES.
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, USE EXTREME CARE TO PREVENT ANY
FOREIGN MATERIAL FROM ENTERING THE PASSEN-
GER AIRBAG, OR BECOMING ENTRAPPED
BETWEEN THE PASSENGER AIRBAG CUSHION AND
THE PASSENGER AIRBAG DOOR. FAILURE TO
OBSERVE THIS WARNING COULD RESULT IN OCCU-
PANT INJURIES UPON AIRBAG DEPLOYMENT.
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, THE PASSENGER AIRBAG DOOR MUST
NEVER BE PAINTED. REPLACEMENT AIRBAG
DOORS ARE SERVICED IN THE ORIGINAL COL-
ORS. PAINT MAY CHANGE THE WAY IN WHICH THE
MATERIAL OF THE AIRBAG DOOR RESPONDS TO
AN AIRBAG DEPLOYMENT. FAILURE TO OBSERVE
THIS WARNING COULD RESULT IN OCCUPANT
INJURIES UPON AIRBAG DEPLOYMENT.
(1) Careful l y posi ti on the passenger ai rbag onto
the wel d studs on the i nstrument panel structural
support (Fi g. 32).
(2) I nstal l and ti ghten the three nuts that secure
the passenger ai rbag upper and l ower rear mounti ng
brackets to the wel d studs on the i nstrument panel
structural support. Ti ghten the nuts to 12 N·m (105
i n. l bs.).
(3) Rei nstal l the i nstrument panel i nto the passen-
ger compartment of the vehi cl e. (Refer to 23 - BODY/
I NSTRUMENT PANEL - I NSTALLATI ON). When
i nstal l i ng the i nstrument panel , be certai n the pas-
senger ai rbag pi gtai l wi re connector i s ful l y engaged
and l atched.
(4) Do not reconnect the battery negati ve cabl e at
thi s ti me. The suppl emental restrai nt system veri fi -
cati on test procedure shoul d be performed fol l owi ng
servi ce of any suppl emental restrai nt system compo-
nent. (Refer to 8 - ELECTRI CAL/RESTRAI NTS -
STANDARD PROCEDURE - VERI FI CATI ON TEST).
PASSENGER AIRBAG DOOR
REMOVAL
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE SUPPLEMENTAL RESTRAINT SYS-
TEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, AIRBAG, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE BEFORE PERFORMING FURTHER DIAG-
NOSIS OR SERVICE. THIS IS THE ONLY SURE WAY
TO DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT.
(1) Di sconnect and i sol ate the battery negati ve
cabl e. Wai t two mi nutes for the system capaci tor to
di scharge before further servi ce.
(2) Remove the passenger ai rbag from the i nstru-
ment panel . (Refer to 8 - ELECTRI CAL/RE-
STRAI NTS/PASSENGER AI RBAG - REMOVAL).
(3) Remove the fi ve screws that secure the upper
fl ange of the passenger ai rbag door to the top of the
i nstrument panel structural support (Fi g. 33).
(4) Remove the grab handl e bezel from the i nstru-
ment panel . (Refer to 23 - BODY/I NSTRUMENT
PANEL/GRAB HANDLE BEZEL - REMOVAL).
(5) Remove the fi ve screws that secure the l ower
fl ange of the passenger ai rbag door to the upper
gl ove box openi ng rei nforcement.
(6) Remove the two screws that secure the ends of
the passenger ai rbag door bracket to the i nstrument
panel structural support (Fi g. 34).
(7) Remove and di scard the two passenger ai rbag
door bracket J-nuts from the i nstrument panel struc-
tural support. These J-nuts must be repl aced wi th
new parts whenever the passenger ai rbag door
bracket screws are removed.
(8) Remove the passenger ai rbag door from the
i nstrument panel .
TJ RESTRAINTS 8O - 29
PASSENGER AIRBAG (Continued)
INSTALLATION
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE SUPPLEMENTAL RESTRAINT SYS-
TEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, AIRBAG, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE BEFORE PERFORMING FURTHER DIAG-
NOSIS OR SERVICE. THIS IS THE ONLY SURE WAY
TO DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT.
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, USE EXTREME CARE TO PREVENT ANY
FOREIGN MATERIAL FROM ENTERING THE PAS-
SENGER AIRBAG, OR BECOMING ENTRAPPED
BETWEEN THE PASSENGER AIRBAG CUSHION
AND THE PASSENGER AIRBAG DOOR. FAILURE TO
OBSERVE THIS WARNING COULD RESULT IN
OCCUPANT INJURIES UPON AIRBAG DEPLOY-
MENT.
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, THE PASSENGER AIRBAG DOOR MUST
NEVER BE PAINTED. REPLACEMENT AIRBAG
DOORS ARE SERVICED IN THE ORIGINAL COL-
ORS. PAINT MAY CHANGE THE WAY IN WHICH THE
MATERIAL OF THE AIRBAG DOOR RESPONDS TO
AN AIRBAG DEPLOYMENT. FAILURE TO OBSERVE
THIS WARNING COULD RESULT IN OCCUPANT
INJURIES UPON AIRBAG DEPLOYMENT.
(1) I nstal l two new passenger ai rbag door bracket
J-nuts onto the i nstrument panel structural support
(Fi g. 34). These J-nuts must be repl aced wi th new
parts whenever the passenger ai rbag door bracket
screws are removed.
(2) Posi ti on the passenger ai rbag door onto the
i nstrument panel and al i gn the mounti ng hol es i n
each end of the ai rbag door bracket wi th the J-nuts
on the i nstrument panel structural support.
(3) I nstal l and ti ghten the two screws that secure
the passenger ai rbag door bracket to the i nstrument
panel structural support. Ti ghten the screws to 12
N·m (105 i n. l bs.).
(4) I nstal l and ti ghten the fi ve screws that secure
the l ower fl ange of the passenger ai rbag door to the
upper gl ove box openi ng rei nforcement. Ti ghten the
screws to 2 N·m (20 i n. l bs.).
(5) Rei nstal l the grab handl e bezel onto the i nstru-
ment panel . (Refer to 23 - BODY/I NSTRUMENT
PANEL/GRAB HANDLE BEZEL - I NSTALLATI ON).
(6) I nstal l and ti ghten the fi ve screws that secure
the upper fl ange of the passenger ai rbag door to the
top of the i nstrument panel structural support (Fi g.
33). Ti ghten the screws to 2 N·m (20 i n. l bs.).
(7) Rei nstal l the passenger ai rbag onto the i nstru-
ment panel . (Refer to 8 - ELECTRI CAL/RE-
STRAI NTS/PASSENGER AI RBAG -
I NSTALLATI ON).
Fig. 33 Passenger Airbag Door Upper Flange
Remove/Install
1 - SCREW (5)
2 - PASSENGER AIRBAG DOOR
Fig. 34 Passenger Airbag Door Remove/Install
1 - J-NUT (2)
2 - PASSENGER AIRBAG DOOR
3 - STRUCTURAL SUPPORT
4 - SCREW (2)
8O - 30 RESTRAINTS TJ
PASSENGER AIRBAG DOOR (Continued)
PASSENGER AIRBAG ON/OFF
SWITCH
DESCRIPTION
The passenger ai rbag on/off swi tch i s standard
equi pment on al l versi ons of thi s model that are
equi pped wi th the dual front ai rbag system, but are
not equi pped wi th a rear seat (Fi g. 35). Thi s swi tch
i s a two-posi ti on, resi stor mul ti pl exed swi tch wi th a
si ngl e i ntegral red Li ght-Emi tti ng Di ode (LED), and
a non-coded key cyl i nder-type actuator. The swi tch i s
l ocated on the passenger si de end of the accessory
swi tch bezel near the bottom of the i nstrument cl us-
ter center bezel to make the Off i ndi cator vi si bl e to
the front passenger seat occupant. When the swi tch
i s i n i ts i nstal l ed posi ti on, the onl y component vi si bl e
through the dedi cated openi ng of the accessory
swi tch bezel i s the key cyl i nder actuator. A smal l ,
tethered, mol ded pl asti c cap fi ts i nto the key cyl i nder
actuator hol e when the swi tch i s not bei ng used. The
swi tch nomencl ature and the Off i ndi cator l ens are
i ntegral to the accessory swi tch bezel . The text of the
ЉOffЉ i ndi cator i s i l l umi nated i n amber when the Off
posi ti on i s sel ected wi th the i gni ti on swi tch i n the On
posi ti on, whi l e the On posi ti on of the swi tch i s desi g-
nated by text i mpri nted upon the accessory swi tch
bezel , but i s not i l l umi nated. The remai nder of the
swi tch i s conceal ed behi nd the accessory swi tch bezel .
The passenger ai rbag on/off swi tch housi ng i s con-
structed of mol ded pl asti c and has three i ntegral
mounti ng tabs (Fi g. 36). These mounti ng tabs are
used to secure the swi tch to the back of the mol ded
pl asti c accessory swi tch bezel wi th three smal l
screws. The accessory swi tch bezel i s secured to the
i nstrument panel wi th four screws. A mol ded pl asti c
connector receptacl e on the back of the swi tch hous-
i ng connects the swi tch to the vehi cl e el ectri cal sys-
tem through a dedi cated take out of the body wi re
harness. The mol ded pl asti c harness connector i nsu-
l ator i s keyed and l atched to ensure proper and
secure swi tch el ectri cal connecti ons. The passenger
ai rbag on/off swi tch cannot be adjusted or repai red
and, i f faul ty or damaged, the swi tch must be
repl aced.
OPERATION
The passenger ai rbag on/off swi tch al l ows the cus-
tomer to turn the passenger ai rbag functi on On or
Off to accommodate certai n uses of the ri ght front
seati ng posi ti on where ai rbag protecti on may not be
desi red. See the owner’s manual i n the vehi cl e gl ove
box for speci fi c recommendati ons on when to enabl e
or di sabl e the passenger ai rbag. The Off i ndi cator of
the swi tch wi l l be i l l umi nated whenever the swi tch i s
turned to the Off posi ti on and the i gni ti on swi tch i s
i n the On posi ti on.
The i gni ti on key i s the onl y key or object that
shoul d ever be i nserted i nto the key cyl i nder actuator
of the swi tch. The on/off swi tch requi res onl y a par-
ti al key i nserti on to ful l y depress a spri ng-l oaded
l ocki ng pl unger. The spri ng-l oaded l ocki ng pl unger
prevents the user from l eavi ng the key i n the swi tch.
The key wi l l be automati cal l y ejected when force i s
Fig. 35 Accessory Switch Bezel
1 - ACCESSORY SWITCH BEZEL
2 - REAR WINDOW DEFOGGER SWITCH (HARDTOP ONLY)
3 - REAR WIPER/WASHER SWITCH (HARDTOP ONLY)
4 - OVERDRIVE-OFF SWITCH (AUTOMATIC TRANSMISSION
ONLY)
5 - AXLE LOCK SWITCH (OFF ROAD PACKAGE ONLY)
6 - PASSENGER AIRBAG ON/OFF SWITCH (WITHOUT REAR
SEAT ONLY)
7 - ACCESSORY POWER OUTLET
8 - CIGAR LIGHTER
Fig. 36 Passenger Airbag On/Off Switch
1 - HOUSING
2 - CONNECTOR RECEPTACLE
3 - MOUNTING TAB (3)
4 - OFF INDICATOR
5 - KEY CYLINDER ACTUATOR
TJ RESTRAINTS 8O - 31
not appl i ed. To actuate the passenger ai rbag on/off
swi tch, i nsert the i gni ti on key i nto the swi tch key
actuator far enough to ful l y depress the pl unger, then
rotate the actuator to the desi red swi tch posi ti on.
When the swi tch key actuator i s rotated to i ts cl ock-
wi se stop (the key actuator sl ot wi l l be al i gned wi th
the Off i ndi cator), the Off i ndi cator i s i l l umi nated
and the passenger ai rbag i s di sabl ed. When the
swi tch i s rotated to i ts countercl ockwi se stop (the key
actuator sl ot wi l l be i n a verti cal posi ti on), the Off
i ndi cator wi l l be exti ngui shed and the passenger ai r-
bag i s enabl ed.
The passenger ai rbag on/off swi tch connects one of
two i nternal resi stors i n seri es between the passen-
ger ai rbag mux swi tch sense and passenger ai rbag
mux swi tch return ci rcui ts of the Ai rbag Control
Modul e (ACM). The ACM conti nual l y moni tors the
resi stance i n these ci rcui ts to determi ne the swi tch
posi ti on that has been sel ected. When the swi tch i s
i n the Off posi ti on, the ACM provi des a ground i nput
to the swi tch through the passenger ai rbag i ndi cator
dri ver ci rcui t, whi ch energi zes the Li ght-Emi tti ng
Di ode (LED) that i l l umi nates the Off i ndi cator of the
swi tch.
The ACM wi l l al so i l l umi nate the Off i ndi cator of
the swi tch for about seven seconds each ti me the
i gni ti on swi tch i s turned to the On posi ti on as a bul b
test. The ACM wi l l store a Di agnosti c Troubl e Code
(DTC) for any faul t i t detects i n the passenger ai rbag
on/off swi tch or Off i ndi cator ci rcui ts, and wi l l i l l umi -
nate the ai rbag i ndi cator i n the i nstrument cl uster i f
a faul t i s detected. For proper di agnosi s of the pas-
senger ai rbag on/off swi tch or the ACM, a DRBI I I ௡
scan tool i s requi red. Refer to the appropri ate di ag-
nosti c i nformati on.
REMOVAL
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE SUPPLEMENTAL RESTRAINT SYS-
TEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, AIRBAG, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE BEFORE PERFORMING FURTHER DIAG-
NOSIS OR SERVICE. THIS IS THE ONLY SURE WAY
TO DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT.
(1) Di sconnect and i sol ate the battery negati ve
cabl e. Wai t two mi nutes for the system capaci tor to
di scharge before further servi ce.
(2) Remove the passenger ai rbag on/off swi tch and
accessory swi tch bezel from the i nstrument panel as
a uni t. (Refer to 23 - BODY/I NSTRUMENT PANEL/
ACCESSORY SWI TCH BEZEL - REMOVAL).
(3) From the back of the accessory swi tch bezel ,
remove the three screws that secure the passenger
ai rbag on/off swi tch to the back of the bezel (Fi g. 37).
(4) Remove the passenger ai rbag on/off swi tch
from the accessory swi tch bezel .
INSTALLATION
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE SUPPLEMENTAL RESTRAINT SYS-
TEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, AIRBAG, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE BEFORE PERFORMING FURTHER DIAG-
NOSIS OR SERVICE. THIS IS THE ONLY SURE WAY
TO DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT.
(1) Posi ti on the passenger ai rbag on/off swi tch to
the back of the accessory swi tch bezel (Fi g. 37).
(2) I nstal l and ti ghten the three screws that secure
the passenger ai rbag on/off swi tch to the back of the
accessory swi tch bezel . Ti ghten the screws to 2 N·m
(20 i n. l bs.).
Fig. 37 Passenger Airbag On/Off Switch Remove/
Install
1 - PASSENGER AIRBAG ON/OFF SWITCH
2 - SCREW DRIVER
3 - ACCESSORY SWITCH BEZEL
4 - SCREW (3)
8O - 32 RESTRAINTS TJ
PASSENGER AIRBAG ON/OFF SWITCH (Continued)
(3) Rei nstal l the passenger ai rbag on/off swi tch
and accessory swi tch bezel uni t to the i nstrument
panel . (Refer to 23 - BODY/I NSTRUMENT PANEL/
ACCESSORY SWI TCH BEZEL - I NSTALLATI ON).
(4) Do not reconnect the battery negati ve cabl e at
thi s ti me. The suppl emental restrai nt system veri fi -
cati on test procedure shoul d be performed fol l owi ng
servi ce of any suppl emental restrai nt system compo-
nent. (Refer to 8 - ELECTRI CAL/RESTRAI NTS -
STANDARD PROCEDURE - VERI FI CATI ON TEST).
REAR SEAT BELT &
RETRACTOR
REMOVAL
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, DURING AND FOLLOWING ANY SEAT BELT
OR CHILD RESTRAINT ANCHOR SERVICE, CARE-
FULLY INSPECT ALL SEAT BELTS, BUCKLES,
MOUNTING HARDWARE, RETRACTORS, TETHER
STRAPS, AND ANCHORS FOR PROPER INSTALLA-
TION, OPERATION, OR DAMAGE. REPLACE ANY
BELT THAT IS CUT, FRAYED, OR TORN.
STRAIGHTEN ANY BELT THAT IS TWISTED.
TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY
BELT THAT HAS A DAMAGED OR INOPERATIVE
BUCKLE OR RETRACTOR. REPLACE ANY BELT
THAT HAS A BENT OR DAMAGED LATCH PLATE
OR ANCHOR PLATE. REPLACE ANY CHILD
RESTRAINT ANCHOR OR THE UNIT TO WHICH THE
ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR
DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT
BELT OR CHILD RESTRAINT COMPONENT.
ALWAYS REPLACE DAMAGED OR FAULTY SEAT
BELT AND CHILD RESTRAINT COMPONENTS WITH
THE CORRECT, NEW AND UNUSED REPLACEMENT
PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR
PARTS CATALOG.
(1) Sl i de both rear seat bel t buckl e uni ts between
the seat cushi on and seat back i nto the cargo area.
(2) Li ft the rear seat back rel ease l ever and fol d
the rear seat back forward, then tumbl e the fol ded
rear seat cushi on and back uni t forward agai nst the
backs of the two front bucket seats.
(3) Remove the screw that secures the l ower sear
bel t anchor to the i nner rear wheel house panel
(Fi g. 38).
(4) Remove the rear seat bel t l ower anchor from
the i nner rear wheel house panel .
(5) Unsnap and l i ft the tri m cover from the rear
seat bel t turni ng l oop to access the screw that
secures the turni ng l oop to the upper sport bar
(Fi g. 39).
(6) Remove the screw that secures the seat bel t
turni ng l oop to the upper sport bar.
(7) Remove the seat bel t turni ng l oop from the
upper sport bar.
Fig. 38 Rear Seat Shoulder Belt & Retractor
Remove/Install
1 - TURNING LOOP
2 - SPACER
3 - BELT & RETRACTOR
4 - SPORT BAR
5 - WASHER
6 - SPACER
Fig. 39 Turning Loop
1 - SPORT BAR
2 - TURNING LOOP COVER
3 - TURNING LOOP
4 - REAR SEAT BELT
5 - SCREW
TJ RESTRAINTS 8O - 33
PASSENGER AIRBAG ON/OFF SWITCH (Continued)
(8) Remove the screw that secures the rear seat
bel t retractor to the l ower sport bar near the top of
the i nner rear wheel house panel .
(9) Remove the rear seat bel t and retractor from
the l ower sport bar.
INSTALLATION
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, DURING AND FOLLOWING ANY SEAT BELT
OR CHILD RESTRAINT ANCHOR SERVICE, CARE-
FULLY INSPECT ALL SEAT BELTS, BUCKLES,
MOUNTING HARDWARE, RETRACTORS, TETHER
STRAPS, AND ANCHORS FOR PROPER INSTALLA-
TION, OPERATION, OR DAMAGE. REPLACE ANY
BELT THAT IS CUT, FRAYED, OR TORN.
STRAIGHTEN ANY BELT THAT IS TWISTED.
TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY
BELT THAT HAS A DAMAGED OR INOPERATIVE
BUCKLE OR RETRACTOR. REPLACE ANY BELT
THAT HAS A BENT OR DAMAGED LATCH PLATE
OR ANCHOR PLATE. REPLACE ANY CHILD
RESTRAINT ANCHOR OR THE UNIT TO WHICH THE
ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR
DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT
BELT OR CHILD RESTRAINT COMPONENT.
ALWAYS REPLACE DAMAGED OR FAULTY SEAT
BELT AND CHILD RESTRAINT COMPONENTS WITH
THE CORRECT, NEW AND UNUSED REPLACEMENT
PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR
PARTS CATALOG.
(1) Posi ti on the rear seat bel t and retractor to the
l ower sport bar near the top of the i nner rear wheel
house panel (Fi g. 38). Be certai n to engage the l oca-
tor tab on the retractor i n the l ocator hol e on the
sport bar.
(2) I nstal l and ti ghten the screw that secures the
rear seat bel t retractor to the l ower sport bar.
Ti ghten the screw to 43 N·m (32 ft. l bs.).
(3) Posi ti on the rear seat bel t turni ng l oop to the
upper sport bar (Fi g. 39).
(4) I nstal l and ti ghten the screw that secures the
rear seat bel t turni ng l oop to the upper sport bar.
Ti ghten the screw to 43 N·m (32 ft. l bs.).
(5) Fol d and snap the tri m cover for the rear seat
bel t turni ng l oop back i nto pl ace over the screw that
secures the turni ng l oop to the upper sport bar.
(6) Posi ti on the rear seat bel t l ower anchor to the
i nner rear wheel house panel .
(7) I nstal l and ti ghten the screw that secures the
rear seat bel t l ower anchor to the i nner rear wheel
house panel . Ti ghten the screw to 43 N·m (32 ft.
l bs.).
(8) Tumbl e the fol ded rear seat cushi on and back
uni t rearward onto the rear fl oor panel .
(9) Sl i de both rear seat bel t buckl e uni ts between
the seat cushi on and the seat back.
(10) Unfol d the rear seat back from the seat cush-
i on unti l the seat back l atch i s ful l y engaged.
REAR SEAT BELT BUCKLE
REMOVAL
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, DURING AND FOLLOWING ANY SEAT BELT
OR CHILD RESTRAINT ANCHOR SERVICE, CARE-
FULLY INSPECT ALL SEAT BELTS, BUCKLES,
MOUNTING HARDWARE, RETRACTORS, TETHER
STRAPS, AND ANCHORS FOR PROPER INSTALLA-
TION, OPERATION, OR DAMAGE. REPLACE ANY
BELT THAT IS CUT, FRAYED, OR TORN.
STRAIGHTEN ANY BELT THAT IS TWISTED.
TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY
BELT THAT HAS A DAMAGED OR INOPERATIVE
BUCKLE OR RETRACTOR. REPLACE ANY BELT
THAT HAS A BENT OR DAMAGED LATCH PLATE
OR ANCHOR PLATE. REPLACE ANY CHILD
RESTRAINT ANCHOR OR THE UNIT TO WHICH THE
ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR
DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT
BELT OR CHILD RESTRAINT COMPONENT.
ALWAYS REPLACE DAMAGED OR FAULTY SEAT
BELT AND CHILD RESTRAINT COMPONENTS WITH
THE CORRECT, NEW AND UNUSED REPLACEMENT
PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR
PARTS CATALOG.
(1) Sl i de both rear seat bel t buckl e uni ts between
the seat cushi on and seat back i nto the rear cargo
area.
(2) Li ft the rear seat back rel ease l ever and fol d
the rear seat back forward, then tumbl e the fol ded
rear seat cushi on and back uni t forward agai nst the
backs of the two front bucket seats.
(3) Li ft the rear cargo area carpet between the two
rear seat bel t buckl e uni ts far enough to access and
remove the screw that secures the anchor of the rear
seat bel t buckl e uni ts to the rear cargo fl oor panel
through one of the cl earance sl ots i n the carpet (Fi g.
40).
(4) Remove the rear seat bel t buckl e uni t from the
rear fl oor panel through one of the cl earance sl ots i n
the rear cargo area carpet.
8O - 34 RESTRAINTS TJ
REAR SEAT BELT & RETRACTOR (Continued)
INSTALLATION
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, DURING AND FOLLOWING ANY SEAT BELT
OR CHILD RESTRAINT ANCHOR SERVICE, CARE-
FULLY INSPECT ALL SEAT BELTS, BUCKLES,
MOUNTING HARDWARE, RETRACTORS, TETHER
STRAPS, AND ANCHORS FOR PROPER INSTALLA-
TION, OPERATION, OR DAMAGE. REPLACE ANY
BELT THAT IS CUT, FRAYED, OR TORN.
STRAIGHTEN ANY BELT THAT IS TWISTED.
TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY
BELT THAT HAS A DAMAGED OR INOPERATIVE
BUCKLE OR RETRACTOR. REPLACE ANY BELT
THAT HAS A BENT OR DAMAGED LATCH PLATE
OR ANCHOR PLATE. REPLACE ANY CHILD
RESTRAINT ANCHOR OR THE UNIT TO WHICH THE
ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR
DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT
BELT OR CHILD RESTRAINT COMPONENT.
ALWAYS REPLACE DAMAGED OR FAULTY SEAT
BELT AND CHILD RESTRAINT COMPONENTS WITH
THE CORRECT, NEW AND UNUSED REPLACEMENT
PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR
PARTS CATALOG.
(1) Li ft the rear cargo area carpet far enough to
posi ti on the rear seat bel t buckl e uni t onto the rear
cargo fl oor panel through one of the cl earance sl ots i n
the carpet.
(2) Worki ng through one of the cl earance sl ots i n
the rear cargo area carpet, i nstal l and ti ghten the
screw that secures the anchor of the rear seat bel t
buckl e uni t to the rear cargo fl oor panel (Fi g. 40).
Ti ghten the screw to 43 N·m (32 ft. l bs.).
(3) Tumbl e the fol ded rear seat cushi on and back
uni t rearward onto the rear cargo fl oor panel .
(4) Sl i de both rear seat bel t buckl e uni ts between
the seat cushi on and the seat back.
(5) Unfol d the rear seat back from the seat cush-
i on unti l the seat back l atch i s ful l y engaged.
SEAT BELT SWITCH
DESCRIPTION
The seat bel t swi tch i s a smal l , normal l y cl osed,
si ngl e pol e, si ngl e throw, l eaf contact, momentary
swi tch. Onl y one seat bel t swi tch i s i nstal l ed i n the
vehi cl e, and i t i s i ntegral to the buckl e of the dri ver
si de front seat bel t buckl e-hal f, l ocated on the
i nboard si de of the dri ver si de front seat track (Fi g.
41). The seat bel t swi tch i s connected to the vehi cl e
el ectri cal system through a two-wi re pi gtai l wi re and
connector on the seat bel t buckl e-hal f, whi ch i s con-
nected to a wi re harness connector and take out of
the body wi re harness routed al ong the l eft si de of
the body si l l i n the passenger compartment.
The seat bel t swi tch cannot be adjusted or repai red
and, i f faul ty or damaged, the enti re dri ver si de front
seat bel t buckl e-hal f uni t must be repl aced.
OPERATION
The seat bel t swi tch i s desi gned to control a path
to ground for the seat bel t swi tch sense i nput of the
El ectroMechani cal I nstrument Cl uster (EMI C). When
Fig. 40 Rear Seat Belt Buckles Remove/Install
1 - REAR SEAT BELT BUCKLE UNIT
Fig. 41 Seat Belt Switch
1 - WIRE HARNESS CONNECTOR
2 - DRIVER SEAT RISER
4 - FLOOR PANEL
TJ RESTRAINTS 8O - 35
REAR SEAT BELT BUCKLE (Continued)
the dri ver si de front seat bel t ti p-hal f i s i nserted i nto
the seat bel t buckl e, the swi tch opens the path to
ground; and, when the dri ver si de front seat bel t ti p-
hal f i s removed from the seat bel t buckl e, the swi tch
cl oses the ground path. The swi tch i s actuated by the
l atch mechani sm wi thi n the seat bel t buckl e.
The seat bel t swi tch i s connected i n seri es between
ground and the seat bel t swi tch sense i nput of the
i nstrument cl uster. The seat bel t swi tch recei ves
ground at al l ti mes through i ts pi gtai l wi re connec-
ti on to the body wi re harness from another take out
of the body wi re harness. An eyel et termi nal connec-
tor on that ground take out i s secured beneath a
ground screw on the l eft cowl si de i nner panel ,
beneath the i nstrument panel . The seat bel t swi tch
may de di agnosed usi ng conventi onal di agnosti c tool s
and methods.
DIAGNOSIS AND TESTING - SEAT BELT
SWITCH
Refer to the appropri ate wi ri ng i nformati on. The
wi ri ng i nformati on i ncl udes wi ri ng di agrams, proper
wi re and connector repai r procedures, detai l s of wi re
harness routi ng and retenti on, connector pi n-out
i nformati on and l ocati on vi ews for the vari ous wi re
harness connectors, spl i ces and grounds.
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE SUPPLEMENTAL RESTRAINT SYS-
TEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, AIRBAG, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE BEFORE PERFORMING FURTHER DIAG-
NOSIS OR SERVICE. THIS IS THE ONLY SURE WAY
TO DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT.
(1) Di sconnect and i sol ate the battery negati ve
cabl e. Di sconnect the seat bel t swi tch pi gtai l wi re
connector from the body wi re harness connector for
the seat bel t swi tch on the fl oor near the dri ver si de
front seat bel t buckl e-hal f anchor. Check for conti nu-
i ty between the seat bel t swi tch sense ci rcui t and the
ground ci rcui t cavi ti es of the seat bel t swi tch pi gtai l
wi re connector. There shoul d be conti nui ty wi th the
seat bel t unbuckl ed, and no conti nui ty wi th the seat
bel t buckl ed. I f OK, go to Step 2. I f not OK, repl ace
the faul ty front seat bel t buckl e-hal f assembl y.
(2) Check for conti nui ty between the ground ci r-
cui t cavi ty i n the body wi re harness connector for the
seat bel t swi tch and a good ground. There shoul d be
conti nui ty. I f OK, go to Step 3. I f not OK, repai r the
open ground ci rcui t to ground (G302) as requi red.
(3) Remove the i nstrument cl uster from the i nstru-
ment panel . Check for conti nui ty between the seat
bel t swi tch sense ci rcui t cavi ty of the body wi re har-
ness connector for the seat bel t swi tch and a good
ground. There shoul d be no conti nui ty. I f OK, go to
Step 4. I f not OK, repai r the shorted seat bel t swi tch
sense ci rcui t between the seat bel t swi tch and the
i nstrument cl uster as requi red.
(4) Check for conti nui ty between the seat bel t
swi tch sense ci rcui t cavi ti es of the body wi re harness
connector for the seat bel t swi tch and the i nstrument
panel wi re harness connector (Connector C2) for the
i nstrument cl uster. There shoul d be conti nui ty. I f
OK, test and repl ace the faul ty i nstrument cl uster as
requi red. (Refer to 8 - ELECTRI CAL/I NSTRUMENT
CLUSTER - DI AGNOSI S AND TESTI NG). I f not OK,
repai r the open seat bel t swi tch sense ci rcui t between
the seat bel t swi tch and the i nstrument cl uster as
requi red.
SEAT BELT TURNING LOOP
ADJ USTER
REMOVAL
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, DURING AND FOLLOWING ANY SEAT BELT
OR CHILD RESTRAINT ANCHOR SERVICE, CARE-
FULLY INSPECT ALL SEAT BELTS, BUCKLES,
MOUNTING HARDWARE, RETRACTORS, TETHER
STRAPS, AND ANCHORS FOR PROPER INSTALLA-
TION, OPERATION, OR DAMAGE. REPLACE ANY
BELT THAT IS CUT, FRAYED, OR TORN.
STRAIGHTEN ANY BELT THAT IS TWISTED.
TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY
BELT THAT HAS A DAMAGED OR INOPERATIVE
BUCKLE OR RETRACTOR. REPLACE ANY BELT
THAT HAS A BENT OR DAMAGED LATCH PLATE
OR ANCHOR PLATE. REPLACE ANY CHILD
RESTRAINT ANCHOR OR THE UNIT TO WHICH THE
ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR
DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT
BELT OR CHILD RESTRAINT COMPONENT.
ALWAYS REPLACE DAMAGED OR FAULTY SEAT
BELT AND CHILD RESTRAINT COMPONENTS WITH
THE CORRECT, NEW AND UNUSED REPLACEMENT
PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR
PARTS CATALOG.
(1) Unsnap and l i ft the tri m cover from the front
seat bel t turni ng l oop to access the screw that
8O - 36 RESTRAINTS TJ
SEAT BELT SWITCH (Continued)
secures the turni ng l oop to the hei ght adjuster on the
upper sport bar (Fi g. 42).
(2) Remove the screw that secures the shoul der
bel t turni ng l oop to the hei ght adjuster.
(3) Remove the front seat bel t turni ng l oop and the
support/gui de washer from the hei ght adjuster.
(4) Unsnap and remove the tri m cover from the
front seat bel t turni ng l oop hei ght adjuster to access
the screws that secure the adjuster to the upper
sport bar.
(5) Remove the two screws that secure the hei ght
adjuster to the upper sport bar.
(6) Remove the front seat bel t turni ng l oop hei ght
adjuster from the upper sport bar.
INSTALLATION
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, DURING AND FOLLOWING ANY SEAT BELT
OR CHILD RESTRAINT ANCHOR SERVICE, CARE-
FULLY INSPECT ALL SEAT BELTS, BUCKLES,
MOUNTING HARDWARE, RETRACTORS, TETHER
STRAPS, AND ANCHORS FOR PROPER INSTALLA-
TION, OPERATION, OR DAMAGE. REPLACE ANY
BELT THAT IS CUT, FRAYED, OR TORN.
STRAIGHTEN ANY BELT THAT IS TWISTED.
TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY
BELT THAT HAS A DAMAGED OR INOPERATIVE
BUCKLE OR RETRACTOR. REPLACE ANY BELT
THAT HAS A BENT OR DAMAGED LATCH PLATE
OR ANCHOR PLATE. REPLACE ANY CHILD
RESTRAINT ANCHOR OR THE UNIT TO WHICH THE
ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR
DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT
BELT OR CHILD RESTRAINT COMPONENT.
ALWAYS REPLACE DAMAGED OR FAULTY SEAT
BELT AND CHILD RESTRAINT COMPONENTS WITH
THE CORRECT, NEW AND UNUSED REPLACEMENT
PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR
PARTS CATALOG.
(1) Posi ti on the front seat bel t turni ng l oop hei ght
adjuster onto the upper sport bar (Fi g. 42). Be cer-
tai n that the word “Up” stamped on the adjuster i s
properl y ori ented.
(2) I nstal l and ti ghten the two screws that secure
the seat bel t turni ng l oop hei ght adjuster to the
upper sport bar. Ti ghten the screws to 43 N·m (32 ft.
l bs.).
(3) Al i gn the tri m cover over the front seat bel t
turni ng l oop hei ght adjuster and, usi ng hand pres-
sure, press fi rml y and evenl y on the cover unti l i t
snaps i nto pl ace over the adjuster on the upper sport
bar.
(4) Posi ti on the support/gui de washer and the
front seat bel t turni ng l oop onto the hei ght adjuster.
(5) I nstal l and ti ghten the screw that secures the
front seat bel t turni ng l oop to the hei ght adjuster.
Ti ghten the screw to 43 N·m (32 ft. l bs.).
(6) Fol d and snap the tri m cover for the seat bel t
turni ng l oop back i nto pl ace over the screw that
secures the turni ng l oop to the hei ght adjuster.
Fig. 42 Front Turning Loop Height Adjuster
1 - ADJUSTER
2 - SPORT BAR
3 - TRIM COVER
4 - TURNING LOOP
TJ RESTRAINTS 8O - 37
SEAT BELT TURNING LOOP ADJ USTER (Continued)
SPEED CONTROL
TABLE OF CONTENTS
page page
SPEED CONTROL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DIAGNOSIS AND TESTING - ROAD TEST . . . . . 2
SPECIFICATIONS
TORQUE - SPEED CONTROL . . . . . . . . . . . . . 2
CABLE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 3
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVO
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 4
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 5
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 6
VACUUM RESERVOIR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DIAGNOSIS AND TESTING - VACUUM
RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . 7
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SPEED CONTROL
DESCRIPTION
The speed control system i s el ectroni cal l y con-
trol l ed and vacuum operated. El ectroni c control of
the speed control system i s i ntegrated i nto the Pow-
ertrai n Control Modul e (PCM). The control s consi st
of two steeri ng wheel mounted swi tches. The
swi tches are l abel ed: ON/OFF, RES/ACCEL, SET,
COAST, and CANCEL.
The system i s desi gned to operate at speeds above
30 mph (50 km/h).
WARNING: THE USE OF SPEED CONTROL IS NOT
RECOMMENDED WHEN DRIVING CONDITIONS DO
NOT PERMIT MAINTAINING A CONSTANT SPEED,
SUCH AS IN HEAVY TRAFFIC OR ON ROADS THAT
ARE WINDING, ICY, SNOW COVERED, OR SLIP-
PERY.
OPERATION
When speed control i s sel ected by depressi ng the
ON swi tch, the PCM al l ows a set speed to be stored
i n PCM RAM for speed control . To store a set speed,
depress the SET swi tch whi l e the vehi cl e i s movi ng
at a speed between 35 and 85 mph. I n order for the
speed control to engage, the brakes cannot be
appl i ed, nor can the gear sel ector be i ndi cati ng the
transmi ssi on i s i n Park or Neutral .
The speed control can be di sengaged manual l y by:
• Steppi ng on the brake pedal
• Depressi ng the OFF swi tch
• Depressi ng the CANCEL swi tch.
• Depressi ng the cl utch pedal (i f equi pped).
NOTE: Depressing the OFF switch or turning off the
ignition switch will erase the set speed stored in
the PCM.
For added safety, the speed control system i s pro-
grammed to di sengage for any of the fol l owi ng condi -
ti ons:
• An i ndi cati on of Park or Neutral
• A rapi d i ncrease rpm (i ndi cates that the cl utch
has been di sengaged)
• Excessi ve engi ne rpm (i ndi cates that the trans-
mi ssi on may be i n a l ow gear)
• The speed si gnal i ncreases at a rate of 10 mph
per second (i ndi cates that the coeffi ci ent of fri cti on
between the road surface and ti res i s extremel y l ow)
• The speed si gnal decreases at a rate of 10 mph
per second (i ndi cates that the vehi cl e may have
decel erated at an extremel y hi gh rate)
Once the speed control has been di sengaged,
depressi ng the RES/ACCEL swi tch (when speed i s
greater than 30 mph) restores the vehi cl e to the tar-
get speed that was stored i n the PCM.
Whi l e the speed control i s engaged, the dri ver can
i ncrease the vehi cl e speed by depressi ng the RES/AC-
CEL swi tch. The new target speed i s stored i n the
PCM when the RES/ACCEL i s rel eased. The PCM
al so has a Љtap-upЉ feature i n whi ch vehi cl e speed
i ncreases at a rate of approxi matel y 2 mph for each
momentary swi tch acti vati on of the RES/ACCEL
swi tch.
TJ SPEED CONTROL 8P - 1
A “tap down” feature i s used to decel erate wi thout
di sengagi ng the speed control system. To decel erate
from an exi sti ng recorded target speed, momentari l y
depress the COAST swi tch. For each swi tch acti va-
ti on, speed wi l l be l owered approxi matel y 1 mph.
OVERSHOOT/UNDERSHOOT
I f the vehi cl e operator repeatedl y presses and
rel eases the SET button wi th thei r foot off of the
accel erator (referred to as a “l i ft foot set”), the vehi cl e
may accel erate and exceed the desi red set speed by
up to 5 mph (8 km/h). I t may al so decel erate to l ess
than the desi red set speed, before fi nal l y achi evi ng
the desi red set speed.
The Speed Control System has an adapti ve strat-
egy that compensates for vehi cl e-to-vehi cl e vari ati ons
i n speed control cabl e l engths. When the speed con-
trol i s set wi th the vehi cl e operators foot off of the
accel erator pedal , the speed control thi nks there i s
excessi ve speed control cabl e sl ack and adapts
accordi ngl y. I f the “l i ft foot sets” are conti nual l y used,
a speed control overshoot/undershoot condi ti on wi l l
devel op.
To “unl earn” the overshoot/undershoot condi ti on,
the vehi cl e operator has to press and rel ease the set
button whi l e mai ntai ni ng the desi red set speed usi ng
the accel erator pedal (not decel erati ng or accel erat-
i ng), and then turni ng the crui se control swi tch to
the OFF posi ti on (or press the CANCEL button i f
equi pped) after wai ti ng 10 seconds. Thi s procedure
must be performed approxi matel y 10–15 ti mes to
compl etel y unl earn the overshoot/undershoot condi -
ti on.
DIAGNOSIS AND TESTING - ROAD TEST
Perform a vehi cl e road test to veri fy reports of
speed control system mal functi on. The road test
shoul d i ncl ude attenti on to the speedometer. Speed-
ometer operati on shoul d be smooth and wi thout fl ut-
ter at al l speeds.
Fl utter i n the speedometer i ndi cates a probl em
whi ch mi ght cause surgi ng i n the speed control sys-
tem. The cause of any speedometer probl ems shoul d
be corrected before proceedi ng. Refer to Group 8J,
I nstrument Cl uster for speedometer di agnosi s.
I f a road test veri fi es a system probl em and the
speedometer operates properl y, check for:
• A Di agnosti c Troubl e Code (DTC). I f a DTC
exi sts, conduct tests per the Powertrai n Di agnosti c
Procedures servi ce manual .
• A mi sadjusted brake (stop) l amp swi tch. Thi s
coul d al so cause an i ntermi ttent probl em.
• Loose, damaged or corroded el ectri cal connec-
ti ons at the servo. Corrosi on shoul d be removed from
el ectri cal termi nal s and a l i ght coati ng of Mopar
Mul ti Purpose Grease, or equi val ent, appl i ed.
• Leaki ng vacuum reservoi r.
• Loose or l eaki ng vacuum hoses or connecti ons.
• Defecti ve one-way vacuum check val ve.
• Secure attachment of both ends of the speed con-
trol servo cabl e.
• Smooth operati on of throttl e l i nkage and throttl e
body ai r val ve.
• Fai l ed speed control servo. Do the servo vacuum
test.
CAUTION: When test probing for voltage or conti-
nuity at electrical connectors, care must be taken
not to damage connector, terminals or seals. If
these components are damaged, intermittent or
complete system failure may occur.
SPECIFICATIONS
TORQUE - SPEED CONTROL
DESCRIPTION N-m Ft. Lbs. In. Lbs.
Servo Mounting Bracket-
to-Servo Nuts
8.5 - 75
Speed Control Switch
Mounting Screws
1.5 - 14
Vacuum Reservoir
Mounting Bolt (screw)
1.2 - 10
8P - 2 SPEED CONTROL TJ
SPEED CONTROL (Continued)
CABLE
DESCRIPTION
The speed control servo cabl e i s connected between
the speed control vacuum servo di aphragm and the
throttl e body control l i nkage.
OPERATION
Thi s cabl e causes the throttl e control l i nkage to
open or cl ose the throttl e val ve i n response to move-
ment of the vacuum servo di aphragm.
REMOVAL
2. 4L
(1) Di sconnect negati ve battery cabl e at battery.
(2) Hol d throttl e i n wi de open posi ti on. Whi l e hel d
i n thi s posi ti on, sl i de throttl e control cabl e pi n (Fi g.
1) from throttl e body bel l crank. Al so sl i de servo cabl e
pi n from throttl e body bel l crank.
(3) Usi ng a pi ck or smal l screwdri ver, press rel ease
tab (Fi g. 1) to rel ease pl asti c cabl e mount from
bracket. Press on tab only enough to release
cable from bracket. If tab is pressed too much,
it will be broken. To remove throttl e cabl e from
throttl e body bracket, sl i de cabl e towards front of
vehi cl e.
(4) After removi ng throttl e control cabl e at throttl e
body, sl i de servo cabl e from throttl e body.
(5) I f necessary, di sconnect opposi te end of servo
cabl e at servo. Refer to Servo Removal /I nstal l ati on.
4. 0L
(1) Di sconnect negati ve battery cabl e at battery.
(2) Usi ng fi nger pressure onl y, remove cabl e con-
nector by pushi ng connector off the throttl e body
bel l crank pi n (Fi g. 2). DO NOT try to pull cable
connector off perpendicular to the bellcrank
pin. Connector will be broken.
(3) Two rel ease tabs are l ocated on si des of speed
control cabl e at cabl e bracket (Fi g. 2). Squeeze tabs
together and push cabl e out of bracket.
(4) Uncl i p cabl e from cabl e gui de at val ve cover.
(5) I f necessary, di sconnect opposi te end of servo
cabl e at servo. Refer to Servo Removal /I nstal l ati on.
INSTALLATION
2. 4L
(1) I nstal l end of cabl e to speed control servo.
Refer to Servo Removal /I nstal l ati on.
(2) Sl i de speed control cabl e pl asti c mount i nto
throttl e body bracket.
(3) I nstal l speed control cabl e connector onto throt-
tl e body bel l crank pi n (push rearward to snap i nto
l ocati on).
Fig. 1 SERVO CABLE AT THROTTLE BODY - 2.4L
1 - MOUNTING BRACKET
2 - SPEED CONTROL CABLE
3 - THROTTLE CABLE
4 - RELEASE TAB
5 - CABLE PINS
6 - BELLCRANK
Fig. 2 SERVO CABLE AT THROTTLE BODY - 4.0L
1 - ACCELERATOR CABLE
2 - OFF
3 - OFF
4 - THROTTLE BODY BELLCRANK
5 - SPEED CONTROL CABLE
6 - RELEASE TABS
7 - BRACKET
TJ SPEED CONTROL 8P - 3
(4) Sl i de throttl e (accel erator) cabl e pl asti c mount
i nto throttl e body bracket. Conti nue sl i di ng unti l
cabl e rel ease tab i s al i gned to hol e i n throttl e body
mounti ng bracket.
(5) Whi l e hol di ng throttl e to wi de open posi ti on,
pl ace throttl e cabl e pi n i nto throttl e body bel l crank.
(6) Connect negati ve battery cabl e at battery.
(7) Before starti ng engi ne, operate accel erator
pedal to check for any bi ndi ng.
4. 0L
(1) Attach end of cabl e to speed control servo.
Refer to Servo Removal /I nstal l ati on.
(2) I nstal l cabl e i nto cabl e bracket (snaps i n).
(3) I nstal l cabl e connector at throttl e body
bel l crank pi n (snaps on).
(4) Cl i p cabl e to cabl e gui de at val ve cover.
(5) Connect negati ve battery cabl e to battery.
(6) Before starti ng engi ne, operate accel erator
pedal to check for any bi ndi ng.
SERVO
DESCRIPTION
The servo uni t consi sts of a sol enoi d val ve body,
and a vacuum chamber. The sol enoi d val ve body con-
tai ns three sol enoi ds:
• Vacuum
• Vent
• Dump
The vacuum chamber contai ns a di aphragm wi th a
cabl e attached to control the throttl e l i nkage.
OPERATION
The Powertrai n Control Modul e (PCM) control s the
sol enoi d val ve body. The sol enoi d val ve body control s
the appl i cati on and rel ease of vacuum to the di a-
phragm of the vacuum servo. The servo uni t cannot
be repai red and i s servi ced onl y as a compl ete assem-
bl y.
Power i s suppl i ed to the servo’s by the PCM
through the brake swi tch. The PCM control s the
ground path for the vacuum and vent sol enoi ds.
The dump sol enoi d i s energi zed anyti me i t recei ves
power. I f power to the dump sol enoi d i s i nterrupted,
the sol enoi d dumps vacuum i n the servo. Thi s pro-
vi des a safety backup to the vent and vacuum sol e-
noi ds.
The vacuum and vent sol enoi ds must be grounded
at the PCM to operate. When the PCM grounds the
vacuum servo sol enoi d, the sol enoi d al l ows vacuum
to enter the servo and pul l open the throttl e pl ate
usi ng the cabl e. When the PCM breaks the ground,
the sol enoi d cl oses and no more vacuum i s al l owed to
enter the servo. The PCM al so operates the vent sol e-
noi d vi a ground. The vent sol enoi d opens and cl oses a
passage to bl eed or hol d vacuum i n the servo as
requi red.
The PCM duty cycl es the vacuum and vent sol e-
noi ds to mai ntai n the set speed, or to accel erate and
decel erate the vehi cl e. To i ncrease throttl e openi ng,
the PCM grounds the vacuum and vent sol enoi ds. To
decrease throttl e openi ng, the PCM removes the
grounds from the vacuum and vent sol enoi ds. When
the brake i s rel eased, i f vehi cl e speed exceeds 30
mph to resume, 35 mph to set, and the RES/ACCEL
swi tch has been depressed, ground for the vent and
vacuum ci rcui ts i s restored.
REMOVAL
(1) Di sconnect negati ve battery cabl e at battery.
(2) Di sconnect vacuum l i ne at servo (Fi g. 3).
(3) Di sconnect el ectri cal connector at servo.
(4) Di sconnect servo cabl e at throttl e body. Refer to
Cabl e Removal /I nstal l ati on.
(5) Remove three bracket mounti ng bol ts (Fi g. 3).
Fig. 3 SPEED CONTROL SERVO LOCATION
1 - BRAKE POWER BOOSTER
2 - VACUUM LINE
3 - SERVO
4 - BRACKET BOLTS (3)
5 - SERVO MOUNTING BRACKET
8P - 4 SPEED CONTROL TJ
CABLE (Continued)
(6) Remove 2 mounti ng nuts hol di ng servo cabl e
sl eeve to bracket (Fi g. 4).
(7) Pul l speed control cabl e sl eeve and servo away
from servo mounti ng bracket to expose cabl e retai n-
i ng cl i p (Fi g. 4) and remove cl i p. Note: The servo
mounti ng bracket di spl ayed i n (Fi g. 4) i s a typi cal
bracket and may/may not be appl i cabl e to thi s model
vehi cl e.
(8) Remove servo from mounti ng bracket. Whi l e
removi ng, note ori entati on of servo to bracket.
INSTALLATION
(1) Posi ti on servo to mounti ng bracket.
(2) Al i gn hol e i n cabl e connector wi th hol e i n servo
pi n. I nstal l cabl e-to-servo retai ni ng cl i p.
(3) I nsert servo mounti ng studs through hol es i n
servo mounti ng bracket.
(4) I nstal l servo mounti ng nuts and ti ghten to 8.5
N·m (75 i n. l bs.).
(5) Connect vacuum l i ne at servo.
(6) Connect el ectri cal connector at servo.
(7) Connect servo cabl e to throttl e body. Refer to
Cabl e Removal /I nstal l ati on.
(8) Connect negati ve battery cabl e to battery.
(9) Before starti ng engi ne, operate accel erator
pedal to check for any bi ndi ng.
SWITCH
DESCRIPTION
There are two separate swi tch pods that operate
the speed control system. The steeri ng-wheel -
mounted swi tches use mul ti pl exed ci rcui ts to provi de
i nputs to the PCM for ON, OFF, RESUME, ACCEL-
ERATE, SET, DECEL and CANCEL modes. Refer to
the owner’s manual for more i nformati on on speed
control swi tch functi ons and setti ng procedures.
The i ndi vi dual swi tches cannot be repai red. I f one
swi tch fai l s, the enti re swi tch modul e must be
repl aced.
OPERATION
When speed control i s sel ected by depressi ng the
ON, OFF swi tch, the PCM al l ows a set speed to be
stored i n i ts RAM for speed control . To store a set
speed, depress the SET swi tch whi l e the vehi cl e i s
movi ng at a speed between approxi matel y 35 and 85
mph. I n order for the speed control to engage, the
brakes cannot be appl i ed, nor can the gear sel ector
be i ndi cati ng the transmi ssi on i s i n Park or Neutral .
The speed control can be di sengaged manual l y by:
• Steppi ng on the brake pedal
• Depressi ng the OFF swi tch
• Depressi ng the CANCEL swi tch.
The speed control can be di sengaged al so by any of
the fol l owi ng condi ti ons:
• An i ndi cati on of Park or Neutral
• The VSS si gnal i ncreases at a rate of 10 mph
per second (i ndi cates that the co-effi ci ent of fri cti on
between the road surface and ti res i s extremel y l ow)
• Depressi ng the cl utch pedal .
• Excessi ve engi ne rpm (i ndi cates that the trans-
mi ssi on may be i n a l ow gear)
• The VSS si gnal decreases at a rate of 10 mph
per second (i ndi cates that the vehi cl e may have
decel erated at an extremel y hi gh rate)
• I f the actual speed i s not wi thi n 20 mph of the
set speed
The previ ous di sengagement condi ti ons are pro-
grammed for added safety.
Once the speed control has been di sengaged,
depressi ng the ACCEL swi tch restores the vehi cl e to
the target speed that was stored i n the PCM’s RAM.
Fig. 4 SERVO CABLE CLIP REMOVE/INSTALL -
TYPICAL
1 - SERVO MOUNTING NUTS (2)
2 - SERVO
3 - CABLE RETAINING CLIP
4 - SERVO CABLE AND SLEEVE
TJ SPEED CONTROL 8P - 5
SERVO (Continued)
NOTE: Depressing the OFF switch will erase the set
speed stored in the PCM’s RAM.
I f, whi l e the speed control i s engaged, the dri ver
wi shes to i ncrease vehi cl e speed, the PCM i s pro-
grammed for an accel erati on feature. Wi th the
ACCEL swi tch hel d cl osed, the vehi cl e accel erates
sl owl y to the desi red speed. The new target speed i s
stored i n the PCM’s RAM when the ACCEL swi tch i s
rel eased. The PCM al so has a Љtap-upЉ feature i n
whi ch vehi cl e speed i ncreases at a rate of approxi -
matel y 2 mph for each momentary swi tch acti vati on
of the ACCEL swi tch.
The PCM al so provi des a means to decel erate wi th-
out di sengagi ng speed control . To decel erate from an
exi sti ng recorded target speed, depress and hol d the
COAST swi tch unti l the desi red speed i s reached.
Then rel ease the swi tch. The ON, OFF swi tch oper-
ates two components: the PCM’s ON, OFF i nput, and
the battery vol tage to the brake swi tch, whi ch powers
the speed control servo.
Multiplexing
The PCM sends out 5 vol ts through a fi xed resi stor
and moni tors the vol tage change between the fi xed
resi stor and the swi tches. I f none of the swi tches are
depressed, the PCM wi l l measure 5 vol ts at the sen-
sor poi nt (open ci rcui t). I f a swi tch wi th no resi stor i s
cl osed, the PCM wi l l measure 0 vol ts (grounded ci r-
cui t). Now, i f a resi stor i s added to a swi tch, then the
PCM wi l l measure some vol tage proporti onal to the
si ze of the resi stor. By addi ng a di fferent resi stor to
each swi tch, the PCM wi l l see a di fferent vol tage
dependi ng on whi ch swi tch i s pushed.
Another resi stor has been added to the ’at rest ci r-
cui t’ causi ng the PCM to never see 5 vol ts. Thi s was
done for di agnosti c purposes. I f the swi tch ci rcui t
shoul d open (bad connecti on), then the PCM wi l l see
the 5 vol ts and know the ci rcui t i s bad. The PCM wi l l
then set an open ci rcui t faul t.
REMOVAL
WARNING: BEFORE ATTEMPTING TO DIAGNOSE,
REMOVE OR INSTALL ANY AIRBAG SYSTEM OR
RELATED STEERING WHEEL AND STEERING COL-
UMN COMPONENTS, YOU MUST FIRST DISCON-
NECT AND ISOLATE THE BATTERY NEGATIVE
(GROUND) CABLE. WAIT 2 MINUTES FOR SYSTEM
CAPACITOR TO DISCHARGE BEFORE FURTHER
SYSTEM SERVICE. FAILURE TO DO SO COULD
RESULT IN ACCIDENTAL DEPLOYMENT AND POS-
SIBLE PERSONAL INJURY.
(1) Di sconnect and i sol ate negati ve battery cabl e
from battery.
(2) Remove ai rbag modul e. Refer to 8, Passi ve
Restrai nt Systems.
(3) From undersi de of steeri ng wheel , remove
speed control swi tch mounti ng screw (Fi g. 5).
(4) Remove swi tch from steeri ng wheel and unpl ug
el ectri cal connector.
INSTALLATION
(1) Pl ug el ectri cal connector i nto swi tch.
(2) Posi ti on swi tch to steeri ng wheel .
(3) I nstal l swi tch mounti ng screw and ti ghten to
1.5 N·m (14 i n. l bs.) torque.
(4) I nstal l ai rbag modul e. Refer to 8, Passi ve
Restrai nt Systems.
(5) Connect negati ve battery cabl e to battery.
Fig. 5 Speed Control Switches - Remove / Install
1 - MOUNTING SCREW
2 - SPEED CONTROL SWITCHES
8P - 6 SPEED CONTROL TJ
SWITCH (Continued)
VACUUM RESERVOIR
DESCRIPTION
The vacuum reservoi r i s a pl asti c storage tank con-
nected to an engi ne vacuum source by vacuum l i nes.
OPERATION
The vacuum reservoi r i s used to suppl y the vac-
uum needed to mai ntai n proper speed control opera-
ti on when engi ne vacuum drops, such as i n cl i mbi ng
a grade whi l e dri vi ng. A one-way check val ve i s used
i n the vacuum l i ne between the reservoi r and the
vacuum source. Thi s check val ve i s used to trap
engi ne vacuum i n the reservoi r. On certai n vehi cl e
appl i cati ons, thi s reservoi r i s shared wi th the heat-
i ng/ai r-condi ti oni ng system. The vacuum reservoi r
cannot be repai red and must be repl aced i f faul ty.
DIAGNOSIS AND TESTING - VACUUM
RESERVOIR
(1) Di sconnect vacuum hose at speed control servo
and i nstal l a vacuum gauge i nto the di sconnected
hose.
(2) Start engi ne and observe gauge at i dl e. Vac-
uum gauge shoul d read at l east ten i nches of mer-
cury.
(3) I f vacuum i s l ess than ten i nches of mercury,
determi ne source of l eak. Check vacuum l i ne to
engi ne for l eaks. Al so check actual engi ne i ntake
mani fol d vacuum. I f mani fol d vacuum does not meet
thi s requi rement, check for poor engi ne performance
and repai r as necessary.
(4) I f vacuum l i ne to engi ne i s not l eaki ng, check
for l eak at vacuum reservoi r. To l ocate and gai n
access to reservoi r, refer to Vacuum Reservoi r Remov-
al /I nstal l ati on i n thi s group. Di sconnect vacuum l i ne
at reservoi r and connect a hand-operated vacuum
pump to reservoi r fi tti ng. Appl y vacuum. Reservoi r
vacuum shoul d not bl eed off. I f vacuum i s bei ng l ost,
repl ace reservoi r.
(5) Veri fy operati on of one-way check val ve and
check i t for l eaks.
(a) Locate one-way check val ve. The val ve i s
l ocated i n vacuum l i ne between vacuum reservoi r
and engi ne vacuum source. Di sconnect vacuum
hoses (l i nes) at each end of val ve.
(b) Connect a hand-operated vacuum pump to
reservoi r end of check val ve. Appl y vacuum. Vac-
uum shoul d not bl eed off. I f vacuum i s bei ng l ost,
repl ace one-way check val ve.
(c) Connect a hand-operated vacuum pump to
vacuum source end of check val ve. Appl y vacuum.
Vacuum shoul d fl ow through val ve. I f vacuum i s
not fl owi ng, repl ace one-way check val ve. Seal the
fi tti ng at opposi te end of val ve wi th a fi nger and
appl y vacuum. I f vacuum wi l l not hol d, di aphragm
wi thi n check val ve has ruptured. Repl ace val ve.
REMOVAL
The vacuum reservoi r i s l ocated under the vehi cl e
battery tray (Fi g. 6).
(1) Remove battery and battery tray. Refer to Bat-
tery Removal /I nstal l ati on.
(2) Di sconnect vacuum suppl y l i ne at reservoi r
(Fi g. 6).
(3) Remove screw securi ng reservoi r to i nner
fender.
(4) Remove reservoi r from vehi cl e.
INSTALLATION
The vacuum reservoi r i s l ocated under the vehi cl e
battery tray (Fi g. 6).
(1) Posi ti on reservoi r to vehi cl e and i nstal l mount-
i ng screw.
(2) Ti ghten screw to 1.2 N·m (10 i n. l bs.) torque.
(3) Connect vacuum l i ne to reservoi r.
(4) I nstal l battery and battery tray. Refer to Bat-
tery Removal /I nstal l ati on.
Fig. 6 Vacuum Reservoir Removal/Installation
1 - SCREW
2 - VACUUM CHECK VALVE (2)
3 - VACUUM LINE RETAINER (2)
4 - ACCESSORY VACUUM SUPPLY LINE
5 - ENGINE VACUUM FITTING
6 - HVAC VACUUM SUPPLY LINE
7 - INNER FENDER
8 - VACUUM RESERVOIR
TJ SPEED CONTROL 8P - 7
VEHICLE THEFT SECURITY
TABLE OF CONTENTS
page page
VEHICLE THEFT SECURITY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DIAGNOSIS AND TESTING - SENTRY KEY
IMMOBILIZER SYSTEM . . . . . . . . . . . . . . . . . . 2
STANDARD PROCEDURE
STANDARD PROCEDURE - SKIS
INITIALIZATION . . . . . . . . . . . . . . . . . . . . . . . . 4
STANDARD PROCEDURE - SENTRY KEY
TRANSPONDER PROGRAMMING. . . . . . . . . . 4
SKIS INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 5
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
TRANSPONDER KEY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 6
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
VEHICLE THEFT SECURITY
DESCRIPTION
The Sentry Key I mmobi l i zer System (SKI S) i s
avai l abl e as a factory-i nstal l ed opti on on thi s model .
Vehi cl es equi pped wi th thi s opti on can be readi l y
i denti fi ed by the presence of an amber SKI S i ndi ca-
tor i n the i nstrument cl uster that wi l l i l l umi nate for
about three seconds each ti me the i gni ti on swi tch i s
turned to the On posi ti on, or by a gray mol ded rub-
ber cap on the head of the i gni ti on key. Model s not
equi pped wi th SKI S sti l l have a SKI S i ndi cator i n
the cl uster, but i t wi l l not i l l umi nate when the i gni -
ti on swi tch i s turned to the On posi ti on. Al so, model s
not equi pped wi th the SKI S have a bl ack mol ded
rubber cap on the head of the i gni ti on key.
The SKI S i ncl udes the fol l owi ng major components,
whi ch are descri bed i n further detai l el sewhere i n
thi s servi ce manual :
• Powertrain Control Module (PCM) - The
PCM i s l ocated on the ri ght si de of the dash panel i n
the engi ne compartment.
• Sentry Key Immobilizer Module (SKIM) -
The SKI M i s l ocated on the steeri ng col umn near the
i gni ti on l ock cyl i nder housi ng and an i ntegral mol ded
pl asti c antenna ri ng ci rcl es the i gni ti on l ock cyl i nder
l i ke a hal o. The SKI M and i ts antenna are conceal ed
beneath the steeri ng col umn shrouds.
• Sentry Key Transponder - The Sentry Key
transponder i s mol ded i nto the head of the i gni ti on
key, and conceal ed by a gray mol ded rubber cap.
• SKIS Indicator - The SKI S i ndi cator i s l ocated
i n the upper l eft corner of the i nstrument cl uster
overl ay.
Except for the Sentry Key transponders, whi ch rel y
upon Radi o Frequency (RF) communi cati on, hard
wi red ci rcui try connects the SKI S components to the
el ectri cal system of the vehi cl e. These hard wi red ci r-
cui ts are i ntegral to several wi re harnesses, whi ch
are routed throughout the vehi cl e and retai ned by
many di fferent methods. These ci rcui ts may be con-
nected to each other, to the vehi cl e el ectri cal system
and to the SKI S components through the use of a
combi nati on of sol dered spl i ces, spl i ce bl ock connec-
tors, and many di fferent types of wi re harness termi -
nal connectors and i nsul ators. Refer to the
appropri ate wi ri ng i nformati on. The wi ri ng i nforma-
ti on i ncl udes wi ri ng di agrams, proper wi re and con-
nector repai r procedures, further detai l s on wi re
harness routi ng and retenti on, as wel l as pi n-out and
l ocati on vi ews for the vari ous wi re harness connec-
tors, spl i ces and grounds.
OPERATION
The Sentry Key I mmobi l i zer System (SKI S) i s
desi gned to provi de passi ve protecti on agai nst unau-
thori zed vehi cl e use by di sabl i ng the engi ne, after
about two seconds of runni ng, whenever any method
other than a val i d Sentry Key i s used to start the
vehi cl e. The SKI S i s consi dered a passi ve protecti on
system because i t i s al ways acti ve when the i gni ti on
system i s energi zed and does not requi re any cus-
tomer i nterventi on. The SKI S uses Radi o Frequency
(RF) communi cati on to obtai n confi rmati on that the
key i n the i gni ti on swi tch i s a val i d key for operati ng
the vehi cl e. The mi croprocessor-based SKI S hard-
ware and software al so uses el ectroni c messages to
communi cate wi th other el ectroni c modul es i n the
vehi cl e over the Programmabl e Communi cati ons
I nterface (PCI ) data bus (Refer to 8 - ELECTRI CAL/
ELECTRONI C CONTROL MODULES/COMMUNI -
CATI ON - OPERATI ON).
TJ VEHICLE THEFT SECURITY 8Q - 1
Pre-programmed Sentry Key transponders are pro-
vi ded wi th the vehi cl e from the factory. Each Sentry
Key I mmobi l i zer Modul e (SKI M) wi l l recogni ze a
maxi mum of ei ght Sentry Keys. I f the customer
woul d l i ke addi ti onal keys other than those provi ded
wi th the vehi cl e, they may be purchased from any
authori zed deal er. These addi ti onal keys must be pro-
grammed to the SKI M i n the vehi cl e i n order for the
system to recogni ze them as val i d keys. Thi s can be
done by the deal er usi ng a DRBI I I ௡ scan tool or, i f
Customer Learn programmi ng i s an avai l abl e SKI S
feature i n the market where the vehi cl e was pur-
chased, the customer can program the addi ti onal
keys, as l ong as at l east two val i d Sentry Keys are
al ready avai l abl e. (Refer to 8 - ELECTRI CAL/VEHI -
CLE THEFT SECURI TY - STANDARD PROCE-
DURE - SENTRY KEY TRANSPONDER
PROGRAMMI NG).
The SKI S performs a sel f-test each ti me the i gni -
ti on swi tch i s turned to the On posi ti on, and wi l l
store faul t i nformati on i n the form of Di agnosti c
Troubl e Codes (DTC’s) i f a system mal functi on i s
detected. The SKI S can be di agnosed, and any stored
DTC’s can be retri eved usi ng a DRBI I I ௡ scan tool .
Refer to the appropri ate di agnosti c i nformati on.
DIAGNOSIS AND TESTING - SENTRY KEY
IMMOBILIZER SYSTEM
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
SENTRY KEY IMMOBILIZER SYSTEM DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
SKIS INDICATOR FAILS TO
LIGHT DURING BULB TEST
1. Indicator faulty. 1. Test and replace the faulty instrument cluster
or bulb as required.
2. Fuse faulty. 2. Test and replace the SKIM fused B(+) and
fused ignition switch output (run-start) fuses in the
fuse block as required.
3. Ground circuit faulty. 3. Test and repair the SKIM ground circuit as
required.
4. Fused B(+) circuit faulty. 4. Test and repair the SKIM fused B(+) circuit as
required.
5. Fised ignition switch
output circuit faulty.
5. Terst and repair the SKIM fused ignition switch
output (run-start) circuit as required.
SKIS INDICATOR FLASHES
WHEN IGNITION SWITCH IS
TURNED TO THE ЉONЉ
POSITION
1. Invalid key in ignition
switch lock cylinder.
1. Replace the key with a known valid key.
2. Key-related fault. 2. Use a DRBIIIா scan tool to diagnose the
key-related fault. Refer to the appropriate
diagnostic information.
SKIS INDICATOR LIGHTS
SOLID FOLLOWING BULB
TEST
1. SKIS system malfunction/
fault detected.
1. Use a DRBIIIா scan tool to diagnose the SKIS.
Refer to the appropriate diagnostic information.
8Q - 2 VEHICLE THEFT SECURITY TJ
VEHICLE THEFT SECURITY (Continued)
SKIS INDICATOR FAILS TO LIGHT DURING BULB TEST
I f the Sentry Key I mmobi l i zer System (SKI S) i ndi -
cator i n the i nstrument cl uster fai l s to i l l umi nate for
about three seconds after the i gni ti on swi tch i s
turned to the On posi ti on (bul b test), perform the
i nstrument cl uster actuator test. (Refer to 8 - ELEC-
TRI CAL/I NSTRUMENT CLUSTER - DI AGNOSI S
AND TESTI NG - ACTUATOR TEST). I f the SKI S
i ndi cator sti l l fai l s to l i ght duri ng the bul b test, a
wi ri ng probl em resul ti ng i n the l oss of battery cur-
rent or ground to the Sentry Key I mmobi l i zer Modul e
(SKI M) shoul d be suspected, and the fol l owi ng proce-
dure shoul d be used for di agnosi s. Refer to the appro-
pri ate wi ri ng i nformati on. The wi ri ng i nformati on
i ncl udes wi ri ng di agrams, proper wi re and connector
repai r procedures, detai l s of wi re harness routi ng
and retenti on, connector pi n-out i nformati on and
l ocati on vi ews for the vari ous wi re harness connec-
tors, spl i ces and grounds.
NOTE: The following tests may not prove conclu-
sive in the diagnosis of this system. The most reli-
able, efficient, and accurate means to diagnose the
Sentry Key Immobilizer System requires the use of
a DRBIIIா scan tool. Refer to the appropriate diag-
nostic information.
(1) Check the B(+) fuse (Fuse 1 - 20 ampere) i n the
fuse bl ock. I f OK, go to Step 2. I f not OK, repai r the
shorted ci rcui t or component as requi red and repl ace
the faul ty fuse.
(2) Check for battery vol tage at the B(+) fuse
(Fuse 1 - 20 ampere) i n the fuse bl ock. I f OK, go to
Step 3. I f not OK, repai r the open B(+) ci rcui t
between the fuse bl ock and the battery as requi red.
(3) Check the i gni ti on swi tch output (run-start)
fuse (Fuse 12 - 10 ampere) i n the fuse bl ock. I f OK,
go to Step 4. I f not OK, repai r the shorted ci rcui t or
component as requi red and repl ace the faul ty fuse.
(4) Turn the i gni ti on swi tch to the On posi ti on.
Check for battery vol tage at the fused i gni ti on swi tch
output (run-start) fuse (Fuse 12 - 10 ampere) i n the
fuse bl ock. I f OK, go to Step 5. I f not OK, repai r the
open fused i gni ti on swi tch output (run-start) ci rcui t
between the fuse bl ock and the i gni ti on swi tch as
requi red.
(5) Di sconnect and i sol ate the battery negati ve
cabl e. Di sconnect the i nstrument panel wi re harness
connector for the Sentry Key I mmobi l i zer Modul e
(SKI M) from the SKI M connector receptacl e. Check
for conti nui ty between each of the two ground ci rcui t
cavi ti es of the i nstrument panel wi re harness connec-
tor for the SKI M and a good ground. There shoul d be
conti nui ty. I f OK, go to Step 6. I f not OK, repai r the
open ground ci rcui t(s) to ground (G105 and G302) as
requi red.
(6) Reconnect the battery negati ve cabl e. Check for
battery vol tage at the fused B(+) ci rcui t cavi ty of the
i nstrument panel wi re harness connector for the
SKI M. I f OK, go to Step 7. I f not OK, repai r the open
fused B(+) ci rcui t between the SKI M and the fuse
bl ock as requi red.
(7) Turn the i gni ti on swi tch to the On posi ti on.
Check for battery vol tage at the fused i gni ti on swi tch
output (run-start) ci rcui t cavi ty of the i nstrument
panel wi re harness connector for the SKI M. I f OK,
use a DRBI I I ௡ scan tool to compl ete the di agnosi s of
the SKI S. Refer to the appropri ate di agnosti c i nfor-
mati on. I f not OK, repai r the open fused i gni ti on
swi tch output (run-start) ci rcui t between the SKI M
and the fuse bl ock as requi red.
SKIS INDICATOR FLASHES OR LIGHTS SOLID FOLLOWING
BULB TEST
A SKI S i ndi cator that fl ashes fol l owi ng a successful
bul b test i ndi cates that an i nval i d key has been
detected, or that a key-rel ated faul t has been set. A
SKI S i ndi cator that l i ghts sol i d fol l owi ng a successful
bul b test i ndi cates that the SKI M has detected a sys-
tem mal functi on or that the SKI S i s i noperati ve. I n
ei ther case, faul t i nformati on wi l l be stored i n the
SKI M memory. For retri eval of thi s faul t i nformati on
and further di agnosi s of the SKI S, the PCI data bus,
the SKI M message outputs to the i nstrument cl uster
that control the SKI S i ndi cator and/or chi me servi ce,
or the message i nputs and outputs between the
SKI M and the Powertrai n Control Modul e (PCM)
that control engi ne operati on, a DRBI I I ௡ scan tool i s
requi red. Refer to the appropri ate di agnosti c i nfor-
mati on. Fol l owi ng are prel i mi nary troubl eshooti ng
gui del i nes to be fol l owed duri ng di agnosi s usi ng a
DRBI I I ௡ scan tool :
(1) Usi ng the DRBI I I ௡ scan tool , read and record
the faul ts as they exi st i n the SKI M when you fi rst
begi n your di agnosi s of the vehi cl e. I t i s i mportant to
document these faul ts because the SKI M does not
di fferenti ate between hi stori cal faul ts (those that
have occurred i n the past) and acti ve faul ts (those
that are currentl y present). I f thi s probl em turns out
to be an i ntermi ttent condi ti on, thi s i nformati on may
become i nval uabl e to your di agnosi s.
(2) Usi ng the DRBI I I ௡ scan tool , erase al l of the
faul ts from the SKI M.
(3) Cycl e the i gni ti on swi tch to the Off posi ti on,
then back to the On posi ti on.
(4) Usi ng the DRBI I I ௡ scan tool , read any faul ts
that are now present i n the SKI M. These are the
acti ve faul ts.
(5) Usi ng thi s acti ve faul t i nformati on, refer to the
proper procedure i n the appropri ate di agnosti c i nfor-
mati on for the addi ti onal speci fi c di agnosti c steps.
TJ VEHICLE THEFT SECURITY 8Q - 3
VEHICLE THEFT SECURITY (Continued)
STANDARD PROCEDURE
STANDARD PROCEDURE - SKIS
INITIALIZATION
The Sentry Key I mmobi l i zer System (SKI S) must
be i ni ti al i zed fol l owi ng a Sentry Key I mmobi l i zer
Modul e (SKI M) repl acement. SKI S i ni ti al i zati on
requi res the use of a DRBI I I ௡ scan tool . I ni ti al i zati on
wi l l al so requi re that you have access to the uni que
four-di gi t PI N code that was assi gned to the ori gi nal
SKI M. The PI N code must be used to enter the
Secured Access Mode i n the SKI M. Thi s PI N number
may be obtai ned from the vehi cl e owner, from the
ori gi nal vehi cl e i nvoi ce, or from the Dai ml erChrysl er
Customer Center. (Refer to 8 - ELECTRI CAL/ELEC-
TRONI C CONTROL MODULES - STANDARD PRO-
CEDURE - PCM/SKI M PROGRAMMI NG).
NOTE: If a Powertrain Control Module (PCM) is
replaced on a vehicle equipped with the Sentry Key
Immobilizer System (SKIS), the unique Secret Key
data must be transferred from the Sentry Key
Immobilizer Module (SKIM) to the new PCM using
the PCM replacement procedure. This procedure
also requires the use of a DRBIIIா scan tool and the
unique four-digit PIN code to enter the Secured
Access Mode in the SKIM. Refer to the appropriate
diagnostic information for the proper PCM replace-
ment procedures.
STANDARD PROCEDURE - SENTRY KEY
TRANSPONDER PROGRAMMING
Al l Sentry Keys i ncl uded wi th the vehi cl e are pre-
programmed to work wi th the Sentry Key I mmobi -
l i zer System (SKI S) when i t i s shi pped from the
factory. The Sentry Key I mmobi l i zer Modul e (SKI M)
can be programmed to recogni ze up to a total of ei ght
Sentry Keys. When programmi ng a bl ank Sentry Key
transponder, the key must fi rst be cut to match the
i gni ti on swi tch l ock cyl i nder i n the vehi cl e for whi ch
i t wi l l be used. Once the addi ti onal or new key has
been cut, the SKI M must be programmed to recog-
ni ze i t as a val i d key. There are two possi bl e methods
to program the SKI M to recogni ze a new or addi -
ti onal val i d key, the Secured Access Method and the
Customer Learn Method. Fol l owi ng are the detai l s of
these two programmi ng methods.
SECURED ACCESS METHOD
The Secured Access method appl i es to al l vehi cl es.
Thi s method requi res the use of a DRBI I I ௡ scan tool .
Thi s method wi l l al so requi re that you have access to
the uni que four-di gi t PI N code that was assi gned to
the ori gi nal SKI M. The PI N code must be used to
enter the Secured Access Mode i n the SKI M. Thi s
PI N number may be obtai ned from the vehi cl e owner,
from the ori gi nal vehi cl e i nvoi ce, or from the
Dai ml erChrysl er Customer Center. Refer to the
appropri ate di agnosti c i nformati on for the proper
Secured Access method programmi ng procedures.
CUSTOMER LEARN METHOD
The Customer Learn feature i s onl y avai l abl e on
domesti c vehi cl es, or those vehi cl es whi ch have a
U.S. country code desi gnator. Thi s programmi ng
method al so requi res access to at l east two val i d Sen-
try Keys. I f two val i d Sentry Keys are not avai l abl e,
or i f the vehi cl e does not have a U.S. country code
desi gnator, the Secured Access Method must be used
to program new or addi ti onal val i d keys to the SKI M.
The Customer Learn programmi ng method proce-
dures are as fol l ows:
(1) Obtai n the bl ank Sentry Key(s) that are to be
programmed as val i d keys for the vehi cl e. Cut the
bl ank key(s) to match the i gni ti on swi tch l ock cyl i n-
der mechani cal key codes.
(2) I nsert one of the two val i d Sentry Keys i nto the
i gni ti on swi tch and turn the i gni ti on swi tch to the
On posi ti on.
(3) After the i gni ti on swi tch has been i n the On
posi ti on for l onger than three seconds, but no more
than fi fteen seconds, cycl e the i gni ti on swi tch back to
the Off posi ti on. Repl ace the fi rst val i d Sentry Key i n
the i gni ti on swi tch l ock cyl i nder wi th the second
val i d Sentry Key and turn the i gni ti on swi tch back to
the On posi ti on. The second val i d Sentry Key must
be i nserted i n the l ock cyl i nder wi thi n fi fteen seconds
of removi ng the fi rst val i d key.
(4) About ten seconds after the compl eti on of Step
3, the SKI S i ndi cator i n the i nstrument cl uster wi l l
start to fl ash and a si ngl e audi bl e chi me wi l l sound
to i ndi cate that the system has entered the Customer
Learn programmi ng mode.
(5) Wi thi n si xty seconds of enteri ng the Customer
Learn programmi ng mode, turn the i gni ti on swi tch to
the Off posi ti on, repl ace the val i d Sentry Key wi th a
bl ank Sentry Key transponder, and turn the i gni ti on
swi tch back to the On posi ti on.
(6) About ten seconds after the compl eti on of Step
5, a si ngl e audi bl e chi me wi l l sound and the SKI S
i ndi cator wi l l stop fl ashi ng, stay on sol i d for three
seconds, then turn off to i ndi cate that the bl ank Sen-
try Key has been successful l y programmed. The
SKI S wi l l i mmedi atel y exi t the Customer Learn pro-
grammi ng mode and the vehi cl e may now be started
usi ng the newl y programmed val i d Sentry Key.
8Q - 4 VEHICLE THEFT SECURITY TJ
VEHICLE THEFT SECURITY (Continued)
Each of these steps must be repeated and com-
pl eted i n thei r enti rety for each addi ti onal Sentry
Key that i s to be programmed. I f the above steps are
not compl eted i n the gi ven sequence, or wi thi n the
al l otted ti me, the SKI S wi l l exi t the Customer Learn
programmi ng mode and the programmi ng wi l l be
unsuccessful . The SKI S wi l l al so automati cal l y exi t
the Customer Learn programmi ng mode i f i t sees a
non-bl ank Sentry Key transponder when i t shoul d
see a bl ank, i f i t has al ready programmed ei ght (8)
val i d Sentry Keys, or i f the i gni ti on swi tch i s turned
to the Off posi ti on for more than about fi fty seconds.
NOTE: If an attempt is made to start the vehicle
while in the Customer Learn mode (SKIS indicator
flashing), the SKIS will respond as though the vehi-
cle were being started with an invalid key. In other
words, the engine will stall after about two seconds
of operation. No faults will be set.
NOTE: Once a Sentry Key has been programmed as
a valid key to a vehicle, it cannot be programmed
as a valid key for use on any other vehicle.
SKIS INDICATOR
DESCRIPTION
A Sentry Key I mmobi l i zer System (SKI S) i ndi cator
i s standard equi pment on al l i nstrument cl usters, but
i s onl y operati onal on vehi cl es equi pped wi th the
opti onal SKI S. The SKI S i ndi cator i s l ocated near the
upper edge of the i nstrument cl uster overl ay, i n the
upper l eft quadrant of the cl uster. The SKI S i ndi ca-
tor consi sts of a stenci l -l i ke cutout of a graphi cal rep-
resentati on or i con of a key that i s ci rcl ed and
crossed-out i n the opaque l ayer of the i nstrument
cl uster overl ay. The dark outer l ayer of the overl ay
prevents the i ndi cator from bei ng cl earl y vi si bl e
when i t i s not i l l umi nated. An amber l ens behi nd the
cutout i n the opaque l ayer of the overl ay causes the
i ndi cator to appear i n amber through the transl ucent
outer l ayer of the overl ay when i t i s i l l umi nated from
behi nd by a Li ght Emi tti ng Di ode (LED) sol dered
onto the i nstrument cl uster el ectroni c ci rcui t board.
The SKI S i ndi cator i s servi ced as a uni t wi th the
i nstrument cl uster.
OPERATION
The Sentry Key I mmobi l i zer System (SKI S) i ndi ca-
tor gi ves an i ndi cati on to the vehi cl e operator of the
status of the SKI S. Thi s i ndi cator i s control l ed by the
i nstrument cl uster el ectroni c ci rcui t board based
upon el ectroni c messages recei ved by the cl uster from
the Sentry Key I mmobi l i zer Modul e (SKI M) over the
Programmabl e Communi cati ons I nterface (PCI ) data
bus. The SKI S i ndi cator Li ght Emi tti ng Di ode (LED)
recei ves battery current on the i nstrument cl uster
el ectroni c ci rcui t board through the fused i gni ti on
swi tch output (run-start) ci rcui t whenever the i gni -
ti on swi tch i s i n the On or Start posi ti ons; therefore,
the i ndi cator wi l l al ways be off when the i gni ti on
swi tch i s i n any posi ti on except On or Start. The
LED onl y i l l umi nates when i t i s swi tched to ground
by the i nstrument cl uster transi stor. The i nstrument
cl uster wi l l turn on the SKI S i ndi cator for the fol l ow-
i ng reasons:
• Bulb Test - Each ti me the i gni ti on swi tch i s
turned to the On posi ti on, the SKI M tel l s the cl uster
to i l l umi nate the SKI S i ndi cator for about three sec-
onds as a bul b test.
• SKIM Lamp-On Message - Each ti me the cl us-
ter recei ves a l amp-on message from the SKI M, the
SKI S i ndi cator wi l l be i l l umi nated. The i ndi cator can
be fl ashed on and off, or i l l umi nated sol i d, as di c-
tated by the SKI M message. For more i nformati on on
the SKI S and the SKI S i ndi cator control parameters,
(Refer to 8 - ELECTRI CAL/VEHI CLE THEFT SECU-
RI TY - OPERATI ON). The i ndi cator remai ns i l l umi -
nated unti l the cl uster recei ves a l amp-off message
from the SKI M or unti l the i gni ti on swi tch i s turned
to the Off posi ti on, whi chever occurs fi rst.
• Actuator Test - Each ti me the cl uster i s put
through the actuator test, the SKI S i ndi cator wi l l be
turned on, then off agai n i n a prescri bed sequence to
confi rm the functi onal i ty of the LED and the cl uster
control ci rcui try.
The SKI M performs a sel f-test each ti me the i gni -
ti on swi tch i s turned to the On posi ti on to deci de
whether the system i s i n good operati ng condi ti on.
The SKI M then sends the proper SKI S l amp-on or
l amp-off messages to the i nstrument cl uster. For fur-
ther di agnosi s of the SKI S i ndi cator or the i nstru-
ment cl uster ci rcui try that control s the i ndi cator,
(Refer to 8 - ELECTRI CAL/I NSTRUMENT CLUS-
TER - DI AGNOSI S AND TESTI NG). I f the i nstru-
ment cl uster turns on the SKI S i ndi cator after the
bul b test, ei ther sol i d or fl ashi ng, i t i ndi cates that a
SKI S mal functi on has occurred or that the SKI S i s
i noperati ve. For proper di agnosi s of the SKI S, the
PCI data bus, or the message i nputs to the i nstru-
ment cl uster that control the SKI S i ndi cator, a
DRBI I I ௡ scan tool i s requi red. Refer to the appropri -
ate di agnosti c i nformati on.
TJ VEHICLE THEFT SECURITY 8Q - 5
VEHICLE THEFT SECURITY (Continued)
TRANSPONDER KEY
DESCRIPTION
Each i gni ti on key used i n the Sentry Key I mmobi -
l i zer System (SKI S) has an i ntegral transponder chi p
(Fi g. 1). I gni ti on keys wi th thi s feature can be readi l y
i denti fi ed by a gray rubber cap mol ded onto the head
of the key, whi l e conventi onal i gni ti on keys have a
bl ack mol ded rubber cap. The transponder chi p i s
conceal ed beneath the mol ded rubber cap, where i t i s
mol ded wi thi n a pl asti c mount i nto the head of the
metal key. I n addi ti on to bei ng cut to match the
mechani cal codi ng of the i gni ti on l ock cyl i nder, each
new Sentry Key has a uni que transponder i denti fi ca-
ti on code permanentl y programmed i nto i t by the
manufacturer. The Sentry Key transponder cannot be
adjusted or repai red. I f faul ty or damaged, the enti re
key must be repl aced.
OPERATION
When the i gni ti on swi tch i s turned to the On posi -
ti on, the Sentry Key I mmobi l i zer Modul e (SKI M)
communi cates through i ts antenna wi th the Sentry
Key transponder usi ng a Radi o Frequency (RF) si g-
nal . The SKI M then l i stens for a RF response from
the transponder through the same antenna. The Sen-
try Key transponder chi p i s wi thi n the range of the
SKI M transcei ver antenna ri ng when i t i s i nserted
i nto the i gni ti on l ock cyl i nder. The SKI M determi nes
whether a val i d key i s present i n the i gni ti on l ock
cyl i nder based upon the response from the transpon-
der. I f a val i d key i s detected, that fact i s communi -
cated by the SKI M to the Powertrai n Control Modul e
(PCM) over the Programmabl e Communi cati ons
I nterface (PCI ) data bus, and the PCM al l ows the
engi ne to conti nue runni ng. I f the PCM recei ves an
i nval i d key message, or recei ves no message from the
SKI M over the PCI data bus, the engi ne wi l l be di s-
abl ed after about two seconds of operati on. The El ec-
troMechani cal I nstrument Cl uster (EMI C) wi l l al so
respond to the i nval i d key message on the PCI data
bus by fl ashi ng the SKI S i ndi cator on and off.
Each Sentry Key has a uni que transponder i denti -
fi cati on code permanentl y programmed i nto i t by the
manufacturer. Li kewi se, the SKI M has a uni que
Secret Key code programmed i nto i t by the manufac-
turer. When a Sentry Key i s programmed i nto the
memory of the SKI M, the SKI M stores the transpon-
der i denti fi cati on code from the Sentry Key, and the
Sentry Key l earns the Secret Key code from the
SKI M. Once the Sentry Key l earns the Secret Key
code of the SKI M, i t i s permanentl y stored i n the
memory of the transponder. Therefore, once a Sentry
Key has been programmed to a parti cul ar vehi cl e, i t
cannot be used on any other vehi cl e. (Refer to 8 -
ELECTRI CAL/VEHI CLE THEFT SECURI TY -
STANDARD PROCEDURE - SENTRY KEY TRAN-
SPONDER PROGRAMMI NG).
The SKI S performs a sel f-test each ti me the i gni -
ti on swi tch i s turned to the On posi ti on, and wi l l
store key-rel ated faul t i nformati on i n the form of
Di agnosti c Troubl e Codes (DTC’s) i n SKI M memory i f
a Sentry Key transponder probl em i s detected. The
Sentry Key transponder chi p can be di agnosed, and
any stored DTC’s can be retri eved usi ng a DRBI I I ௡
scan tool . Refer to the appropri ate di agnosti c
i nformati on.
Fig. 1 Sentry Key Immobilizer Transponder
1 - MOLDED CAP
2 - TRANSPONDER CHIP
3 - MOLDED CAP REMOVED
4 - TRANSPONDER KEY
8Q - 6 VEHICLE THEFT SECURITY TJ
WIPERS/WASHERS
TABLE OF CONTENTS
page page
FRONT WIPERS/WASHERS . . . . . . . . . . . . . . . . . . 1 REAR WIPERS/WASHERS . . . . . . . . . . . . . . . . . . 24
FRONT WIPERS/WASHERS
TABLE OF CONTENTS
page page
FRONT WIPERS/WASHERS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DIAGNOSIS AND TESTING - FRONT WIPER &
WASHER SYSTEM . . . . . . . . . . . . . . . . . . . . . 5
CLEANING - FRONT WIPER & WASHER
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSPECTION - FRONT WIPER & WASHER
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
FRONT CHECK VALVE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10
FRONT WASHER HOSES/TUBES
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 10
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
FRONT WASHER NOZZLE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 10
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11
FRONT WASHER PUMP MOTOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 11
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 13
FRONT WIPER ARM
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 13
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14
FRONT WIPER BLADE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 14
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 15
FRONT WIPER MODULE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 15
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 17
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 17
RIGHT MULTI-FUNCTION SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 18
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
DIAGNOSIS AND TESTING - RIGHT MULTI-
FUNCTION SWITCH . . . . . . . . . . . . . . . . . . . 19
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 21
WASHER RESERVOIR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 22
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 23
FRONT WIPERS/WASHERS
DESCRIPTION
An el ectri cal l y operated i ntermi ttent front wi per
and washer system i s standard factory-i nstal l ed
safety equi pment on thi s model (Fi g. 1). The front
wi per and washer system i ncl udes the fol l owi ng
major components, whi ch are descri bed i n further
detai l el sewhere i n thi s servi ce i nformati on:
• Front Check Valve - The front washer system
check val ve i s l ocated i n the washer pl umbi ng on the
undersi de of the hood panel between the cowl and
the front washer nozzl e.
TJ WIPERS/WASHERS 8R - 1
• Front Washer Nozzle - The si ngl e fl ui di c front
washer nozzl e i s secured by an i ntegral l atch feature
to a dedi cated openi ng near the rear of the hood
panel . The washer pl umbi ng fi tti ng for the washer
nozzl e i s conceal ed beneath the hood panel .
• Front Washer Pump/Motor - The front washer
pump/motor uni t i s l ocated i n a dedi cated hol e on the
l ower i nboard si de of the washer reservoi r, on the top
of the l eft front wheel house i n the engi ne compart-
ment. The front washer pump/motor uni t i s l ocated
bel ow and forward of the opti onal rear washer pump/
motor uni t mounti ng hol e.
• Front Washer Plumbing - The pl umbi ng for
the front washer system consi sts of rubber hoses and
mol ded pl asti c fi tti ngs. The pl umbi ng i s routed al ong
the l eft si de of the engi ne compartment from the
washer reservoi r, and up the cowl panel to the hood
panel rear rei nforcement. Then al ong the hood panel
rear rei nforcement to the front washer nozzl e fi tti ng.
• Front Wiper Arm - The two front wi per arms
are secured wi th i ntegral l atches to the serrated ends
Fig. 1 Front Wiper & Washer System
1 - WASHER RESERVOIR, PUMP/MOTOR
2 - FRONT WASHER NOZZLE
3 - FRONT WIPER MODULE
4 - FRONT WIPER ARM & BLADE (2)
5 - RIGHT MULTI-FUNCTION SWITCH
8R - 2 FRONT WIPERS/WASHERS TJ
FRONT WIPERS/WASHERS (Continued)
of the two wi per pi vot shafts, whi ch extend through
the cowl pl enum cover/gri l l e panel l ocated near the
base of the wi ndshi el d.
• Front Wiper Blade - The two front wi per
bl ades are secured to the two front wi per arms wi th
i ntegral l atches, and are parked on the gl ass near
the bottom of the wi ndshi el d when the front wi per
system i s not i n operati on.
• Front Wiper Module - The front wi per pi vot
shafts are the onl y vi si bl e components of the front
wi per modul e. The remai nder of the modul e i s con-
ceal ed wi thi n the cowl pl enum area beneath the cowl
pl enum cover/gri l l e panel . The front wi per modul e
i ncl udes the wi per modul e bracket, three rubber-i so-
l ated wi per modul e mounts, the front wi per motor,
the front wi per motor crank arm, the front wi per
dri ve l i nk, the front wi per connector l i nk, and the
two front wi per pi vots.
• Right Multi-Function Switch - The ri ght
mul ti -functi on swi tch i s l ocated near the top of the
steeri ng col umn, just bel ow the steeri ng wheel . The
ri ght mul ti -functi on swi tch i ncl udes a control stal k
wi th a control knob on the end that extends through
a dedi cated openi ng on the ri ght si de of the steeri ng
col umn shrouds. The ri ght mul ti -functi on swi tch i s
dedi cated to provi di ng al l of the dri ver control s for
the front wi per and washer systems.
• Washer Reservoir - The mol ded pl asti c washer
reservoi r i s secured by two screws through i ntegral
mounti ng tabs to the top of the l eft front fender
wheel house, i n the l eft front corner of the engi ne
compartment. The washer reservoi r fi l l er neck i s
accessed from the l eft front corner of the engi ne com-
partment.
Hard wi red ci rcui try connects the front wi per and
washer system components to the el ectri cal system of
the vehi cl e. These hard wi red ci rcui ts are i ntegral to
several wi re harnesses, whi ch are routed throughout
the vehi cl e and retai ned by many di fferent methods.
These ci rcui ts may be connected to each other, to the
vehi cl e el ectri cal system and to the front wi per and
washer system components through the use of a com-
bi nati on of sol dered spl i ces, spl i ce bl ock connectors,
and many di fferent types of wi re harness termi nal
connectors and i nsul ators. Refer to the appropri ate
wi ri ng i nformati on. The wi ri ng i nformati on i ncl udes
wi ri ng di agrams, proper wi re and connector repai r
procedures, further detai l s on wi re harness routi ng
and retenti on, as wel l as pi n-out and l ocati on vi ews
for the vari ous wi re harness connectors, spl i ces and
grounds.
OPERATING MODES
The components of the wi per and washer system
are desi gned to work i n concert to provi de the fol l ow-
i ng operati ng modes:
• Continuous Wipe Modes - The control stal k of
the ri ght mul ti -functi on swi tch has two conti nuous
wi pe posi ti ons, Low and Hi gh. When sel ected, these
swi tch posi ti ons wi l l cause the two-speed wi per motor
to operate i n a conti nuous l ow or hi gh speed cycl e.
• Intermittent Wipe Mode - The control stal k of
the ri ght mul ti -functi on swi tch has an i ntermi ttent
wi pe posi ti on, and the control knob has several mi nor
detent posi ti ons whi ch wi l l each cause the wi per sys-
tem to operate at di fferent del ay i nterval s between
compl ete wi pe cycl es. The i nternal ci rcui try of the
ri ght mul ti -functi on swi tch provi des the i ntermi ttent
wi pe mode and adjustabl e del ay i nterval s between
wi pe cycl es of about one second to about fi fteen sec-
onds.
• Mist Wipe Mode - The control stal k of the ri ght
mul ti -functi on swi tch has a momentary mi st wi pe
posi ti on that wi l l operate the front wi pers for a si n-
gl e compl ete cycl e, then park the wi per bl ades near
the base of the wi ndshi el d.
• Washer Mode - When the control stal k of ri ght
mul ti -functi on swi tch i s pul l ed toward the steeri ng
wheel to the momentary Wash posi ti on whi l e the
front wi per system i s operati ng, washer fl ui d wi l l be
di spensed onto the wi ndshi el d gl ass through the
washer nozzl es for as l ong as the front washer pump
i s energi zed.
• Wipe-After-Wash Mode - When the control
stal k of ri ght mul ti -functi on swi tch i s pul l ed toward
the steeri ng wheel to the momentary Wash posi ti on
whi l e the front wi per system i s not operati ng, the
i nternal ci rcui try of the ri ght mul ti -functi on swi tch
provi des a wi pe-after-wash feature whi ch wi l l operate
the front washer pump/motor and the front wi pers
for as l ong as the washer system i s acti vated, then
provi de one or two addi ti onal wi pe cycl es after the
washer system i s deacti vated before parki ng the
front wi per bl ades near the base of the wi ndshi el d.
OPERATION
The front wi per and washer system i s desi gned to
provi de the vehi cl e operator wi th a conveni ent, safe,
and rel i abl e means of mai ntai ni ng vi si bi l i ty through
the wi ndshi el d gl ass. The vari ous components of thi s
system are desi gned to convert el ectri cal energy pro-
duced by the vehi cl e el ectri cal system i nto the
mechani cal acti on of the wi per bl ades to wi pe the
outsi de surface of the gl ass, as wel l as i nto the
hydraul i c acti on of the washer system to appl y
washer fl ui d stored i n an on-board reservoi r to the
area of the gl ass to be wi ped. When combi ned, these
components provi de the means to effecti vel y mai n-
tai n cl ear vi si bi l i ty for the vehi cl e operator by remov-
i ng excess accumul ati ons of rai n, snow, bugs, mud, or
other mi nor debri s from the outsi de wi ndshi el d gl ass
surface that mi ght be encountered whi l e dri vi ng the
TJ FRONT WIPERS/WASHERS 8R - 3
FRONT WIPERS/WASHERS (Continued)
vehi cl e under numerous types of i ncl ement operati ng
condi ti ons.
The vehi cl e operator i ni ti ates al l front wi per and
washer system functi ons wi th the control stal k and
control knob of the ri ght mul ti -functi on swi tch that
extends from the ri ght si de of the steeri ng col umn,
just bel ow the steeri ng wheel . Movi ng the control
stal k upward sel ects the front wi per system operat-
i ng mode. The front wi per system al l ows the vehi cl e
operator to sel ect from two conti nuous wi per speeds,
Hi gh or Low, or the i ntermi ttent wi pe Del ay mode.
Pul l i ng the control stal k downwards and rel easi ng i t
sel ects the front wi per system Mi st mode, whi ch
operates the front wi pers for one compl ete wi pe cycl e
after the control stal k i s rel eased. Rotati ng the con-
trol knob on the end of the control stal k al l ows the
vehi cl e operator to sel ect the i ntermi ttent wi pe Del ay
i nterval . Pul l i ng the control stal k towards the steer-
i ng wheel acti vates the front washer pump/motor,
whi ch di spenses washer fl ui d onto the wi ndshi el d
gl ass through the front washer nozzl e.
When the i gni ti on swi tch i s i n the Accessory or On
posi ti ons, battery current from a fuse i n the Power
Di stri buti on Center (PDC) i s provi ded to the front
wi per and washer system fuse i n the fuse bl ock. Thi s
fuse provi des battery current through separate fused
i gni ti on swi tch output (run-acc) ci rcui ts to the ri ght
mul ti -functi on swi tch, and to the front wi per motor.
Wi thi n the ri ght mul ti -functi on swi tch, thi s battery
current i s fed to one si de of the control coi l i n the
wi per motor rel ay, and to the el ectroni c i ntermi ttent
wi pe l ogi c ci rcui t, whi ch are both i ntegral to the
swi tch.
The i ntermi ttent wi pe and wi pe-after-wash fea-
tures of the front wi per and washer system are both
provi ded by the el ectroni c i ntermi ttent wi pe l ogi c ci r-
cui t wi thi n the ri ght mul ti -functi on swi tch. I n order
to provi de the i ntermi ttent wi pe feature, the l ogi c ci r-
cui t moni tors the wi per swi tch state, the i ntermi ttent
del ay resi stance setti ng, and the wi per motor park
swi tch state. I n order to provi de the wi pe-after-wash
feature, the l ogi c ci rcui t moni tors both the front
washer swi tch state and the wi per motor park swi tch
state.
The hard wi red ci rcui ts and components of the
front wi per and washer system may be di agnosed
and tested usi ng conventi onal di agnosti c tool s and
procedures. However, conventi onal di agnosti c meth-
ods are not possi bl e i n the di agnosi s of the i ntermi t-
tent wi pe mode ci rcui try and l ogi c wi thi n the ri ght
mul ti -functi on swi tch. I f the front wi per and washer
system operates sati sfactori l y i n al l modes except the
Del ay mode, the faul ty ri ght mul ti -functi on swi tch
must be repl aced. Refer to the appropri ate di agnosti c
i nformati on.
OPERATING MODES
Fol l owi ng are paragraphs that bri efl y descri be the
operati on of each of the front wi per and washer sys-
tem operati ng modes.
CONTINUOUS WIPE MODE
When the Low posi ti on of the ri ght mul ti -functi on
swi tch control stal k i s sel ected, the Low mode ci r-
cui try wi thi n the swi tch di rects battery current to
the l ow speed brush of the front wi per motor, whi ch
causes the front wi pers to cycl e at a l ow speed. When
the Hi gh posi ti on of the control stal k i s sel ected, the
Hi gh mode ci rcui try wi thi n the swi tch di rects battery
current to the hi gh speed brush of the front wi per
motor, whi ch causes the front wi pers to cycl e at a
hi gh speed.
When the Off posi ti on of the ri ght mul ti -functi on
swi tch control stal k i s sel ected, one of two events i s
possi bl e. The event that occurs depends upon the
posi ti on of the wi per bl ades on the wi ndshi el d at the
moment that the control stal k Off posi ti on i s
sel ected. I f the wi per bl ades are i n the down posi ti on
on the wi ndshi el d when the Off posi ti on i s sel ected,
the park swi tch that i s i ntegral to the front wi per
motor i s cl osed to ground and the wi per motor ceases
to operate.
I f the wi per bl ades are not i n the down posi ti on on
the wi ndshi el d at the moment the Off posi ti on i s
sel ected, the park swi tch i s cl osed to battery current
through the fused i gni ti on swi tch output (run-acc)
ci rcui t of the front wi per motor. The park swi tch
sense ci rcui t di rects thi s battery current to the l ow
speed brush of the wi per motor through the normal l y
cl osed ci rcui t of the wi per motor rel ay and the Off
mode ci rcui try of the wi per swi tch. Thi s causes the
wi per motor to conti nue runni ng unti l the wi per
bl ades are i n the down posi ti on on the wi ndshi el d
and the park swi tch i s agai n cl osed to ground.
INTERMITTENT WIPE MODE
When the control stal k of the ri ght mul ti -functi on
swi tch i s moved to the Del ay posi ti on, the Del ay
mode ci rcui try wi thi n the swi tch di rects battery cur-
rent to a request i nput of the i ntegral l ogi c ci rcui t.
The Del ay mode ci rcui try al so di rects battery current
through an i nternal vari abl e resi stor to the i ntermi t-
tent wi pe del ay sense i nput of the l ogi c ci rcui t, whi ch
i ndi cates the del ay i nterval that has been sel ected by
the vehi cl e operator usi ng the control knob on the
end of the ri ght mul ti -functi on swi tch control stal k.
The l ogi c ci rcui t responds to the Del ay mode
request i nputs by cal cul ati ng the correct del ay i nter-
val . The l ogi c ci rcui t then energi zes the wi per motor
rel ay by pul l i ng the rel ay control coi l to ground. The
energi zed wi per motor rel ay di rects battery current
from the normal l y open rel ay termi nal through the
8R - 4 FRONT WIPERS/WASHERS TJ
FRONT WIPERS/WASHERS (Continued)
common feed rel ay termi nal and the Del ay mode
wi per swi tch ci rcui try to the l ow speed brush of the
wi per motor. The l ogi c ci rcui t moni tors the front
wi per motor operati on through the wi per park swi tch
sense ci rcui t, whi ch al l ows the l ogi c ci rcui t to deter-
mi ne the proper ti mi ng to begi n the next wi per bl ade
sweep.
MIST MODE
When the control stal k of the ri ght mul ti -functi on
swi tch i s moved to the momentary Mi st posi ti on, the
Mi st mode ci rcui try wi thi n the swi tch di rects battery
current to the l ow speed brush of the front wi per
motor, whi ch causes the front wi pers to cycl e at l ow
speed for as l ong as the swi tch i s hel d i n the Mi st
posi ti on. When the control stal k i s rel eased, the
wi per motor compl etes the current wi pe cycl e then
parks the wi per bl ades near the base of the wi nd-
shi el d.
WASH MODE
When the momentary Wash posi ti on of the ri ght
mul ti -functi on swi tch control stal k i s sel ected whi l e
the front wi per system i s operati ng, the Wash mode
ci rcui try wi thi n the swi tch di rects battery current to
the front washer pump/motor for as l ong as the Wash
mode ci rcui try wi thi n the swi tch remai ns cl osed.
When the control stal k i s rel eased the Wash mode
ci rcui try wi thi n the swi tch opens and the front
washer pump/motor ceases operati on.
WIPE-AFTER-WASH MODE
When the washer swi tch i s cl osed wi th the front
wi per system turned Off, the i ntermi ttent wi pe l ogi c
ci rcui t operates the front wi per motor through the
wi per motor rel ay i n the same manner as i t does to
provi de the Del ay mode operati on, but uses the Off
mode ci rcui try of the wi per swi tch to feed battery
current to the l ow speed brush of the front wi per
motor. When the Wash mode ci rcui try state changes
to open, the i ntermi ttent wi pe l ogi c ci rcui t de-ener-
gi zes the front washer pump/motor uni t, but al l ows
the wi per motor to operate for several addi ti onal
wi pe cycl es before i t de-energi zes the wi per motor
and parks the wi per bl ades near the base of the
wi ndshi el d. The i ntermi ttent wi pe l ogi c ci rcui t moni -
tors the front wi per motor through the wi per park
swi tch sense ci rcui t, whi ch al l ows the l ogi c ci rcui t to
count the number of wi per bl ade sweeps.
DIAGNOSIS AND TESTING - FRONT WIPER &
WASHER SYSTEM
WIPER SYSTEM
The di agnosi s found here addresses an el ectri cal l y
i noperati ve front wi per system. I f the front wi per
motor operates, but the wi pers do not move on the
wi ndshi el d, repl ace the faul ty front wi per modul e. I f
the wi pers operate, but chatter, l i ft, or do not cl ear
the gl ass, cl ean and i nspect the front wi per system
components as requi red. (Refer to 8 - ELECTRI CAL/
FRONT WI PERS/WASHERS - CLEANI NG) and
(Refer to 8 - ELECTRI CAL/FRONT WI PERS/WASH-
ERS - I NSPECTI ON). Refer to the appropri ate wi r-
i ng i nformati on. The wi ri ng i nformati on i ncl udes
wi ri ng di agrams, proper wi re and connector repai r
procedures, detai l s of wi re harness routi ng and
retenti on, connector pi n-out i nformati on and l ocati on
vi ews for the vari ous wi re harness connectors, spl i ces
and grounds.
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE SUPPLEMENTAL RESTRAINT SYS-
TEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, AIRBAG, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE BEFORE PERFORMING FURTHER DIAG-
NOSIS OR SERVICE. THIS IS THE ONLY SURE WAY
TO DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT.
(1) Check the front wi per and washer system fuse
(Fuse 14 - 25 ampere) i n the fuse bl ock. I f OK, go to
Step 2. I f not OK, repai r the shorted ci rcui t or com-
ponent as requi red and repl ace the faul ty fuse.
(2) Turn the i gni ti on swi tch to the On posi ti on.
Check for battery vol tage at the front wi per and
washer system fuse (Fuse 14 - 25 ampere) i n the fuse
bl ock. I f OK, go to Step 3. I f not OK, repai r the open
fused i gni ti on swi tch output (run-acc) ci rcui t between
the fuse bl ock and the i gni ti on swi tch as requi red.
(3) Di sconnect and i sol ate the battery negati ve
cabl e. Di sconnect the body wi re harness connector for
the ri ght mul ti -functi on swi tch from the swi tch con-
nector receptacl e. Check for conti nui ty between the
ground ci rcui t cavi ty of the body wi re harness con-
nector for the ri ght mul ti -functi on swi tch and a good
ground. There shoul d be conti nui ty. I f OK, go to Step
4. I f not OK, repai r the open ground ci rcui t to ground
(G300) as requi red.
(4) Reconnect the battery negati ve cabl e. Turn the
i gni ti on swi tch to the On posi ti on. Check for battery
vol tage at the fused i gni ti on swi tch output (run-acc)
ci rcui t cavi ty of the body wi re harness connector for
the ri ght mul ti -functi on swi tch. I f OK, go to Step 5.
I f not OK, repai r the open fused i gni ti on swi tch out-
TJ FRONT WIPERS/WASHERS 8R - 5
FRONT WIPERS/WASHERS (Continued)
put (run-acc) ci rcui t between the ri ght mul ti -functi on
swi tch and the fuse bl ock as requi red.
(5) Turn the i gni ti on swi tch to the Off posi ti on.
Di sconnect and i sol ate the battery negati ve cabl e.
Remove the ri ght mul ti -functi on swi tch from the
steeri ng col umn and check the swi tch conti nui ty.
(Refer to 8 - ELECTRI CAL/FRONT WI PERS/WASH-
ERS/RI GHT MULTI -FUNCTI ON SWI TCH - DI AG-
NOSI S AND TESTI NG). I f OK, go to Step 6. I f not
OK, repl ace the faul ty swi tch.
(6) Di sconnect the body wi re harness connector for
the front wi per motor from the wi per motor pi gtai l
wi re connector. Check for conti nui ty between the
ground ci rcui t cavi ty i n the body wi re harness con-
nector for the front wi per motor and a good ground.
There shoul d be conti nui ty. I f OK, go to Step 7. I f not
OK, repai r the open ground ci rcui t to ground (G300)
as requi red.
(7) Reconnect the battery negati ve cabl e. Turn the
i gni ti on swi tch to the On posi ti on. Check for battery
vol tage at the fused i gni ti on swi tch output (run-acc)
ci rcui t cavi ty of the body wi re harness connector for
the front wi per motor. I f OK, go to Step 8. I f not OK,
repai r the open fused i gni ti on swi tch output (run-acc)
ci rcui t between the front wi per motor and the fuse
bl ock as requi red.
(8) Turn the i gni ti on swi tch to the Off posi ti on.
Di sconnect and i sol ate the battery negati ve cabl e.
The body wi re harness connector for the ri ght mul ti -
functi on swi tch i s sti l l di sconnected. Check each of
the fol l owi ng ci rcui ts at the proper cavi ty of the body
wi re harness connector for the front wi per motor for
conti nui ty to ground. I n each case, there shoul d be
no conti nui ty. I f OK, go to Step 9. I f not OK, repai r
the shorted ci rcui t between the front wi per motor
and the ri ght mul ti -functi on swi tch as requi red.
• Wi per park swi tch sense
• Wi per swi tch l ow speed output
• Wi per swi tch hi gh speed output
(9) Check the conti nui ty of each of the fol l owi ng
ci rcui ts between the proper cavi ti es of the body wi re
harness connectors for the front wi per motor and the
ri ght mul ti -functi on swi tch. I n each case, there
shoul d be conti nui ty. I f OK, repl ace the faul ty front
wi per modul e. I f not OK, repai r the open ci rcui t
between the front wi per motor and the ri ght mul ti -
functi on swi tch as requi red.
• Wi per park swi tch sense
• Wi per swi tch l ow speed output
• Wi per swi tch hi gh speed output
WASHER SYSTEM
The di agnosi s found here addresses an el ectri cal l y
i noperati ve front washer system. I f the front washer
pump/motor operates, but no washer fl ui d i s emi tted
from the washer nozzl e, be certai n to check the fl ui d
l evel i n the reservoi r. Al so cl ean and i nspect the front
washer system components as requi red. (Refer to 8 -
ELECTRI CAL/FRONT WI PERS/WASHERS -
CLEANI NG) and (Refer to 8 - ELECTRI CAL/FRONT
WI PERS/WASHERS - I NSPECTI ON). Refer to the
appropri ate wi ri ng i nformati on. The wi ri ng i nforma-
ti on i ncl udes wi ri ng di agrams, proper wi re and con-
nector repai r procedures, detai l s of wi re harness
routi ng and retenti on, connector pi n-out i nformati on
and l ocati on vi ews for the vari ous wi re harness con-
nectors, spl i ces and grounds.
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE SUPPLEMENTAL RESTRAINT SYS-
TEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, AIRBAG, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE BEFORE PERFORMING FURTHER DIAG-
NOSIS OR SERVICE. THIS IS THE ONLY SURE WAY
TO DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT.
(1) Turn the i gni ti on swi tch to the On posi ti on.
Move the ri ght mul ti -functi on swi tch control stal k to
the Low or Hi gh conti nuous wi pe posi ti on. Check
whether the front wi per system operates. I f OK, go to
Step 2. I f not OK, repai r the front wi per system as
requi red before you proceed wi th front washer sys-
tem di agnosi s. Refer to WI PER SYSTEM.
(2) Turn the i gni ti on swi tch to the Off posi ti on.
Di sconnect and i sol ate the battery negati ve cabl e.
Di sconnect the headl amp and dash wi re harness con-
nector for the front washer pump/motor from the
washer pump/motor connector receptacl e. Check for
conti nui ty between the ground ci rcui t cavi ty of the
headl amp and dash wi re harness connector for the
front washer pump/motor and a good ground. There
shoul d be conti nui ty. I f OK, go to Step 3. I f not OK,
repai r the open ground ci rcui t to ground (G102) as
requi red.
(3) Reconnect the battery negati ve cabl e. Turn the
i gni ti on swi tch to the On posi ti on. Whi l e pul l i ng the
ri ght mul ti -functi on swi tch control stal k toward the
steeri ng wheel to cl ose the washer swi tch, check for
battery vol tage at the washer pump control swi tch
output ci rcui t cavi ty of the headl amp and dash wi re
harness connector for the front washer pump/motor.
I f OK, repl ace the faul ty front washer pump/motor. I f
not OK, go to Step 4.
(4) Turn the i gni ti on swi tch to the Off posi ti on.
Di sconnect and i sol ate the battery negati ve cabl e.
8R - 6 FRONT WIPERS/WASHERS TJ
FRONT WIPERS/WASHERS (Continued)
Di sconnect the body wi re harness connector for the
ri ght mul ti -functi on swi tch from the swi tch connector
receptacl e. Check for conti nui ty between the washer
pump control swi tch output ci rcui t cavi ty of the
headl amp and dash wi re harness connector for the
front washer pump/motor and a good ground. There
shoul d be no conti nui ty. I f OK, go to Step 5 I f not
OK, repai r the shorted washer pump control swi tch
output ci rcui t between the front washer pump/motor
and the ri ght mul ti -functi on swi tch as requi red.
(5) Check for conti nui ty between the washer pump
control swi tch output ci rcui t cavi ti es of the headl amp
and dash wi re harness connector for the front washer
pump/motor and the body wi re harness connector for
the ri ght mul ti -functi on swi tch. There shoul d be con-
ti nui ty. I f OK, repl ace the faul ty ri ght mul ti -functi on
swi tch. I f not OK, repai r the open washer pump con-
trol swi tch output ci rcui t between the front washer
pump/motor and the ri ght mul ti -functi on swi tch as
requi red.
CLEANING - FRONT WIPER & WASHER
SYSTEM
WIPER SYSTEM
The squeegees of wi per bl ades exposed to the el e-
ments for a l ong ti me tend to l ose thei r wi pi ng effec-
ti veness. Peri odi c cl eani ng of the squeegees i s
suggested to remove any deposi ts of sal t or road fi l m.
The wi per bl ades, arms, and wi ndshi el d gl ass shoul d
onl y be cl eaned usi ng a sponge or soft cl oth and
wi ndshi el d washer fl ui d, a mi l d detergent, or a non-
abrasi ve cl eaner. I f the wi per bl ades conti nue to
l eave streaks, smears, hazi ng, or beadi ng on the
gl ass after thorough cl eani ng of the squeegees and
the gl ass, the enti re wi per bl ade assembl y must be
repl aced.
CAUTION: Protect the rubber squeegees of the
wiper blades from any petroleum-based cleaners,
solvents, or contaminants. These products can rap-
idly deteriorate the rubber squeegees.
WASHER SYSTEM
I f the washer system i s contami nated wi th forei gn
materi al , drai n the washer reservoi r by removi ng the
front washer pump/motor from the reservoi r. Cl ean
forei gn materi al from the i nsi de of the washer pump/
motor i nl et fi l ter screen and the washer reservoi r
usi ng cl ean washer fl ui d, a mi l d detergent, or a non-
abrasi ve cl eaner. Fl ush forei gn materi al from the
washer system pl umbi ng by fi rst di sconnecti ng the
washer hoses from the front washer nozzl e, then run-
ni ng the front washer pump/motor to run cl ean
washer fl ui d or water through the system. Pl ugged or
restri cted washer nozzl es shoul d be careful l y back-
fl ushed usi ng compressed ai r. I f the washer nozzl e
obstructi on cannot be cl eared, repl ace the washer
nozzl e.
CAUTION: Never introduce petroleum-based clean-
ers, solvents, or contaminants into the washer sys-
tem. These products can rapidly deteriorate the
rubber seals and hoses of the washer system, as
well as the rubber squeegees of the wiper blades.
CAUTION: Never use compressed air to flush the
washer system plumbing. Compressed air pres-
sures are too great for the washer system plumbing
components and will result in further system dam-
age. Never use sharp instruments to clear a
plugged washer nozzle or damage to the nozzle ori-
fice and improper nozzle spray patterns will result.
INSPECTION - FRONT WIPER & WASHER
SYSTEM
WIPER SYSTEM
The front wi per bl ades and wi per arms shoul d be
i nspected peri odi cal l y, not just when wi per perfor-
mance probl ems are experi enced. Thi s i nspecti on
shoul d i ncl ude the fol l owi ng poi nts:
(1) I nspect the wi per arms for any i ndi cati ons of
damage, or contami nati on. I f the wi per arms are con-
tami nated wi th any forei gn materi al , cl ean them as
requi red. (Refer to 8 - ELECTRI CAL/FRONT WI P-
ERS/WASHERS - CLEANI NG). I f a wi per arm i s
damaged or corrosi on i s evi dent, repl ace the wi per
arm wi th a new uni t. Do not attempt to repai r a
wi per arm that i s damaged or corroded.
(2) Careful l y l i ft the wi per bl ade off of the gl ass.
Note the acti on of the wi per arm hi nge. The wi per
arm shoul d pi vot freel y at the hi nge, but wi th no l at-
eral l ooseness evi dent. I f there i s any bi ndi ng evi dent
i n the wi per arm hi nge, or there i s evi dent l ateral
pl ay i n the wi per arm hi nge, repl ace the wi per arm.
CAUTION: Do not allow the wiper arm to spring
back against the glass without the wiper blade in
place or the glass may be damaged.
(3) Once proper hi nge acti on of the wi per arm i s
confi rmed, check the hi nge for proper spri ng tensi on.
Remove the wi per bl ade from the wi per arm. Ei ther
pl ace a smal l postal scal e between the bl ade end of
the wi per arm and the gl ass, or careful l y l i ft the
bl ade end of the arm away from the gl ass usi ng a
smal l fi sh scal e. Compare the scal e readi ngs between
the ri ght and l eft wi per arms. Repl ace a wi per arm i f
TJ FRONT WIPERS/WASHERS 8R - 7
FRONT WIPERS/WASHERS (Continued)
i t has comparati vel y l ower spri ng tensi on, as evi -
denced by a l ower scal e readi ng.
(4) I nspect the wi per bl ades and squeegees for any
i ndi cati ons of damage, contami nati on, or rubber dete-
ri orati on (Fi g. 2). I f the wi per bl ades or squeegees
are contami nated wi th any forei gn materi al , cl ean
them and the gl ass as requi red. (Refer to 8 - ELEC-
TRI CAL/FRONT WI PERS/WASHERS - CLEANI NG).
After cl eani ng the wi per bl ade and the gl ass, i f the
wi per bl ade sti l l fai l s to cl ear the gl ass wi thout
smeari ng, streaki ng, chatteri ng, hazi ng, or beadi ng,
repl ace the wi per bl ade. Al so, i f a wi per bl ade i s
damaged or the squeegee rubber i s damaged or dete-
ri orated, repl ace the wi per bl ade wi th a new uni t. Do
not attempt to repai r a wi per bl ade that i s damaged.
WASHER SYSTEM
The washer system components shoul d be
i nspected peri odi cal l y, not just when washer perfor-
mance probl ems are experi enced. Thi s i nspecti on
shoul d i ncl ude the fol l owi ng poi nts:
(1) Check for i ce or other forei gn materi al i n the
washer reservoi r. I f contami nated, cl ean and fl ush
the washer system. (Refer to 8 - ELECTRI CAL/
FRONT WI PERS/WASHERS - CLEANI NG).
(2) I nspect the washer pl umbi ng for pi nched, l eak-
i ng, deteri orated, or i ncorrectl y routed hoses and
damaged or di sconnected hose fi tti ngs. Repl ace dam-
aged or deteri orated hoses and hose fi tti ngs. Leaki ng
washer hoses can someti mes be repai red by cutti ng
the hose at the l eak and spl i ci ng i t back together
usi ng an i n-l i ne connector fi tti ng. Si mi l arl y, secti ons
of deteri orated hose can be cut out and repl aced by
spl i ci ng i n new secti ons of hose usi ng i n-l i ne connec-
tor fi tti ngs. Whenever routi ng a washer hose or a
wi re harness contai ni ng a washer hose, i t must be
routed away from hot, sharp, or movi ng parts. Al so,
sharp bends that mi ght pi nch the washer hose must
be avoi ded.
FRONT CHECK VALVE
DESCRIPTION
A si ngl e front washer system check val ve i s stan-
dard equi pment on thi s model , and i s i nstal l ed i n the
front washer system pl umbi ng (Fi g. 3). The front
check val ve i s l ocated i n the engi ne compartment i n
the washer suppl y hose on the undersi de of the hood
panel about 5 centi meters (2 i nches) from the barbed
ni ppl e of the front washer nozzl e. The check val ve
consi sts of a mol ded pl asti c val ve body wi th a rai sed
arrowhead mol ded i nto i ts center secti on that i ndi -
cates the di recti on of the fl ow through the val ve. A
barbed hose ni ppl e i s formed on each si de of the
rai sed center secti on of the val ve body. Wi thi n the
check val ve body, a smal l di aphragm i s hel d agai nst
the l i p of an i ntegral sump wel l by a smal l pl asti c
pi ston and a coi l ed spri ng. The front check val ve can-
not be adjusted or repai red and, i f faul ty or damaged,
i t must be repl aced.
Fig. 2 Wiper Blade Inspection
1 - WORN OR UNEVEN EDGES
2 - ROAD FILM OR FOREIGN MATERIAL DEPOSITS
3 - HARD, BRITTLE, OR CRACKED
4 - DEFORMED OR FATIGUED
5 - SPLIT
6 - DAMAGED SUPPORT COMPONENTS
Fig. 3 Check Valve
1 - INLET NIPPLE
2 - CHECK VALVE
3 - OUTLET NIPPLE
4 - FLOW DIRECTION ARROW
8R - 8 FRONT WIPERS/WASHERS TJ
FRONT WIPERS/WASHERS (Continued)
OPERATION
The front check val ve provi des more than one func-
ti on i n thi s appl i cati on. I t prevents washer fl ui d from
drai ni ng out of the front washer suppl y hoses back to
the washer reservoi r. Thi s drai n-back woul d resul t i n
a l engthy del ay from when the front washer swi tch i s
actuated unti l washer fl ui d was di spensed through
the front washer nozzl e, because the front washer
pump woul d have to refi l l the front washer pl umbi ng
from the reservoi r to the nozzl e. Such a drai n-back
condi ti on coul d al so resul t i n water, di rt, or other
outsi de contami nants bei ng si phoned i nto the washer
system through the washer nozzl e ori fi ce. Thi s water
coul d subsequentl y freeze and pl ug the nozzl e, whi l e
other contami nants coul d i nterfere wi th proper noz-
zl e operati on and cause i mproper nozzl e spray pat-
terns. I n addi ti on, the front check val ve prevents
washer fl ui d from si phoni ng out through the front
washer nozzl e after the front washer system i s
turned Off.
When the front washer pump pressuri zes and
pumps washer fl ui d from the reservoi r through the
front washer pl umbi ng, the fl ui d pressure unseats a
di aphragm from over a sump wel l wi thi n the val ve
by overri di ng the spri ng pressure appl i ed to i t by a
pi ston (Fi g. 4). Wi th the di aphragm unseated, washer
fl ui d i s al l owed to fl ow toward the front washer noz-
zl e. When the front washer pump stops operati ng,
the spri ng pressure on the pi ston seats the di a-
phragm over the sump wel l i n the val ve and fl ui d
fl ow i n ei ther di recti on wi thi n the front washer
pl umbi ng i s prevented. The front check val ve cannot
be adjusted or repai red and, i f faul ty or damaged, i t
must be repl aced.
REMOVAL
(1) Unl atch, open and support the hood.
(2) Locate the front check val ve i n the washer sup-
pl y hose for the front washer nozzl e. The check val ve
i s i nstal l ed i n the washer suppl y hose about 5 centi -
meters (2 i nches) from the front washer nozzl e ni ppl e
near the rear hood panel rei nforcement (Fi g. 5).
(3) Di sconnect the washer suppl y hose for the
front washer nozzl e from the barbed outl et ni ppl e on
the front washer system check val ve. A smal l quan-
ti ty of washer fl ui d may drai n from the di sconnected
hose.
(4) Di sconnect the washer suppl y hose for the res-
ervoi r from the barbed i nl et ni ppl e of the front check
val ve. Ei ther i nstal l a temporary pl ug i n the washer
suppl y hose for the reservoi r or secure the l oose end
of thi s hose at a poi nt hi gher than the washer reser-
voi r to prevent the contents of the washer reservoi r
from drai ni ng through thi s hose.
(5) Remove the front check val ve from the engi ne
compartment.
Fig. 4 Front Check Valve
1 - SPRING
2 - PISTON
3 - DIAPHRAGM
4 - TO WASHER NOZZLE
5 - FROM WASHER PUMP
Fig. 5 Front Check Valve Remove/Install
1 - HOOD REAR REINFORCEMENT
2 - FRONT WASHER NOZZLE
3 - WASHER HOSE
4 - FRONT CHECK VALVE
TJ FRONT WIPERS/WASHERS 8R - 9
FRONT CHECK VALVE (Continued)
INSTALLATION
(1) Posi ti on the front check val ve i n the engi ne
compartment.
(2) Wi th the di recti onal arrow on the check val ve
poi nted i n the di recti on of the system fl ow, reconnect
the washer suppl y hose from the reservoi r to the
barbed i nl et ni ppl e of the front check val ve (Fi g. 6).
(3) Reconnect the washer suppl y hose from the
front washer nozzl e to the barbed outl et ni ppl e of the
front check val ve.
(4) Check that the washer suppl y hoses are prop-
erl y routed and are not pi nched.
(5) Cl ose and l atch the hood.
FRONT WASHER HOSES/
TUBES
DESCRIPTION
The front washer pl umbi ng consi sts of a smal l
di ameter rubber front washer hose that i s routed
from the barbed outl et ni ppl e of the el ectri c front
washer pump/motor uni t on the washer reservoi r
around the front of the reservoi r to the top of the l eft
front fender wheel house. The hose i s secured by si x
pl asti c ti e wraps to the headl amp and dash wi re har-
ness and routed wi th the harness to the top dash
panel near the center of the engi ne compartment
(Fi g. 7).
Near the center of the dash panel the front washer
hose i s routed to the i nner rear hood panel rei nforce-
ment. Two mol ded pl asti c routi ng cl i ps secure the
front washer hose to the undersi de of the hood panel
rei nforcement. The front washer hose i s connected to
the barbed i nl et ni ppl e of the front washer check
val ve near the i nner center hood panel rei nforce-
ment. A short pi ece of washer hose then connects the
barbed outl et ni ppl e of the front washer check val ve
to the barbed ni ppl e of the front washer nozzl e on
the undersi de of the hood panel .
Washer hose i s avai l abl e for servi ce onl y as rol l
stock, whi ch must then be cut to l ength. Mol ded pl as-
ti c washer hose fi tti ngs cannot be repai red. I f these
fi tti ngs are faul ty or damaged, they must be
repl aced.
OPERATION
Washer fl ui d i n the washer reservoi r i s pressuri zed
and fed by the front washer pump/motor through the
front washer system pl umbi ng and fi tti ngs to the
front washer check val ve and the front washer noz-
zl e. Whenever routi ng the washer hose or a wi re har-
ness contai ni ng a washer hose, i t must be routed
away from hot, sharp, or movi ng parts; and, sharp
bends that mi ght pi nch the hose must be avoi ded.
FRONT WASHER NOZZLE
DESCRIPTION
The mol ded bl ack pl asti c front washer nozzl e has
an i ntegral l atch feature that secures i t i n a dedi -
cated mounti ng hol e l ocated at the center near the
rear edge of the hood panel (Fi g. 8). The washer noz-
zl e i s constructed i n two pi eces. The nozzl e housi ng
i ncl udes the domed hood that i s vi si bl e on the outer
surface of the hood panel , and the i ntegral l atch and
Fig. 6 Check Valve
1 - INLET NIPPLE
2 - CHECK VALVE
3 - OUTLET NIPPLE
4 - FLOW DIRECTION ARROW
Fig. 7 Front Washer Plumbing
1 - FRONT WASHER NOZZLE
2 - CLIP (2)
3 - HARNESS CLIP (2)
4 - WASHER SUPPLY HOSE
5 - FRONT CHECK VALVE
6 - WASHER RESERVOIR
7 - FRONT WASHER PUMP/MOTOR
8R - 10 FRONT WIPERS/WASHERS TJ
FRONT CHECK VALVE (Continued)
barbed i nl et ni ppl e whi ch are conceal ed bel ow the
hood panel .
A rectangul ar openi ng i n the rearward faci ng sur-
face of the nozzl e hood accepts the fl ui di c i nsert of
the nozzl e. The fl ui di c i nsert i s a one-pi ece uni t that
i ncorporates the vari ous chambers, passages, defl ec-
tors and the si ngl e ori fi ce through whi ch the washer
fl ui d stream i s di rected i nto the wi pe pattern on the
wi ndshi el d gl ass. The nozzl e i s accessed for servi ce
from the undersi de of the hood panel . The front
washer nozzl e cannot be adjusted or repai red. I f
faul ty or damaged, i t must be repl aced.
OPERATION
The front washer nozzl e i s desi gned to di spense
washer fl ui d i nto the wi per pattern area on the out-
si de of the wi ndshi el d gl ass. Pressuri zed washer fl ui d
i s fed to the nozzl e from the washer reservoi r by the
front washer pump/motor through a si ngl e hose,
whi ch i s attached to a barbed ni ppl e on the front
washer nozzl e bel ow the hood panel . A fl ui di c matri x
wi thi n the washer nozzl e causes the pressuri zed
washer fl ui d to be emi tted from the nozzl e ori fi ce as
a fan-l i ke stream to more effecti vel y cover a l arger
area of the gl ass to be cl eaned.
REMOVAL
(1) Unl atch, open and support the hood.
(2) From the undersi de of the rear of the hood
panel near the center, di sconnect the washer suppl y
hose from the barbed ni ppl e of the front washer noz-
zl e (Fi g. 9).
(3) From the undersi de of the rear of the hood
panel near the center, gentl y squeeze the l atch fea-
ture of the front washer nozzl e and push the nozzl e
out through the mounti ng hol e towards the outsi de of
the hood panel .
(4) Remove the front washer nozzl e from the top of
the hood panel .
INSTALLATION
(1) Lower the hood panel .
(2) From the top of the hood panel , posi ti on the
ni ppl e end of the front washer nozzl e through the
mounti ng hol e. Be certai n the nozzl e ori fi ce i s ori -
ented towards the wi ndshi el d, then engage the
notched forward-faci ng end of the nozzl e housi ng to
the forward edge of the mounti ng hol e (Fi g. 9).
(3) Usi ng hand pressure, press fi rml y and evenl y
on the top of the front washer nozzl e unti l the i nte-
gral l atch feature l ocks i nto pl ace on the undersi de of
the hood panel .
(4) Open and support the hood.
(5) From the undersi de of the rear of the hood
panel near the center, reconnect the washer suppl y
hose to the barbed ni ppl e of the front washer nozzl e.
(6) Cl ose and l atch the hood.
FRONT WASHER PUMP
MOTOR
DESCRIPTION
The front washer pump/motor uni t i s l ocated on
the i nboard si de near the front and the bottom of the
washer reservoi r (Fi g. 10). The washer reservoi r i s
l ocated on the top of the l eft front fender wheel house
i n the engi ne compartment. A smal l permanentl y
l ubri cated and seal ed el ectri c motor i s coupl ed to the
Fig. 8 Front Washer Nozzle
1 - HOOD
2 - LATCH
3 - ORIFICE (FLUIDIC INSERT)
4 - NIPPLE
Fig. 9 Front Washer Nozzle Remove/Install
1 - HOOD PANEL
2 - WASHER SUPPLY HOSE
3 - FRONT WASHER NOZZLE
TJ FRONT WIPERS/WASHERS 8R - 11
FRONT WASHER NOZZLE (Continued)
rotor-type washer pump. A seal fl ange wi th a barbed
i nl et ni ppl e on the pump housi ng passes through a
rubber grommet seal i nstal l ed i n a dedi cated mount-
i ng hol e i n the sump area near the bottom of the
washer reservoi r. On vehi cl es wi th the opti onal rear
washer system, the front washer pump/motor uni t i s
al ways mounted i n the forward-most, l owest pump
mounti ng hol e of the reservoi r. An i ntegral fi l ter
screen i s l ocated wi thi n the pump i nl et ni ppl e. When
the pump i s i nstal l ed i n the reservoi r a barbed outl et
ni ppl e on the pump housi ng connects the uni t to the
washer system through the front washer suppl y hose.
The washer pump/motor uni t i s retai ned on the
reservoi r by the i nterference fi t between the barbed
pump i nl et ni ppl e and the grommet seal , whi ch i s a
l i ght press fi t. An i ntegral connector receptacl e
between the motor housi ng and the pump housi ng
connects the uni t to the vehi cl e el ectri cal system. A
smal l capaci tor i nternal to the connector receptacl e
i nsul ator i s connected i n paral l el wi th the motor
l eads to control El ectroMagneti c I nterference (EMI )
created by washer motor operati on. The front washer
pump/motor uni t cannot be repai red. I f faul ty or
damaged, the enti re washer pump/motor uni t must
be repl aced.
OPERATION
The front washer pump/motor uni t features a smal l
Di rect Current (DC) el ectri c motor. The motor i s con-
nected to the vehi cl e el ectri cal system through a si n-
gl e take out and two-cavi ty connector of the
headl amp and dash wi re harness. The motor i s
grounded at al l ti mes through another take out of
the headl amp and dash wi re harness wi th a si ngl e
eyel et termi nal connector that i s secured under a
ground screw to the radi ator cl osure panel behi nd
the l eft headl amp i n the engi ne compartment. The
motor recei ves battery current through the cl osed
contacts of the momentary front washer swi tch ci r-
cui try wi thi n the ri ght mul ti -functi on swi tch onl y
when the swi tch control stal k i s pul l ed towards the
steeri ng wheel .
Washer fl ui d i s gravi ty-fed from the washer reser-
voi r to the i nl et si de of the washer pump. When the
pump motor i s energi zed, the motor spi ns the rotor
wi thi n the rotor-type washer pump. The spi nni ng
pump rotor pressuri zes the washer fl ui d and forces i t
through the pump outl et ni ppl e, the front washer
pl umbi ng, and the front washer nozzl e onto the
wi ndshi el d gl ass. The front washer pump/motor uni t
can be di agnosed usi ng conventi onal di agnosti c tool s
and methods.
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Di sconnect the washer suppl y hose from the
barbed outl et ni ppl e of the front washer pump/motor
and al l ow the washer fl ui d from the washer reservoi r
to drai n i nto a cl ean contai ner for reuse (Fi g. 11).
(3) Di sconnect the headl amp and dash wi re har-
ness connector from the connector receptacl e for the
front washer pump/motor.
Fig. 10 Washer Pump/Motor
1 - MOTOR
2 - CONNECTOR RECEPTACLE
3 - OUTLET NIPPLE
4 - INLET NIPPLE
5 - PUMP
Fig. 11 Washer Pump/Motor Remove/Install
1 - REAR BODY WIRE HARNESS
2 - WASHER RESERVOIR
3 - REAR WASHER PUMP/MOTOR
4 - HEADLAMP & DASH WIRE HARNESS
5 - FRONT WASHER SUPPLY HOSE
6 - FRONT WASHER PUMP/MOTOR
7 - REAR WASHER SUPPLY HOSE
8R - 12 FRONT WIPERS/WASHERS TJ
FRONT WASHER PUMP MOTOR (Continued)
(4) Usi ng a tri m sti ck or another sui tabl e wi de
fl at-bl aded tool , gentl y pry the barbed i nl et ni ppl e of
the front washer pump/motor out of the rubber grom-
met seal i n the washer reservoi r. Care must be taken
not to damage the washer reservoi r.
(5) Remove the front washer pump/motor from the
washer reservoi r.
(6) Remove the rubber grommet seal from the
front washer pump/motor mounti ng hol e i n the
washer reservoi r and di scard.
INSTALLATION
(1) I nstal l a new rubber grommet seal i nto the
front washer pump/motor mounti ng hol e of the
washer reservoi r.
(2) Posi ti on the front washer pump/motor i nl et
ni ppl e to the mounti ng hol e i n the washer reservoi r
(Fi g. 11).
(3) Usi ng hand pressure, fi rml y and evenl y press
on the front washer pump/motor to engage the i nl et
ni ppl e through the rubber grommet seal and i nto the
washer reservoi r. Care must be taken not to damage
the washer reservoi r.
(4) Reconnect the headl amp and dash wi re harness
connector for the front washer pump/motor to the
washer pump/motor connector receptacl e.
(5) Reconnect the front washer suppl y hose to the
barbed outl et ni ppl e of the front washer pump/motor.
(6) Refi l l the washer reservoi r wi th the washer
fl ui d drai ned from the reservoi r duri ng the removal
procedure.
(7) Reconnect the battery negati ve cabl e.
FRONT WIPER ARM
DESCRIPTION
The front wi per arms are the ri gi d members
l ocated between the wi per pi vots that protrude from
the cowl pl enum cover/gri l l e panel near the base of
the wi ndshi el d and the wi per bl ades on the wi nd-
shi el d gl ass. The wi per arm has a di e cast metal
pi vot end (Fi g. 12). On the undersi de of thi s pi vot
end i s a l arge i nternal l y serrated socket formati on
wi th a smal l , movabl e, stamped steel l atch pl ate that
i s secured l oosel y under a smal l strap that i s staked
to the pi vot end.
The wi de end of a tapered, stamped steel channel
hi nges on and i s secured wi th a hi nge pi n to the
pi vot end of the wi per arm. One end of a l ong, ri gi d,
stamped steel strap, wi th a smal l hol e near i ts pi vot
end, i s ri veted and cri mped wi thi n the narrow end of
the stamped steel channel . The ti p of the wi per bl ade
end of thi s strap i s bent back under i tsel f to form a
smal l hook. Conceal ed wi thi n the stamped steel
channel , one end of a l ong spri ng i s hooked through a
hol e i n a smal l stamped steel strap on the hi nge pi n
wi thi n the di e cast pi vot end, whi l e the other end of
the spri ng i s hooked through the smal l hol e i n the
steel strap. The enti re wi per arm has a sati n bl ack
fi ni sh appl i ed to al l of i ts vi si bl e surfaces.
A wi per arm cannot be adjusted or repai red. I f
damaged or faul ty, the enti re wi per arm uni t must be
repl aced.
OPERATION
The front wi per arms are desi gned to mechani cal l y
transmi t the moti on from the wi per pi vots to the
wi per bl ades. The wi per arm must be properl y
i ndexed to the wi per pi vot i n order to mai ntai n the
proper wi per bl ade travel on the gl ass. The serrated
socket formati on i n the wi per arm pi vot end i nter-
l ocks wi th the serrati ons on the outer ci rcumference
of the wi per pi vot dri ver, provi di ng posi ti ve engage-
ment and fi ni te adjustment of thi s connecti on. The
l atch pl ate on the undersi de of the wi per arm pi vot
end l ocks the wi per arm to the wi per pi vot dri ver
when i n i ts i nstal l ed posi ti on; and, when i n i ts
unl ocked posi ti on, al so serves as a bl ocker to hol d the
spri ng-l oaded wi per arm off of the gl ass to faci l i tate
removal and i nstal l ati on. The spri ng-l oaded wi per
arm hi nge control s the down-force appl i ed through
the ti p of the wi per arm to the wi per bl ade on the
gl ass. The hook formati on on the ti p of the wi per arm
provi des a cradl e for securi ng and l atchi ng the wi per
bl ade pi vot bl ock to the wi per arm.
REMOVAL
(1) Li ft the front wi per arm far enough to rai se the
wi per bl ade off of the gl ass and permi t the wi per arm
l atch pl ate to be pul l ed out to i ts hol di ng posi ti on,
then rel ease the arm (Fi g. 13). The wi per arm and
Fig. 12 Wiper Arm
1 - LATCH
2 - WIPER ARM PIVOT END
TJ FRONT WIPERS/WASHERS 8R - 13
FRONT WASHER PUMP MOTOR (Continued)
bl ade wi l l remai n off the gl ass wi th the l atch i n thi s
posi ti on.
CAUTION: The use of a screwdriver or other prying
tool to remove a wiper arm may distort it. This dis-
tortion could allow the arm to come off of the wiper
pivot during wiper operation, regardless of how
carefully it is reinstalled.
(2) Usi ng a sl i ght rocki ng moti on, remove the front
wi per arm pi vot end from the wi per pi vot dri ver.
INSTALLATION
NOTE: Be certain that the wiper motor is in the park
position before attempting to install the wiper arms.
Turn the ignition switch to the On position and
move the right multi-function switch control stalk to
its Off position. If the wiper pivots move, wait until
they stop moving, then turn the ignition switch
back to the Off position. The wiper motor is now in
its park position.
(1) The front wi per arms must be i ndexed to the
wi per pi vots wi th the wi per motor i n the park posi -
ti on to be properl y i nstal l ed (Fi g. 14). Posi ti on the
front wi per arm pi vot ends onto the wi per pi vot dri v-
ers so that the ti p of the wi per bl ade i s on the upper
edge of the l ower wi ndshi el d bl ackout area, + 15 mi l -
l i meters/– 0 mi l l i meter (+ 0.59 i nch/– 0 i nch).
(2) Once the wi per arm i s i ndexed to the wi per
pi vot, l i ft the wi per arm away from the wi ndshi el d
sl i ghtl y to rel i eve the spri ng tensi on on the l atch
pl ate, then push the l atch i nto the l ocked posi ti on
(Fi g. 13). Gentl y l ower the wi per arm unti l the wi per
bl ade i s i n posi ti on on the wi ndshi el d gl ass.
(3) Wet the wi ndshi el d gl ass, then operate the
front wi pers. Move the ri ght mul ti -functi on swi tch
control stal k to the Off posi ti on, then check for cor-
rect wi per arm posi ti on. Repeat the adjustment as
requi red.
FRONT WIPER BLADE
DESCRIPTION
Each front wi per bl ade i s secured by an i ntegral
l atchi ng pi vot bl ock to the hook formati on on the ti p
of each front wi per arm, and rests on the gl ass near
the base of the wi ndshi el d when the wi pers are not
i n operati on (Fi g. 15). The wi per bl ade consi sts of the
fol l owi ng components:
• Superstructure - The superstructure i ncl udes
several stamped steel bri dges and l i nks wi th cl aw
formati ons that gri p the wi per bl ade el ement. Al so
i ncl uded i n thi s uni t i s the l atchi ng, mol ded pl asti c
pi vot bl ock that secures the superstructure to the
wi per arm. Al l of the metal components of the wi per
bl ade have a sati n bl ack fi ni sh appl i ed.
Fig. 13 Front Wiper Arm Remove/Install
1 - LATCH
2 - WIPER ARM PIVOT END
Fig. 14 Front Wiper Arm Installation
1 - WINDSHIELD BLACKOUT AREA
2 - PARK BLADE ON UPPER EDGE OF BLACKOUT AREA
+15 mm – 0 mm (+0.59 in. – 0 in.)
Fig. 15 Wiper Blade - Typical
1 - RELEASE TAB
8R - 14 FRONT WIPERS/WASHERS TJ
FRONT WIPER ARM (Continued)
• Element - The wi per el ement or squeegee i s the
resi l i ent rubber member of the wi per bl ade that con-
tacts the gl ass.
• Flexor - The fl exor i s a ri gi d metal component
runni ng al ong the l ength of each si de of the wi per
el ement where i t i s gri pped by the cl aws of the
superstructure.
Al l model s have two 33-centi meter (13-i nch) l ong
front wi per bl ades wi th non-repl aceabl e rubber el e-
ments (squeegees). The wi per bl ades cannot be
adjusted or repai red. I f faul ty, worn, or damaged the
enti re wi per bl ade uni t must be repl aced.
OPERATION
The wi per bl ades are moved back and forth across
the gl ass by the wi per arms when the wi pers are
bei ng operated. The wi per bl ade superstructure i s
the fl exi bl e frame that gri ps the wi per bl ade el ement
and evenl y di stri butes the force of the spri ng-l oaded
wi per arm al ong the l ength of the el ement. The com-
bi nati on of the wi per arm force and the fl exi bi l i ty of
the superstructure makes the el ement conform to
and mai ntai n proper contact wi th the gl ass, even as
the bl ade i s moved over the vari ed curvature that
may be encountered across the gl ass surface. The
wi per el ement fl exor provi des the cl aws of the bl ade
superstructure wi th a ri gi d, yet fl exi bl e component
on the el ement whi ch can be gri pped. The rubber el e-
ment i s desi gned to be sti ff enough to mai ntai n an
even cl eani ng edge as i t i s drawn across the gl ass,
yet resi l i ent enough to conform to the gl ass surface
and fl i p from one cl eani ng edge to the other each
ti me the wi per bl ade changes di recti ons.
REMOVAL
NOTE: The notched end of the wiper element flexor
should always be oriented towards the end of the
wiper blade that is nearest to the wiper pivot.
(1) Li ft the front wi per arm to rai se the wi per
bl ade and el ement off of the gl ass.
(2) To remove the wi per bl ade from the wi per arm,
depress the pi vot bl ock l atch rel ease tab under the
ti p of the arm and sl i de the bl ade away from the ti p
towards the pi vot end of the arm far enough to di s-
engage the pi vot bl ock from the hook formati on on
the end of the arm (Fi g. 16).
(3) Extract the hook formati on on the ti p of the
wi per arm through the openi ng i n the wi per bl ade
superstructure just ahead of the wi per bl ade pi vot
bl ock/l atch uni t.
CAUTION: Do not allow the wiper arm to spring
back against the glass without the wiper blade in
place or the glass may be damaged.
(4) Gentl y l ower the ti p of the wi per arm onto the
gl ass.
INSTALLATION
NOTE: The notched end of the wiper element flexor
should always be oriented towards the end of the
wiper blade that is nearest to the wiper pivot.
(1) Li ft the front wi per arm off of the wi ndshi el d
gl ass.
(2) Posi ti on the front wi per bl ade near the hook
formati on on the ti p of the arm wi th the notched end
of the wi per el ement fl exor ori ented towards the end
of the wi per arm that i s nearest to the wi per pi vot.
(3) I nsert the hook formati on on the ti p of the
wi per arm through the openi ng i n the wi per bl ade
superstructure ahead of the wi per bl ade pi vot bl ock/
l atch uni t far enough to engage the pi vot bl ock i nto
the hook (Fi g. 16).
(4) Sl i de the wi per bl ade pi vot bl ock/l atch up i nto
the hook formati on on the ti p of the wi per arm unti l
the l atch rel ease tab snaps i nto i ts l ocked posi ti on.
Latch engagement wi l l be accompani ed by an audi bl e
cl i ck.
(5) Gentl y l ower the wi per bl ade onto the gl ass.
FRONT WIPER MODULE
DESCRIPTION
The front wi per modul e i s secured wi th three
screws, one each at the motor bracket and the two
pi vot brackets through rubber i nsul ators to the cowl
top panel and conceal ed wi thi n the cowl pl enum area
beneath the cowl pl enum cover/gri l l e panel (Fi g. 17).
The dri ver ends of the wi per pi vot shafts that pro-
trude through dedi cated openi ngs i n the cowl pl enum
cover/gri l l e panel to dri ve the wi per arms and bl ades
are the onl y vi si bl e components of the front wi per
modul e. The front wi per modul e consi sts of the fol -
l owi ng major components:
Fig. 16 Wiper Blade Remove/Install - Typical
1 - RELEASE TAB
TJ FRONT WIPERS/WASHERS 8R - 15
FRONT WIPER BLADE (Continued)
• Bracket - The front wi per modul e bracket con-
si sts of a l ong tubul ar steel mai n member that has a
stamped pi vot bracket formati on near each end
where the two wi per pi vots are secured. A stamped
steel mounti ng pl ate for the wi per motor i s secured
wi th wel ds near the center of the mai n member. The
bracket i ncl udes metal -sl eeved rubber i sol ators at
each of the three bracket mounti ng poi nts.
• Crank Arm - The front wi per motor crank arm
i s a stamped steel uni t wi th a sl otted hol e on the
dri ven end that i s secured to the wi per motor output
shaft wi th a nut, and has a bal l stud secured to the
dri ve end.
• Linkage - The two front wi per l i nkage members
are each constructed of stamped steel . A connecti ng
l i nk wi th a pl asti c socket-type bushi ng i n each end i s
fi t over the pi vot bal l studs to joi n the two pi vots.
The wi per dri ve l i nk has a pl asti c socket-type bush-
i ng on each end. One end of the dri ve l i nk i s snap-fi t
over a second bal l stud on the passenger si de pi vot
crank arm, whi l e the other end i s snap-fi t over the
bal l stud on the wi per motor crank arm.
• Motor - The front wi per motor i s secured wi th
three screws to the motor mounti ng pl ate near the
center of the wi per modul e bracket and i s protected
by a rubber boot. The wi per motor output shaft
passes through a hol e i n the modul e bracket, where a
nut secures the wi per motor crank arm to the motor
output shaft. The two-speed permanent magnet
wi per motor features an i ntegral transmi ssi on, an
i nternal park swi tch, and an i nternal automati c
resetti ng ci rcui t breaker.
• Pivots - The two front wi per pi vots are secured
to the ends of the wi per modul e bracket. A crank arm
extends from the l ower end of each pi vot shaft. The
dri ver si de pi vot crank arm has a si ngl e bal l stud
secured to i t, whi l e the passenger si de crank arm has
two bal l studs. The upper end of each pi vot shaft
where the wi per arms wi l l be fastened each has an
external l y serrated drum-l i ke dri ver secured to i t.
The front wi per modul e for thi s model i s servi ced
onl y as a compl ete uni t. I f any l i nkage component or
the mounti ng bracket of the modul e i s faul ty or dam-
aged, the enti re front wi per modul e uni t must be
repl aced. The front wi per motor and boot are avai l -
abl e for servi ce repl acement as a uni t onl y.
OPERATION
The front wi per modul e operati on i s control l ed by
the battery current i nputs recei ved by the wi per
motor through the ri ght mul ti -functi on swi tch on the
steeri ng col umn. The wi per motor i s connected to the
vehi cl e el ectri cal system through a dedi cated take
out and wi re harness connector of the body wi re har-
ness. The wi per motor speed i s control l ed by current
fl ow to ei ther the l ow speed or the hi gh speed set of
brushes. The park swi tch i s a si ngl e pol e, si ngl e
throw, momentary swi tch wi thi n the wi per motor
that i s mechani cal l y actuated by the wi per motor
transmi ssi on components. The park swi tch al ter-
natel y cl oses the wi per park swi tch sense ci rcui t to
ground or to battery current, dependi ng upon the
posi ti on of the wi pers on the gl ass. Thi s feature
al l ows the motor to compl ete i ts current wi pe cycl e
after the wi per system has been turned Off, and to
park the wi per bl ades i n the l owest porti on of the
wi pe pattern. The automati c resetti ng ci rcui t breaker
protects the motor from overl oads. The wi per motor
crank arm, the two wi per l i nkage members, and the
two wi per pi vots mechani cal l y convert the rotary out-
put of the wi per motor to the back and forth wi pi ng
moti on of the wi per arms and bl ades on the gl ass.
REMOVAL
(1) Remove the front wi per arms from the wi per
pi vots. (Refer to 8 - ELECTRI CAL/FRONT WI PERS/
WASHERS/FRONT WI PER ARM - REMOVAL).
(2) Unl atch, open and support the hood.
(3) Di sconnect and i sol ate the battery negati ve
cabl e.
(4) Remove the cowl pl enum cover/gri l l e panel
from over the cowl pl enum. (Refer to 23 - BODY/EX-
TERI OR/COWL GRI LLE AND SCREEN -
REMOVAL).
Fig. 17 Front Wiper Module
1 - SCREW (3)
2 - MODULE BRACKET
3 - WIRE HARNESS CONNECTOR
4 - WIPER MOTOR
8R - 16 FRONT WIPERS/WASHERS TJ
FRONT WIPER MODULE (Continued)
(5) Di sconnect the body wi re harness connector for
the front wi per motor from the motor pi gtai l wi re
connector (Fi g. 18).
(6) Remove the three screws that secure the front
wi per modul e mounti ng bracket to the cowl pl enum
panel .
(7) Remove the front wi per modul e from the cowl
pl enum panel as a uni t.
DISASSEMBLY
The front wi per motor and i ts rubber boot are
avai l abl e for servi ce repl acement. Fol l owi ng are the
procedures for di sassembl i ng these components from
the front wi per modul e uni t.
(1) Remove the front wi per modul e from the cowl
pl enum. (Refer to 8 - ELECTRI CAL/FRONT WI P-
ERS/WASHERS/FRONT WI PER MODULE -
REMOVAL).
(2) Rel ease the retai ner that secures the wi per
motor pi gtai l wi re connector to the front wi per mod-
ul e bracket.
(3) Turn the front wi per modul e over and remove
the nut that secures the wi per motor crank arm to
the wi per motor output shaft.
(4) Remove the three screws that secure the wi per
motor to the front wi per modul e mounti ng bracket.
(5) Remove the wi per motor from the front wi per
modul e bracket.
ASSEMBLY
The front wi per motor and i ts rubber boot are
avai l abl e for servi ce repl acement. Fol l owi ng are the
procedures for reassembl i ng these components onto
the front wi per modul e uni t.
(1) Posi ti on the wi per motor onto the front wi per
modul e bracket.
(2) I nstal l and ti ghten the three screws that secure
the wi per motor to the front wi per modul e bracket.
Ti ghten the screws to 8 N·m (70 i n. l bs.).
(3) Posi ti on the wi per motor crank arm onto the
front wi per motor output shaft.
(4) I nstal l and ti ghten the nut that secures the
wi per motor crank arm to the front wi per motor out-
put shaft. Ti ghten the nut to 12 N·m (101 i n. l bs.).
(5) Engage the wi per motor pi gtai l wi re connector
retai ner i n the l ocati ng hol e on the front wi per mod-
ul e bracket.
(6) Rei nstal l the front wi per modul e i nto the cowl
pl enum. (Refer to 8 - ELECTRI CAL/FRONT WI P-
ERS/WASHERS/FRONT WI PER MODULE -
I NSTALLATI ON).
INSTALLATION
(1) Posi ti on the front wi per modul e i nto the cowl
pl enum as a uni t (Fi g. 18).
(2) I nstal l and ti ghten the three screws that secure
the front wi per modul e mounti ng bracket to the cowl
pl enum panel . Ti ghten the screws to 12 N·m (105 i n.
l bs.).
(3) Reconnect the body wi re harness connector for
the front wi per motor to the motor pi gtai l wi re con-
nector.
(4) Rei nstal l the cowl pl enum cover/gri l l e panel
over the cowl pl enum. (Refer to 23 - BODY/EXTERI -
OR/COWL GRI LLE AND SCREEN - I NSTALLA-
TI ON).
(5) Reconnect the battery negati ve cabl e.
(6) Cl ose and l atch the hood.
(7) Rei nstal l the front wi per arms onto the wi per
pi vots. (Refer to 8 - ELECTRI CAL/FRONT WI PERS/
WASHERS/FRONT WI PER ARM - I NSTALLATI ON).
Fig. 18 Front Wiper Module Remove/Install
1 - SCREW (3)
2 - MODULE BRACKET
3 - WIRE HARNESS CONNECTOR
4 - WIPER MOTOR
TJ FRONT WIPERS/WASHERS 8R - 17
FRONT WIPER MODULE (Continued)
RIGHT MULTI-FUNCTION
SWITCH
DESCRIPTION
The ri ght mul ti -functi on swi tch i s l ocated on the
ri ght si de of the steeri ng col umn (Fi g. 19). The onl y
vi si bl e components of the ri ght mul ti -functi on swi tch
are the control stal k and control knob that extend
through dedi cated openi ngs i n the ri ght si de of the
steeri ng col umn shrouds, just bel ow the steeri ng
wheel . The remai nder of the swi tch, i ts mounti ng
provi si ons, and i ts el ectri cal connecti ons are al l con-
ceal ed beneath the steeri ng col umn shrouds. The
swi tch housi ng and control s are constructed of
mol ded bl ack pl asti c. The ri ght mul ti -functi on swi tch
i s secured by two screws to a mounti ng housi ng that
i s i ntegral to the l eft mul ti -functi on swi tch.
The ri ght mul ti -functi on swi tch control stal k has
both whi te nomencl ature and I nternati onal Control
and Di spl ay Symbol s graphi cs appl i ed to i t, whi ch
cl earl y i denti fy i ts many functi ons. On the end of the
control stal k i s a pl asti c control knob wi th a rounded
end and a fl attened face to al l ow i t to be easi l y
rotated. A si ngl e connector receptacl e contai ni ng si x
termi nal pi ns i s i ntegral to the back of the swi tch
housi ng and connects the swi tch to the vehi cl e el ec-
tri cal system through a dedi cated take out and con-
nector of the body wi re harness. The ri ght mul ti -
functi on swi tch cannot be adjusted or repai red and, i f
faul ty or damaged, i t must be repl aced.
The ri ght mul ti -functi on swi tch i s the pri mary con-
trol for the front wi per and washer system, and con-
tai ns swi tches, ci rcui try, an i ntermi ttent wi pe l ogi c
ci rcui t, and an i nternal wi per motor rel ay to provi de
the fol l owi ng functi ons and features:
• Continuous Front Wipe Modes - The i nternal
ci rcui try and hardware of the ri ght mul ti -functi on
swi tch control stal k provi de two conti nuous front
wi pe swi tch posi ti ons, l ow speed or hi gh speed.
• Front Washer Mode - The i nternal ci rcui try
and hardware of the ri ght mul ti -functi on swi tch con-
trol stal k provi de front washer system operati on.
• Front Wipe-After-Wash Mode - The i nternal
ci rcui try and hardware of the ri ght mul ti -functi on
swi tch control stal k provi de a wi pe-after-wash mode.
• Front Wiper Mist Mode - The i nternal ci r-
cui try and hardware of the ri ght mul ti -functi on
swi tch control stal k provi de a front wi per system
mi st mode.
• Intermittent Front Wipe Mode - The i nternal
ci rcui try and hardware of the ri ght mul ti -functi on
swi tch control stal k and control knob provi de an
i ntermi ttent front wi pe mode wi th adjustabl e del ay
i nterval posi ti ons.
Fig. 19 Multi-Function Switch
1 - LEFT MULTI-FUNCTION SWITCH CONTROL STALK
2 - HAZARD WARNING SWITCH BUTTON
3 - RIGHT MULTI-FUNCTION SWITCH CONTROL STALK
4 - SCREW (2)
5 - TURN SIGNAL CANCEL ACTUATOR
6 - LEFT MULTI-FUNCTION SWITCH CONTROL RING
7 - LEFT MULTI-FUNCTION SWITCH CONTROL KNOB
8R - 18 FRONT WIPERS/WASHERS TJ
OPERATION
The ri ght mul ti -functi on swi tch uses an i nternal
l ogi c ci rcui t, an i nternal rel ay and conventi onal l y
swi tched outputs to control the many functi ons and
features i t provi des. The swi tch recei ves battery cur-
rent on a fused i gni ti on swi tch output (run-acc) ci r-
cui t from a fuse i n the Power Di stri buti on Center
(PDC) and the wi per and washer system fuse i n the
fuse bl ock whenever the i gni ti on swi tch i s i n the On
or Accessory posi ti ons. The el ectroni c i ntermi ttent
wi pe l ogi c ci rcui t wi thi n the swi tch recei ves a l ogi c
ground at al l ti mes through the body wi re harness
from a take out wi th an eyel et termi nal connector
secured under a ground screw on the l eft i nner cowl
si de panel , bel ow the l eft end of the i nstrument
panel .
Fol l owi ng are descri pti ons of how the ri ght mul ti -
functi on swi tch control stal k and control knob are
operated to control the functi ons and features they
provi de. Refer to the owner’s manual i n the vehi cl e
gl ove box for more i nformati on on the features, use
and operati on of the ri ght mul ti -functi on swi tch.
• Front Wash Mode - Pul l i ng the control stal k of
the ri ght mul ti -functi on swi tch towards the steeri ng
wheel actuates the momentary si ngl e pol e, si ngl e
throw front washer swi tch and operates the front
washer pump/motor.
• Front Wipe Modes - Movi ng the control stal k
of the ri ght mul ti -functi on swi tch up or down to one
of four detent posi ti ons actuates the tri pl e pol e, qua-
drupl e throw front wi per swi tch and sel ects the Off,
Low, Hi gh, or Del ay front wi per operati ng mode.
Movi ng the control stal k downward from the Off
posi ti on actuates a momentary si ngl e pol e, si ngl e
throw swi tch that sel ects the Mi st operati ng mode.
• Intermittent Front Wipe Delay Intervals -
Rotati ng the control knob on the end of the control
stal k actuates the front wi per del ay vari abl e resi stor
and sel ects the wi per del ay i nterval when the Del ay
mode i s sel ected wi th the front wi per swi tch control
stal k.
The i ntermi ttent wi pe l ogi c ci rcui t wi thi n the ri ght
mul ti -functi on swi tch moni tors i nputs from the front
wi per swi tch ci rcui try, the front washer swi tch ci r-
cui try, the front wi per del ay vari abl e resi stor, and the
front wi per motor park swi tch. The programmi ng of
the l ogi c ci rcui t then determi nes the proper outputs
to the front wi per motor. The l ow current l ogi c ci rcui t
control s the hi gh current front wi per motor by pul l -
i ng the control coi l of the i ntegral wi per motor rel ay
to ground. The wi per motor rel ay swi tches a ci rcui t
that feeds battery current to the l ow speed or hi gh
speed brush of the front wi per motor through the
appropri ate ri ght mul ti -functi on swi tch ci rcui ts.
DIAGNOSIS AND TESTING - RIGHT MULTI-
FUNCTION SWITCH
Be certai n to perform the di agnosi s for the front
wi per system and/or front washer system before test-
i ng the ri ght mul ti -functi on swi tch. (Refer to 8 -
ELECTRI CAL/FRONT WI PERS/WASHERS - DI AG-
NOSI S AND TESTI NG). Refer to the appropri ate
wi ri ng i nformati on. The wi ri ng i nformati on i ncl udes
wi ri ng di agrams, proper wi re and connector repai r
procedures, detai l s of wi re harness routi ng and
retenti on, connector pi n-out i nformati on and l ocati on
vi ews for the vari ous wi re harness connectors, spl i ces
and grounds.
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE SUPPLEMENTAL RESTRAINT SYS-
TEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, AIRBAG, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE BEFORE PERFORMING FURTHER DIAG-
NOSIS OR SERVICE. THIS IS THE ONLY SURE WAY
TO DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT.
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the ri ght mul ti -functi on swi tch from
the steeri ng col umn and di sconnect the body wi re
harness connector for the swi tch from the swi tch con-
nector receptacl e.
(3) Usi ng an ohmmeter, check the ri ght mul ti -func-
ti on swi tch conti nui ty at the termi nal s (Fi g. 20) i n
the swi tch connector receptacl e as shown i n the
Ri ght Mul ti -Functi on Swi tch Tests tabl e.
Fig. 20 Right Multi-Function Switch Connector
Receptacle
TJ FRONT WIPERS/WASHERS 8R - 19
RIGHT MULTI-FUNCTION SWITCH (Continued)
RIGHT MULTI-FUNCTION SWITCH TESTS
SWITCH POSITION
CONTINUITY BETWEEN
PINS
OFF 1 & 6
*LOW 4 & 6
*MIST 4 & 6
HIGH 4 & 5
WASH 3 & 4
*DELAY 1 & 6
*The intermittent wipe logic circuit within the right
multi-function switch contains active electronic
elements, which cannot be tested using conventional
diagnostic tools. In addition, the function of the
normally open contacts of the wiper relay internal to
the switch cannot be tested properly unless the switch
is connected to battery current (Pin 4) and ground
(Pin 2). If all circuits and functions of the front wiper
system and the right multi-function switch are
operative except for the intermittent wipe, wipe-after-
wash feature, and/or the front wipers will not park,
replace the right multi-function switch with a known
good unit and test system operation again.
(4) I f the ri ght mul ti -functi on swi tch fai l s any of
the conti nui ty checks, repl ace the faul ty swi tch. I f
the swi tch i s OK, test and repai r the front wi per and
washer system ci rcui ts between the ri ght mul ti -func-
ti on swi tch and the front wi per motor or the front
washer pump/motor as requi red.
REMOVAL
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE SUPPLEMENTAL RESTRAINT SYS-
TEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, AIRBAG, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE BEFORE PERFORMING FURTHER DIAG-
NOSIS OR SERVICE. THIS IS THE ONLY SURE WAY
TO DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT.
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the steeri ng col umn openi ng cover
from the i nstrument panel . (Refer to 23 - BODY/I N-
STRUMENT PANEL/STEERI NG COLUMN OPEN-
I NG COVER - REMOVAL).
(3) From bel ow the steeri ng col umn, remove the
two screws that secure the l ower steeri ng col umn
shroud to the upper shroud (Fi g. 21).
(4) I f the vehi cl e i s equi pped wi th the opti onal ti l t
steeri ng col umn, move the ti l t steeri ng col umn to the
ful l y l owered posi ti on and l eave the ti l t rel ease l ever
i n the rel eased (down) posi ti on.
(5) Remove both the upper and l ower shrouds from
the steeri ng col umn.
(6) Di sconnect the body wi re harness connector for
the l eft mul ti -functi on swi tch from the connector
receptacl e on the back of the swi tch.
(7) Di sconnect the body wi re harness connector for
the ri ght mul ti -functi on swi tch from the connector
receptacl e on the back of the swi tch.
(8) Remove the two screws that secure the mul ti -
functi on swi tch assembl y to the upper steeri ng col -
umn housi ng (Fi g. 22).
(9) Remove the mul ti -functi on swi tch assembl y
from the upper steeri ng col umn housi ng.
(10) Remove the two smal l screws that secure the
ri ght mul ti -functi on swi tch to the l eft mul ti -functi on
swi tch mounti ng housi ng.
(11) Grasp the ri ght mul ti -functi on swi tch control
stal k fi rml y and pul l the swi tch toward the ri ght far
enough to di sengage the al i gnment pi ns on the top (1
Fig. 21 Steering Column Shrouds Remove/Install
1 - LEFT MULTI-FUNCTION SWITCH
2 - UPPER SHROUD
3 - RIGHT MULTI-FUNCTION SWITCH
4 - CLOCKSPRING
5 - IGNITION LOCK CYLINDER HOUSING
6 - LOWER SHROUD
7 - SCREW (2)
8R - 20 FRONT WIPERS/WASHERS TJ
RIGHT MULTI-FUNCTION SWITCH (Continued)
pi n) and bottom (2 pi ns) of the ri ght swi tch housi ng
from the al i gnment ramps on the l eft swi tch mount-
i ng housi ng.
(12) Remove the ri ght mul ti -functi on swi tch from
the l eft mul ti -functi on swi tch mounti ng housi ng.
INSTALLATION
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE SUPPLEMENTAL RESTRAINT SYS-
TEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, AIRBAG, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE BEFORE PERFORMING FURTHER DIAG-
NOSIS OR SERVICE. THIS IS THE ONLY SURE WAY
TO DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT.
(1) Posi ti on the ri ght mul ti -functi on swi tch to the
mounti ng housi ng of the l eft mul ti -functi on swi tch.
(2) Grasp the ri ght mul ti -functi on swi tch control
stal k fi rml y and sl i de the swi tch to the l eft far
enough to engage the al i gnment pi ns on the top (1
pi n) and bottom (2 pi ns) of the ri ght swi tch housi ng
i nto the al i gnment ramps of the l eft mul ti -functi on
swi tch mounti ng housi ng.
(3) I nstal l and ti ghten the two smal l screws that
secure the ri ght mul ti -functi on swi tch to the l eft
mul ti -functi on swi tch mounti ng housi ng (Fi g. 22).
Ti ghten the screws to 2 N·m (20 i n. l bs.).
CAUTION: Before attempting to install the multi-
function switch, be certain that the left switch con-
trol stalk is in the neutral turn signal position and
the turn signal cancel actuator is in the retracted
(neutral) position.
(4) Posi ti on the mul ti -functi on swi tch assembl y
onto the upper steeri ng col umn housi ng.
(5) I nstal l and ti ghten the two screws that secure
the mul ti -functi on swi tch assembl y to the upper
steeri ng col umn housi ng. Ti ghten the screws to 2
N·m (20 i n. l bs.).
(6) Reconnect the body wi re harness connector for
the ri ght mul ti -functi on swi tch to the connector
receptacl e on the back of the swi tch.
(7) Reconnect the body wi re harness connector for
the l eft mul ti -functi on swi tch to the connector recep-
tacl e on the back of the swi tch.
(8) Posi ti on both the upper and l ower shrouds onto
the steeri ng col umn (Fi g. 23). Be certai n that the
l ocati ng tabs for the l eft and ri ght mul ti -functi on
swi tch control stal k watershi el ds are properl y
engaged i n the openi ngs of both the upper and l ower
shrouds.
(9) From bel ow the steeri ng col umn, i nstal l and
ti ghten the two screws that secure the l ower steeri ng
col umn shroud to the upper shroud. Ti ghten the
screws to 2 N·m (18 i n. l bs.).
(10) I f the vehi cl e i s equi pped wi th the opti onal ti l t
steeri ng col umn, move the ti l t steeri ng col umn to the
ful l y rai sed posi ti on and secure i t i n pl ace by movi ng
the ti l t rel ease l ever back to the l ocked (up) posi ti on.
Fig. 22 Multi-Function Switch Remove/Install
1 - LEFT MULTI-FUNCTION SWITCH
2 - SCREW (2)
3 - SCREW (2)
4 - RIGHT MULTI-FUNCTION SWITCH
5 - UPPER STEERING COLUMN HOUSING
Fig. 23 Shroud Remove/Install
1 - UPPER SHROUD
2 - LOWER SHROUD
TJ FRONT WIPERS/WASHERS 8R - 21
RIGHT MULTI-FUNCTION SWITCH (Continued)
(11) Rei nstal l the steeri ng col umn openi ng cover
onto the i nstrument panel . (Refer to 23 - BODY/I N-
STRUMENT PANEL/STEERI NG COLUMN OPEN-
I NG COVER - I NSTALLATI ON).
(12) Reconnect the battery negati ve cabl e.
WASHER RESERVOIR
DESCRIPTION
A si ngl e washer fl ui d reservoi r i s used for both the
standard front and opti onal rear washer systems
(Fi g. 24). The mol ded pl asti c washer fl ui d reservoi r i s
secured to the l eft front fender wheel house i n the
engi ne compartment. A bri ght yel l ow pl asti c fi l l er cap
i s l abel ed wi th the I nternati onal Control and Di spl ay
Symbol i con for “Wi ndshi el d Washer” and the text
“Washer Fl ui d Onl y” mol ded i nto i t and hi ghl i ghted
i n bl ack. The cap hi nges on a hi nge mol ded i nto the
cap and i s secured to the reservoi r by a hook mol ded
i nto the top of the reservoi r behi nd the fi l l er neck.
The cap snaps over the open end of the fi l l er neck
and i s seal ed wi th a rubber gasket.
There are separate, dedi cated hol es on the l ower
i nboard si de of the reservoi r provi ded for the mount-
i ng of the front and rear washer/pump motor uni ts.
On model s not equi pped wi th the opti onal rear
washer system, the rear washer pump/motor mount-
i ng hol e i n the washer reservoi r i s seal ed wi th a
pl asti c pl ug. The washer pump/motor uni ts are
secured and seal ed to the reservoi r by the i nterfer-
ence fi t between the barbed i nl et ni ppl e of each
pump and a rubber grommet seal i nstal l ed i n each
pump mounti ng hol e. A l ocati ng tab on the bottom of
the reservoi r fi ts i nto a mati ng sl ot i n the l eft front
fender wheel house, and the reservoi r i s secured to
the wheel house by two screws i nstal l ed through two
mounti ng tabs that are i ntegral to the reservoi r.
The washer reservoi r cannot be repai red and, i f faul ty
or damaged, i t must be repl aced. The reservoi r fi l l er cap
i s avai l abl e for i ndi vi dual servi ce repl acement.
OPERATION
The washer fl ui d reservoi r provi des a secure,
on-vehi cl e storage l ocati on for a l arge reserve of
washer fl ui d for operati on of the standard front and
opti onal rear washer systems. The washer reservoi r
fi l l er cap provi des a cl earl y marked and readi l y
accessi bl e poi nt from whi ch to add washer fl ui d to
the reservoi r. The front and rear washer/pump motor
uni ts are l ocated i n a sump area on the i nboard si de
of the reservoi r to be certai n that washer fl ui d wi l l
be avai l abl e to the pumps as the fl ui d l evel i n the
reservoi r becomes depl eted. The front washer pump/
motor uni t i s mounted i n the l owest posi ti on i n the
sump so that the front washers wi l l operate even
after the rear washer system wi l l no l onger operate.
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the two screws that secure the washer
reservoi r to the l eft front fender wheel house (Fi g. 25).
Fig. 24 Washer Reservoir
1 - WASHER RESERVOIR
2 - HOOK
3 - CAP
4 - MOUNTING TAB (2)
5 - FRONT WASHER PUMP/MOTOR HOLE
6 - REAR WASHER PUMP/MOTOR HOLE
7 - LOCATING TAB
Fig. 25 Washer Reservoir Remove/Install
1 - WASHER RESERVOIR
2 - SCREW (2)
3 - LEFT FRONT FENDER
4 - FRONT WASHER PUMP/MOTOR
5 - REAR WASHER PUMP/MOTOR
8R - 22 FRONT WIPERS/WASHERS TJ
RIGHT MULTI-FUNCTION SWITCH (Continued)
(3) Li ft the reservoi r far enough to access the
washer pump/motor(s).
(4) Di sconnect the washer suppl y hose(s) from the
barbed outl et ni ppl e(s) of the washer pump/motor
uni t(s) and al l ow the washer fl ui d from the washer
reservoi r to drai n i nto a cl ean contai ner for reuse.
(5) Di sconnect the headl amp and dash wi re har-
ness connector for the front washer pump/motor from
the connector receptacl e on the motor.
(6) I f the vehi cl e i s so equi pped, di sconnect the
rear body wi re harness connector for the rear washer
pump/motor from the connector receptacl e on the
motor.
(7) Remove the washer reservoi r from the engi ne
compartment.
INSTALLATION
(1) Posi ti on the washer reservoi r i nto the engi ne
compartment (Fi g. 25).
(2) I f the vehi cl e i s so equi pped, reconnect the rear
body wi re harness connector for the rear washer
pump/motor to the connector receptacl e on the motor.
(3) Reconnect the headl amp and dash wi re harness
connector for the front washer pump/motor to the
connector receptacl e on the motor.
(4) Reconnect the washer suppl y hose(s) to the
barbed outl et ni ppl e(s) of the washer pump/motor
uni t(s).
(5) Posi ti on the washer reservoi r onto the l eft front
fender wheel house. Be certai n to i nsert the l ocati ng
tab on the bottom of the reservoi r i nto the l ocati ng
sl ot i n the wheel house panel .
(6) I nstal l and ti ghten the two screws that secure
the washer reservoi r to the l eft front fender wheel
house. Ti ghten the screws to 8 N·m (70 i n. l bs.).
(7) Refi l l the washer reservoi r wi th cl ean washer
fl ui d.
(8) Reconnect the battery negati ve cabl e.
TJ FRONT WIPERS/WASHERS 8R - 23
WASHER RESERVOIR (Continued)
REAR WIPERS/WASHERS
TABLE OF CONTENTS
page page
REAR WIPERS/WASHERS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 24
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
DIAGNOSIS AND TESTING - REAR WIPER &
WASHER SYSTEM . . . . . . . . . . . . . . . . . . . . 27
CLEANING - REAR WIPER & WASHER
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
INSPECTION - REAR WIPER & WASHER
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
REAR CHECK VALVE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 30
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 31
REAR WASHER HOSES/TUBES
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 31
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
REAR WASHER NOZZLE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 32
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 33
REAR WASHER PUMP MOTOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 33
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 34
REAR WIPER ARM
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 34
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 35
REAR WIPER BLADE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 36
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 37
REAR WIPER MOTOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 37
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 39
REAR WIPER MOTOR TRIM COVER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 40
REAR WIPER/WASHER SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 40
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
DIAGNOSIS AND TESTING - REAR WIPER &
WASHER SWITCH . . . . . . . . . . . . . . . . . . . . . 41
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 42
REAR WIPERS/WASHERS
DESCRIPTION
An el ectri cal l y operated fi xed speed rear wi per and
washer system i s opti onal factory-i nstal l ed equi p-
ment on thi s model when i t i s al so equi pped wi th the
opti onal hardtop roof (Fi g. 1). The rear wi per and
washer system i ncl udes the fol l owi ng major compo-
nents, whi ch are descri bed i n further detai l el se-
where i n thi s servi ce i nformati on:
• Rear Check Valve - The rear washer system
check val ve i s l ocated near the bel t l i ne i n the l eft
rear corner of the passenger compartment i n the
vehi cl e. The rear check val ve al so serves as the i n-
l i ne connector between the body wi re harness hal f
and the hardtop wi re harness hal f of the rear washer
hose pl umbi ng.
• Rear Washer Nozzle - The rear washer nozzl e
i s l ocated i n a mounti ng hol e i n the rear l i ftgl ass just
bel ow and i nboard of the rear wi per motor output
shaft. A pl asti c nut secures the threaded ni ppl e on
the back of the nozzl e to the i nsi de of the l i ftgl ass.
• Rear Washer Plumbing - The pl umbi ng for
the rear washer system consi sts of rubber hoses and
mol ded pl asti c fi tti ngs. The pl umbi ng i s routed al ong
the l eft si de of the vehi cl e wi th the body wi re har-
ness from the washer reservoi r i n the engi ne com-
partment, through the dash i nto the passenger
compartment, and back to the l eft rear corner of the
body. The rear check val ve spl i ces the body wi re har-
ness hal f of the washer hose to the hardtop wi re har-
ness hal f of the hose at the l eft rear corner of the
body. The hardtop wi re harness and washer hose are
routed up the l eft rear corner of the hardtop and over
the upper l i ftgl ass openi ng header to the rear washer
nozzl e i n the upper ri ght corner of the rear l i ftgl ass.
A mol ded pl asti c washer hose cap i s secured by an
i ntegral bai l strap to the body wi re harness hal f of
the rear washer hose near the l eft rear corner of the
body. Thi s cap serves to pl ug the rear washer hose
when the hardtop i s removed from the vehi cl e.
8R - 24 REAR WIPERS/WASHERS TJ
• Rear Washer Pump/Motor - The rear washer
pump/motor uni t i s l ocated i n a dedi cated hol e on the
l ower i nboard si de of the washer reservoi r, on the top
of the l eft front fender wheel house i n the engi ne
compartment. The opti onal rear washer pump i s
l ocated just behi nd and above the standard front
washer pump/motor uni t on the reservoi r.
• Rear Wiper and Washer Switch - The rear
wi per and washer swi tch i s l ocated i n the accessory
swi tch bezel near the bottom of the center stack area
on the i nstrument panel . Onl y the swi tch rocker but-
ton i s vi si bl e through the l ower openi ng of the i nstru-
ment panel center bezel , the remai nder of the swi tch
i s conceal ed behi nd the accessory swi tch bezel wi thi n
the i nstrument panel . The rear wi per and washer
swi tch i s dedi cated to provi di ng al l of the dri ver con-
trol s for both the rear wi per and the rear washer sys-
tems.
• Rear Wiper Arm- The si ngl e rear wi per arm i s
secured by a nut di rectl y to the rear wi per motor out-
put shaft, whi ch extends through a mounti ng hol e i n
the l i ftgl ass i nboard of the upper ri ght l i ftgl ass
hi nge.
• Rear Wiper Blade - The si ngl e rear wi per
bl ade i s secured to the rear wi per arm wi th an i nte-
gral l atch, and i s parked i n a hori zontal posi ti on near
the top of the l i ftgl ass when the rear wi per system i s
not i n operati on.
Fig. 1 Rear Wiper & Washer System
1 - WIPER ARM & BLADE
2 - WIPER MOTOR
3 - WASHER NOZZLE
4 - REAR WIPER/WASHER SWITCH
5 - REAR WASHER PUMP/MOTOR
6 - REAR WASHER HOSE CAP/CHECK VALVE
TJ REAR WIPERS/WASHERS 8R - 25
REAR WIPERS/WASHERS (Continued)
• Rear Wiper Motor - The rear wi per motor out-
put shaft i s the onl y vi si bl e component of the rear
wi per motor. The remai nder of the motor i s conceal ed
behi nd a pl asti c tri m cover on the i nsi de of the l i ft-
gl ass near the upper ri ght l i ftgl ass hi nge. The rear
wi per motor i ncl udes the motor bracket, the rear
wi per motor, an i nternal automati c resetti ng ci rcui t
breaker, a di ode, and the rear wi per motor park
swi tch.
• Washer Reservoir - The rear washer system
shares a si ngl e reservoi r wi th the front washer sys-
tem, but has i ts own dedi cated washer pump/motor
uni t and uni que pl umbi ng provi si ons. The reservoi r
i s secured to the top of the l eft front fender wheel
house wi thi n the engi ne compartment of the vehi cl e.
Hard wi red ci rcui try connects the rear wi per and
washer system components to the el ectri cal system of
the vehi cl e. These hard wi red ci rcui ts are i ntegral to
several wi re harnesses, whi ch are routed throughout
the vehi cl e and retai ned by many di fferent methods.
These ci rcui ts may be connected to each other, to the
vehi cl e el ectri cal system and to the rear wi per and
washer system components through the use of a com-
bi nati on of sol dered spl i ces, spl i ce bl ock connectors,
and many di fferent types of wi re harness termi nal
connectors and i nsul ators. Refer to the appropri ate
wi ri ng i nformati on. The wi ri ng i nformati on i ncl udes
wi ri ng di agrams, proper wi re and connector repai r
procedures, further detai l s on wi re harness routi ng
and retenti on, as wel l as pi n-out and l ocati on vi ews
for the vari ous wi re harness connectors, spl i ces and
grounds.
OPERATING MODES
The components of the rear wi per and washer sys-
tem are desi gned to work i n concert to provi de the
fol l owi ng operati ng modes:
• Continuous Wipe Mode - When the rear wi per
and washer swi tch rocker i s moved to the Wi pe posi -
ti on, the rear wi per wi l l be operated i n a conti nuous
manner at a fi xed wi pe cycl e speed unti l the swi tch
i s moved to the Off posi ti on. When the Off posi ti on i s
sel ected, the rear wi per motor wi l l conti nue to oper-
ate unti l the current wi pe cycl e i s compl ete, then
park the wi per bl ade i n a hori zontal posi ti on near
the top of the l i ftgl ass.
• Washer Mode - The rear wi per and washer
swi tch rocker must fi rst be moved to the Wi pe detent
i n order to access the momentary Wash posi ti on and
operate the rear washer system. When the Wash
posi ti on i s sel ected, the rear washer system wi l l di s-
pense washer fl ui d onto the l i ftgl ass and the rear
wi per motor wi l l operate i n a conti nuous mode for as
l ong as the swi tch i s hel d cl osed. The rear wi per and
washer swi tch rocker must be manual l y moved back
to the Off posi ti on fol l owi ng rear washer operati on i n
order to turn the rear wi per system off.
OPERATION
The rear wi per and washer system i s desi gned to
provi de the vehi cl e operator wi th a conveni ent, safe,
and rel i abl e means of mai ntai ni ng vi si bi l i ty through
the rear l i ftgl ass. The vari ous components of thi s sys-
tem are desi gned to convert el ectri cal energy pro-
duced by the vehi cl e el ectri cal system i nto the
mechani cal acti on of the wi per bl ade to wi pe the out-
si de surface of the gl ass, as wel l as i nto the hydraul i c
acti on of the washer system to appl y washer fl ui d
stored i n an on-board reservoi r to the area of the
gl ass to be wi ped. When combi ned, these components
provi de the means to effecti vel y mai ntai n cl ear vi si -
bi l i ty for the vehi cl e operator by removi ng excess
accumul ati ons of rai n, snow, bugs, mud, or other
mi nor debri s that mi ght be encountered whi l e dri v-
i ng the vehi cl e under numerous types of i ncl ement
operati ng condi ti ons from the outsi de of the l i ftgl ass
surface.
The vehi cl e operator i ni ti ates al l rear wi per and
washer system functi ons wi th the rear wi per and
washer swi tch l ocated i n the accessory swi tch bezel ,
just bel ow the heater and ai r condi ti oner control s i n
the center stack area of the i nstrument panel . Mov-
i ng the swi tch rocker downward to a detent posi ti on
sel ects the rear wi per system fi xed cycl e operati ng
mode. Movi ng the swi tch rocker downward past the
wi pe mode detent actuates the momentary rear
washer system swi tch.
The rear wi per and washer system wi l l onl y oper-
ate when the i gni ti on swi tch i s i n the On posi ti on.
When the i gni ti on swi tch i s i n the On posi ti on, bat-
tery current i s di rected from a fuse i n the Power Di s-
tri buti on Center (PDC) to the rear wi per and washer
system fuse i n the fuse bl ock. Thi s fuse provi des bat-
tery current through a fused i gni ti on swi tch output
(run) ci rcui t to the rear wi per and washer swi tch,
and to one fi xed contact of the rear wi per motor park
swi tch.
The hard wi red ci rcui ts and components of the rear
wi per and washer system may be di agnosed and
tested usi ng conventi onal di agnosti c tool s and proce-
dures.
OPERATING MODES
Fol l owi ng are paragraphs that bri efl y descri be the
operati on of each of the rear wi per and washer sys-
tem operati ng modes.
CONTINUOUS WIPE MODE
When the Wi pe posi ti on of the rear wi per and
washer swi tch rocker i s sel ected, the Wi pe mode ci r-
cui try wi thi n the swi tch di rects battery current
8R - 26 REAR WIPERS/WASHERS TJ
REAR WIPERS/WASHERS (Continued)
through the rear wi per motor control ci rcui t to the
rear wi per motor, whi ch causes the rear wi per to
cycl e conti nuousl y at a fi xed speed.
When the Off posi ti on of the rear wi per and
washer swi tch i s sel ected, one of two events i s possi -
bl e. The event that wi l l occur depends upon the posi -
ti on of the wi per bl ade on the l i ftgl ass at the moment
that the Off posi ti on i s sel ected. I f the wi per bl ade i s
i n the up posi ti on on the gl ass when the Off posi ti on
i s sel ected, the park swi tch i n the rear wi per motor
i s cl osed to ground through the rear wi per motor con-
trol ci rcui t i nput and the wi per motor ceases to oper-
ate. I f the wi per bl ade i s not i n the up posi ti on on
the gl ass when the Off posi ti on i s sel ected, the park
swi tch i s cl osed to battery current through the fused
i gni ti on swi tch output (run) ci rcui t. The park swi tch
di rects thi s battery current to the rear wi per motor
brush causi ng the motor to conti nue runni ng unti l
the wi per bl ade i s i n the up posi ti on on the gl ass, at
whi ch ti me the park swi tch opens the battery current
feed to the rear wi per motor brush and i s agai n
cl osed to ground through the rear wi per motor con-
trol ci rcui t i nput and the wi per motor ceases to oper-
ate.
WASH MODE
When the momentary Wash posi ti on of the rear
wi per and washer swi tch rocker i s sel ected, the Wash
posi ti on ci rcui try wi thi n the swi tch di rects battery
current to the rear washer pump and to the rear
washer motor control ci rcui t i nput of the rear wi per
motor, whi ch causes both the rear washer pump and
the rear wi per motor to operate for as l ong as the
rear wi per and washer swi tch rocker i s hel d i n the
momentary Wash posi ti on.
DIAGNOSIS AND TESTING - REAR WIPER &
WASHER SYSTEM
WIPER SYSTEM
The di agnosi s found here addresses an el ectri cal l y
i noperati ve rear wi per system. I f the rear wi per
motor operates, but the wi per does not move on the
l i ftgl ass, i nspect the mechani cal connecti on between
the rear wi per arm and the rear wi per motor output
shaft. I f OK, repl ace the faul ty rear wi per motor. I f
the wi per operates, but chatters, l i fts, or does not
cl ear the gl ass, cl ean and i nspect the rear wi per sys-
tem components as requi red. (Refer to 8 - ELECTRI -
CAL/REAR WI PERS/WASHERS - I NSPECTI ON) and
(Refer to 8 - ELECTRI CAL/REAR WI PERS/WASH-
ERS - CLEANI NG). Refer to the appropri ate wi ri ng
i nformati on. The wi ri ng i nformati on i ncl udes wi ri ng
di agrams, proper wi re and connector repai r proce-
dures, detai l s of wi re harness routi ng and retenti on,
connector pi n-out i nformati on and l ocati on vi ews for
the vari ous wi re harness connectors, spl i ces and
grounds.
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE SUPPLEMENTAL RESTRAINT SYS-
TEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, AIRBAG, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE BEFORE PERFORMING FURTHER DIAG-
NOSIS OR SERVICE. THIS IS THE ONLY SURE WAY
TO DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT.
(1) Check the rear wi per and washer fuse (Fuse 6 -
20 ampere) i n the fuse bl ock. I f OK, go to Step 2. I f
not OK, repai r the shorted ci rcui t or component as
requi red and repl ace the faul ty fuse.
(2) Turn the i gni ti on swi tch to the On posi ti on.
Check for battery vol tage at rear wi per and washer
fuse (Fuse 6 - 20 ampere) i n the fuse bl ock. I f OK, go
to Step 3. I f not OK, repai r the open fused i gni ti on
swi tch output (run) ci rcui t between the fuse bl ock
and the i gni ti on swi tch as requi red.
(3) Turn the i gni ti on swi tch to the Off posi ti on.
Di sconnect and i sol ate the battery negati ve cabl e.
Di sconnect the i nstrument panel wi re harness con-
nector for the rear wi per and washer swi tch from the
swi tch connector receptacl e. Reconnect the battery
negati ve cabl e. Turn the i gni ti on swi tch to the On
posi ti on. Check for battery vol tage at the fused i gni -
ti on swi tch output (run) ci rcui t cavi ty of the i nstru-
ment panel wi re harness connector for the rear wi per
and washer swi tch. I f OK, go to Step 4. I f not OK,
repai r the open fused i gni ti on swi tch output (run) ci r-
cui t between the rear wi per and washer swi tch and
the fuse bl ock as requi red.
(4) Turn the i gni ti on swi tch to the Off posi ti on.
Di sconnect and i sol ate the battery negati ve cabl e.
Check for conti nui ty between the ground ci rcui t cav-
i ty of the i nstrument panel wi re harness connector
for the rear wi per and washer swi tch and a good
ground. There shoul d be conti nui ty. I f OK, go to Step
5. I f not OK, repai r the open ground ci rcui t to ground
(G200) as requi red.
(5) Test the rear wi per and washer swi tch conti nu-
i ty. (Refer to 8 - ELECTRI CAL/REAR WI PERS/
WASHERS/REAR WI PER/WASHER SWI TCH -
DI AGNOSI S AND TESTI NG). I f OK, go to Step 6. I f
not OK, repl ace the faul ty rear wi per and washer
swi tch.
TJ REAR WIPERS/WASHERS 8R - 27
REAR WIPERS/WASHERS (Continued)
(6) Di sconnect the hardtop wi re harness connector
for the rear wi per motor from the motor pi gtai l wi re
connector. Reconnect the battery negati ve cabl e. Turn
the i gni ti on swi tch to the On posi ti on. Check for bat-
tery vol tage at the fused i gni ti on swi tch output (run)
ci rcui t cavi ty of the hardtop wi re harness connector
for the rear wi per motor. I f OK, go to Step 7. I f not
OK, repai r the open fused i gni ti on swi tch output
(run) ci rcui t between the rear wi per motor and the
fuse bl ock as requi red.
(7) Turn the i gni ti on swi tch to the Off posi ti on.
Di sconnect and i sol ate the battery negati ve cabl e.
Check for conti nui ty between the ground ci rcui t cav-
i ty of the hardtop wi re harness connector for the rear
wi per motor and a good ground. There shoul d be con-
ti nui ty. I f OK, go to Step 8. I f not OK, repai r the
open ground ci rcui t to ground (G302) as requi red.
(8) Check for conti nui ty between the rear wi per
motor control ci rcui t cavi ty of the hardtop wi re har-
ness connector for the rear wi per motor and a good
ground. There shoul d be no conti nui ty. I f OK, go to
Step 9. I f not OK, repai r the shorted rear wi per
motor control ci rcui t between the rear wi per motor
and the rear wi per and washer swi tch as requi red.
(9) Check for conti nui ty between the rear wi per
motor control ci rcui t cavi ti es of the hardtop wi re har-
ness connector for the rear wi per motor and the
i nstrument panel wi re harness connector for the rear
wi per and washer swi tch. There shoul d be conti nui ty.
I f OK, repl ace the faul ty rear wi per motor. I f not OK,
repai r the open rear wi per motor control ci rcui t
between the rear wi per motor and the rear wi per and
washer swi tch as requi red.
WASHER SYSTEM
The di agnosi s found here addresses an el ectri cal l y
i noperati ve rear washer system. I f the rear washer
pump/motor operates, but no washer fl ui d i s emi tted
from the rear washer nozzl e, be certai n to check the
fl ui d l evel i n the reservoi r. Al so i nspect the rear
washer system components as requi red. (Refer to 8 -
ELECTRI CAL/REAR WI PERS/WASHERS - I NSPEC-
TI ON). Refer to the appropri ate wi ri ng i nformati on.
The wi ri ng i nformati on i ncl udes wi ri ng di agrams,
proper wi re and connector repai r procedures, detai l s
of wi re harness routi ng and retenti on, connector pi n-
out i nformati on and l ocati on vi ews for the vari ous
wi re harness connectors, spl i ces and grounds.
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE SUPPLEMENTAL RESTRAINT SYS-
TEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, AIRBAG, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE BEFORE PERFORMING FURTHER DIAG-
NOSIS OR SERVICE. THIS IS THE ONLY SURE WAY
TO DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT.
(1) Turn the i gni ti on swi tch to the On posi ti on.
Pl ace the rear wi per and washer swi tch rocker i n the
Wi pe posi ti on. Check whether the rear wi per i s oper-
ati ng. I f OK, go to Step 2. I f not OK, repai r the wi per
system as requi red before you proceed wi th washer
system di agnosi s. Refer to WI PER SYSTEM.
(2) Turn the i gni ti on swi tch to the Off posi ti on.
Di sconnect and i sol ate the battery negati ve cabl e.
Di sconnect the body wi re harness connector for the
rear washer pump/motor from the pump/motor con-
nector receptacl e. Check for conti nui ty between the
ground ci rcui t cavi ty of the body wi re harness con-
nector for the rear washer pump/motor and a good
ground. There shoul d be conti nui ty. I f OK, go to Step
3. I f not OK, repai r the open ground ci rcui t to ground
(G302) as requi red.
(3) Reconnect the battery negati ve cabl e. Turn the
i gni ti on swi tch to the On posi ti on. Check for battery
vol tage at the rear washer motor control ci rcui t cav-
i ty of the body wi re harness connector for the rear
washer pump/motor whi l e the rear wi per and washer
swi tch rocker i s actuated to the Wash posi ti on. I f OK,
repl ace the faul ty rear washer pump/motor uni t. I f
not OK, go to Step 4.
(4) Turn the i gni ti on swi tch to the Off posi ti on.
Di sconnect and i sol ate the battery negati ve cabl e.
Di sconnect the i nstrument panel wi re harness con-
nector for the rear wi per and washer swi tch from the
swi tch connector receptacl e. Check for conti nui ty
between the rear washer motor control ci rcui t cavi -
ti es of the body wi re harness connector for the rear
washer pump/motor and the i nstrument panel wi re
harness connector for the rear wi per and washer
swi tch. There shoul d be conti nui ty. I f OK, go to Step
5. I f not OK, repai r the open rear washer motor con-
trol ci rcui t between the rear wi per and washer
swi tch and the rear washer pump/motor as requi red.
(5) Test the rear wi per and washer swi tch conti nu-
i ty. (Refer to 8 - ELECTRI CAL/REAR WI PERS/
WASHERS/REAR WI PER/WASHER SWI TCH -
DI AGNOSI S AND TESTI NG). I f not OK, repl ace the
faul ty rear wi per and washer swi tch.
CLEANING - REAR WIPER & WASHER SYSTEM
WIPER SYSTEM
The squeegee of a wi per bl ade exposed to the el e-
ments for a l ong ti me tends to l ose i ts wi pi ng effec-
ti veness. Peri odi c cl eani ng of the squeegee i s
8R - 28 REAR WIPERS/WASHERS TJ
REAR WIPERS/WASHERS (Continued)
suggested to remove any deposi ts of sal t or road fi l m.
The wi per bl ade, arm, and l i ftgl ass shoul d onl y be
cl eaned usi ng a sponge or soft cl oth and wi ndshi el d
washer fl ui d, a mi l d detergent, or a non-abrasi ve
cl eaner. I f the wi per bl ade conti nues to l eave streaks,
smears, hazi ng, or beadi ng on the gl ass after thor-
ough cl eani ng of the squeegees and the gl ass, the
enti re wi per bl ade assembl y must be repl aced.
CAUTION: Protect the rubber squeegee of the wiper
blade from any petroleum-based cleaners, solvents,
or contaminants. These products can rapidly deteri-
orate the rubber squeegee.
WASHER SYSTEM
I f the washer system i s contami nated wi th forei gn
materi al , drai n the washer reservoi r by removi ng the
front washer pump/motor from the reservoi r. Cl ean
forei gn materi al from the i nsi de of both washer
pump/motor i nl et fi l ter screens and the washer res-
ervoi r usi ng cl ean washer fl ui d, a mi l d detergent, or
a non-abrasi ve cl eaner. Fl ush forei gn materi al from
the washer system pl umbi ng by fi rst di sconnecti ng
the rear washer suppl y hose from the rear washer
nozzl e, then runni ng the rear washer pump/motor to
run cl ean washer fl ui d or water through the system.
A pl ugged or restri cted washer nozzl e shoul d be care-
ful l y back-fl ushed usi ng compressed ai r. I f the
washer nozzl e obstructi on cannot be cl eared, repl ace
the washer nozzl e.
CAUTION: Never introduce petroleum-based clean-
ers, solvents, or contaminants into the washer sys-
tem. These products can rapidly deteriorate the
rubber seals and hoses of the washer system, as
well as the rubber squeegee of the wiper blade.
CAUTION: Never use compressed air to flush the
washer system plumbing. Compressed air pres-
sures are too great for the washer system plumbing
components and will result in further system dam-
age. Never use sharp instruments to clear a
plugged washer nozzle or damage to the nozzle ori-
fice and improper nozzle spray patterns will result.
INSPECTION - REAR WIPER & WASHER
SYSTEM
WIPER SYSTEM
The rear wi per bl ade and wi per arm shoul d be
i nspected peri odi cal l y, not just when wi per perfor-
mance probl ems are experi enced. Thi s i nspecti on
shoul d i ncl ude the fol l owi ng poi nts:
(1) I nspect the wi per arm for any i ndi cati ons of
damage, or contami nati on. I f the wi per arm i s con-
tami nated wi th any forei gn materi al , cl ean as
requi red. (Refer to 8 - ELECTRI CAL/REAR WI PERS/
WASHERS - CLEANI NG). I f a wi per arm i s damaged
or corrosi on i s evi dent, repl ace the wi per arm wi th a
new uni t. Do not attempt to repai r a wi per arm that
i s damaged or corroded.
(2) Careful l y l i ft the wi per bl ade off of the gl ass.
Note the acti on of the wi per arm hi nge. The wi per
arm shoul d pi vot freel y at the hi nge, but wi th no l at-
eral l ooseness evi dent. I f there i s any bi ndi ng evi dent
i n the wi per arm hi nge, or there i s evi dent l ateral
pl ay i n the wi per arm hi nge, repl ace the wi per arm.
CAUTION: Do not allow the wiper arm to spring
back against the glass without the wiper blade in
place or the glass may be damaged.
(3) Once proper hi nge acti on of the wi per arm i s
confi rmed, check the hi nge for proper spri ng tensi on.
The spri ng tensi on of the wi per arm shoul d be suffi -
ci ent to cause the rubber squeegee to conform to the
curvature of the gl ass. Repl ace a wi per arm i f i t has
l ow or no spri ng tensi on.
(4) I nspect the wi per bl ade and squeegee for any
i ndi cati ons of damage, contami nati on, or rubber dete-
ri orati on (Fi g. 2). I f the wi per bl ade or squeegee i s
contami nated wi th any forei gn materi al , cl ean them
and the gl ass as requi red. (Refer to 8 - ELECTRI -
CAL/REAR WI PERS/WASHERS - CLEANI NG). I f
after cl eani ng the wi per bl ade and the gl ass, the
wi per bl ade fai l s to cl ear the gl ass wi thout smeari ng,
streaki ng, chatteri ng, hazi ng, or beadi ng, repl ace the
wi per bl ade. Al so, i f a wi per bl ade i s damaged or i f
the squeegee rubber i s damaged or deteri orated,
repl ace the wi per bl ade wi th a new uni t. Do not
attempt to repai r a wi per bl ade that i s damaged.
WASHER SYSTEM
The washer system components shoul d be
i nspected peri odi cal l y, not just when washer perfor-
mance probl ems are experi enced. Thi s i nspecti on
shoul d i ncl ude the fol l owi ng poi nts:
(1) Check for i ce or other forei gn materi al i n the
washer reservoi r. I f contami nated, cl ean and fl ush
the washer system. (Refer to 8 - ELECTRI CAL/
REAR WI PERS/WASHERS - CLEANI NG).
(2) I nspect the washer pl umbi ng for pi nched, l eak-
i ng, deteri orated, or i ncorrectl y routed hoses and
damaged or di sconnected hose fi tti ngs. Repl ace dam-
aged or deteri orated hoses and hose fi tti ngs. Leaki ng
washer hoses can someti mes be repai red by cutti ng
the hose at the l eak and spl i ci ng i t back together
usi ng an i n-l i ne connector fi tti ng. Si mi l arl y, secti ons
of deteri orated hose can be cut out and repl aced by
spl i ci ng i n new secti ons of hose usi ng i n-l i ne connec-
TJ REAR WIPERS/WASHERS 8R - 29
REAR WIPERS/WASHERS (Continued)
tor fi tti ngs. Whenever routi ng a washer hose or a
wi re harness contai ni ng a washer hose, i t must be
routed away from hot, sharp, or movi ng parts. Al so,
sharp bends that mi ght pi nch the washer hose must
be avoi ded.
REAR CHECK VALVE
DESCRIPTION
Model s equi pped wi th the opti onal rear wi per and
washer system have a rear check val ve (Fi g. 3). The
rear check val ve i s l ocated i n the rear washer pl umb-
i ng connecti on between the rear washer suppl y hose
i n the body wi re harness and the rear washer suppl y
hose i n the hardtop wi re harness, near the bel t l i ne
i n the l eft rear corner of the vehi cl e. The check val ve
consi sts of a mol ded pl asti c val ve body wi th a rai sed
center secti on that i s tapered i n the di recti on of the
fl ow through the val ve. A barbed hose ni ppl e i s
formed on each si de of the rai sed center secti on of
the val ve body. Wi thi n the check val ve body, a smal l
check bal l i s hel d agai nst an i ntegral val ve seat by a
smal l coi l ed spri ng. The rear check val ve cannot be
adjusted or repai red and, i f faul ty or damaged, i t
must be repl aced.
OPERATION
The rear check val ve provi des more than one func-
ti on i n thi s appl i cati on. I t serves as an i n-l i ne con-
nector fi tti ng between the body and hardtop secti ons
of the rear washer suppl y hose. I t prevents washer
fl ui d from drai ni ng out of the rear washer suppl y
hoses back to the washer reservoi r. Thi s drai n-back
woul d resul t i n a l engthy del ay from when the rear
washer swi tch i s actuated unti l washer fl ui d was di s-
pensed through the rear washer nozzl e, because the
rear washer pump woul d have to refi l l the rear
washer pl umbi ng from the reservoi r to the nozzl e.
Such a drai n-back condi ti on coul d al so resul t i n
water, di rt, or other outsi de contami nants bei ng
si phoned i nto the washer system through the washer
nozzl e ori fi ce. Thi s water coul d subsequentl y freeze
and pl ug the nozzl e, whi l e other contami nants coul d
i nterfere wi th proper nozzl e operati on and cause
i mproper nozzl e spray patterns. I n addi ti on, the rear
check val ve prevents washer fl ui d from si phoni ng out
through the rear washer nozzl e after the rear washer
system i s turned Off.
When the rear washer pump pressuri zes and
pumps washer fl ui d from the reservoi r through the
rear washer pl umbi ng, the fl ui d pressure unseats a
check bal l from a seat wi thi n the val ve by overri di ng
the pressure appl i ed to the bal l wi thi n the val ve by a
smal l coi l ed spri ng (Fi g. 4). Wi th the check bal l
unseated, washer fl ui d i s al l owed to fl ow toward the
rear washer nozzl e. When the washer pump stops
operati ng, the spri ng pressure on the check bal l seats
Fig. 2 Wiper Blade Inspection
1 - WORN OR UNEVEN EDGES
2 - ROAD FILM OR FOREIGN MATERIAL DEPOSITS
3 - HARD, BRITTLE, OR CRACKED
4 - DEFORMED OR FATIGUED
5 - SPLIT
6 - DAMAGED SUPPORT COMPONENTS
Fig. 3 Rear Check Valve
1 - LEFT REAR SEAT BELT RETRACTOR TRIM COVER
2 - HARDTOP WIRE HARNESS
3 - BODY WIRE HARNESS
4 - REAR WASHER HOSE CAP
5 - REAR CHECK VALVE
8R - 30 REAR WIPERS/WASHERS TJ
REAR WIPERS/WASHERS (Continued)
the bal l i n the val ve and fl ui d fl ow i n ei ther di recti on
wi thi n the rear washer pl umbi ng i s prevented. The
rear check val ve cannot be adjusted or repai red and,
i f faul ty or damaged, i t must be repl aced.
REMOVAL
(1) Di sconnect the hardtop wi re harness hal f of the
washer suppl y hose from the barbed ni ppl e of the
rear check val ve (Fi g. 5).
(2) Di sconnect the body wi re harness hal f of the
washer suppl y hose from the other barbed ni ppl e of
the rear check val ve.
(3) Remove the rear check val ve from the l eft rear
corner of the vehi cl e near the bel t l i ne.
INSTALLATION
(1) Posi ti on the rear check val ve i nto the l eft rear
corner of the vehi cl e near the bel t l i ne.
(2) Wi th the tapered end of the check val ve
poi nted i n the di recti on of the system fl ow (Fi g. 6),
reconnect the body wi re harness hal f of the washer
suppl y hose to the barbed ni ppl e of the rear check
val ve.
(3) Reconnect the hardtop wi re harness hal f of the
washer suppl y hose to the other barbed ni ppl e of the
rear check val ve.
REAR WASHER HOSES/TUBES
DESCRIPTION
The rear washer pl umbi ng consi sts of smal l di am-
eter rubber hose that i s i ntegral to and routed wi th
the body wi re harness from the barbed outl et ni ppl e
of the rear washer pump/motor on the washer reser-
voi r through the dash panel to the l eft cowl si de
i nner panel under the i nstrument panel . The washer
hose and wi re harness pass from the engi ne compart-
ment i nto the passenger compartment through a rub-
ber grommet i n a dedi cated hol e near the l eft si de of
the l ower dash panel .
The body wi re harness and washer hose are routed
from the l eft cowl si de i nner panel , al ong the l eft
door openi ng si l l , then up the B-pi l l ar and al ong the
upper i nner edge of the l eft rear fender panel to the
l eft rear corner of the passenger compartment. At the
l eft rear corner of the passenger compartment the
hose connects to the rear check val ve, whi ch al so
serves as an i n-l i ne connector between the body and
hardtop hal ves of the rear washer suppl y hose.
There i s al so a washer hose cap attached by an
i ntegral cl i p and bai l strap to the body hal f of the
washer suppl y hose just bel ow the rear check val ve
(Fi g. 7). When the hardtop i s removed from the vehi -
cl e the body hal f of the washer hose must be di scon-
nected from the rear check val ve. The washer hose
cap i s used to pl ug the body hal f of the washer hose
after i t i s di sconnected from the check val ve.
Fig. 4 Rear Check Valve
1 - TO RESERVOIR
2 - CHECK BALL
3 - SPRING
4 - TO REAR NOZZLE
Fig. 5 Rear Check Valve Remove/Install
1 - LEFT REAR SEAT BELT RETRACTOR TRIM COVER
2 - HARDTOP WIRE HARNESS
3 - BODY WIRE HARNESS
4 - REAR WASHER HOSE CAP
5 - REAR CHECK VALVE
Fig. 6 Rear Washer System Check Valve
1 - TO RESERVOIR
2 - CHECK BALL
3 - SPRING
4 - TO REAR NOZZLE
TJ REAR WIPERS/WASHERS 8R - 31
REAR CHECK VALVE (Continued)
The hardtop hal f of the rear washer suppl y hose i s
routed wi th the hardtop wi re harness through the
l eft rear pi l l ar and across the upper l i ftgl ass openi ng
rei nforcement to the rear washer nozzl e l ocated near
the ri ght l i ftgl ass hi nge. The hardtop washer hose i s
connected di rectl y to the barbed ni ppl e of the rear
washer nozzl e on the i nsi de of the l i ftgl ass.
Washer hose i s avai l abl e for servi ce onl y as rol l
stock, whi ch must then be cut to l ength. For servi ce
repl acement of the hose that i s i ntegral to the hard-
top or body wi re harnesses, i t i s suggested that a
sui tabl e l ength of washer hose be careful l y routed
al ong and secured to the outsi de of the harness. The
mol ded pl asti c washer hose fi tti ngs cannot be
repai red. I f these fi tti ngs are faul ty or damaged, they
must be repl aced.
OPERATION
Washer fl ui d i n the washer reservoi r i s pressuri zed
and fed by the rear washer pump/motor through the
rear washer system pl umbi ng and fi tti ngs to the rear
washer nozzl e l ocated near the rear wi per motor out-
put shaft on the outsi de of the hardtop l i ftgl ass.
Whenever routi ng the washer hose or a wi re harness
contai ni ng a washer hose, i t must be routed away
from hot, sharp, or movi ng parts; and, sharp bends
that mi ght pi nch the hose must be avoi ded.
REAR WASHER NOZZLE
DESCRIPTION
The rear washer nozzl e i s a fl ui di c-type uni t con-
structed of mol ded pl asti c. The mol ded hood of the
washer nozzl e i s vi si bl e on the outsi de of the l i ftgl ass
just bel ow and i nboard of the rear wi per motor out-
put shaft (Fi g. 8). The remai nder of the rear washer
nozzl e and i ts pl umbi ng connecti on are conceal ed
behi nd the rear wi per motor tri m cover secured to
the rear wi per motor bracket on the i nsi de of the l i ft-
gl ass. On the back of the nozzl e i s an external l y
threaded and barbed ni ppl e that i s i nserted through
a rubber gasket and a mounti ng hol e from the out-
si de of the l i ftgl ass, and i s secured to the i nsi de of
the l i ftgl ass wi th a pl asti c nut. The rear washer noz-
zl e cannot be adjusted or repai red. I f faul ty or dam-
aged, the enti re nozzl e uni t must be repl aced.
OPERATION
The rear washer nozzl e i s desi gned to di spense
washer fl ui d i nto the wi per pattern area on the out-
si de of the l i ftgl ass. Pressuri zed washer fl ui d i s fed to
the nozzl e from the washer reservoi r by the rear
washer pump/motor through a si ngl e hose, whi ch i s
attached to a barbed ni ppl e on the back of the rear
washer nozzl e behi nd the rear wi per motor tri m
cover on the i nsi de of the l i ftgl ass. A fl ui di c matri x
wi thi n the washer nozzl e causes the pressuri zed
washer fl ui d to be emi tted from the nozzl e ori fi ce as
a fan-l i ke stream to more effecti vel y cover a l arger
area of the gl ass to be cl eaned.
Fig. 7 Rear Washer Hose Cap
1 - WASHER HOSE CAP
2 - REAR WASHER SUPPLY HOSE - BODY HALF
Fig. 8 Rear Washer Nozzle
1 - REAR WIPER BLADE
2 - LIFTGLASS
3 - REAR WIPER ARM
4 - REAR WIPER MOTOR OUTPUT SHAFT
5 - MOUNTING STUD
6 - REAR WASHER NOZZLE
8R - 32 REAR WIPERS/WASHERS TJ
REAR WASHER HOSES/TUBES (Continued)
REMOVAL
(1) Remove the tri m cover from the rear wi per
motor on the i nsi de of the l i ftgl ass. (Refer to 8 -
ELECTRI CAL/REAR WI PERS/WASHERS/REAR
WI PER MOTOR TRI M COVER - REMOVAL).
(2) From the i nsi de of the l i ftgl ass, di sconnect the
rear washer suppl y hose from the barbed ni ppl e on
the back of the rear washer nozzl e (Fi g. 9).
(3) Whi l e hol di ng the hood of the rear washer noz-
zl e securel y from the outsi de of the l i ftgl ass, remove
the pl asti c nut that secures the threaded ni ppl e of
the rear washer nozzl e to the i nsi de of the l i ftgl ass.
(4) From the i nsi de of the l i ftgl ass, push the ni ppl e
of the rear washer nozzl e out through the mounti ng
hol e i n the l i ftgl ass.
(5) Remove the rear washer nozzl e and rubber gas-
ket from the outsi de of the l i ftgl ass.
INSTALLATION
(1) Posi ti on the rear washer nozzl e and rubber
gasket to the outsi de of the l i ftgl ass wi th the ori fi ce
of the nozzl e ai med at the nozzl e al i gnment arrow-
head vi si bl e on the outsi de of the gl ass.
(2) From the i nsi de of the l i ftgl ass, i nstal l and
ti ghten the pl asti c nut that secures the threaded ni p-
pl e on the back of the rear washer nozzl e to the
i nsi de of the l i ftgl ass (Fi g. 9). Ti ghten the nut to 1
N·m (8 i n. l bs.).
(3) Reconnect the rear washer suppl y hose to the
barbed ni ppl e of the rear washer nozzl e.
(4) Rei nstal l the tri m cover onto the rear wi per
motor on the i nsi de of the l i ftgl ass. (Refer to 8 -
ELECTRI CAL/REAR WI PERS/WASHERS/REAR
WI PER MOTOR TRI M COVER - I NSTALLATI ON).
REAR WASHER PUMP MOTOR
DESCRIPTION
The rear washer pump/motor uni t i s l ocated on the
i nboard si de just behi nd and above the front washer
pump/motor on the washer reservoi r (Fi g. 10). The
washer reservoi r i s l ocated on the top of the l eft front
fender wheel house i n the engi ne compartment. A
smal l permanentl y l ubri cated and seal ed el ectri c
motor i s coupl ed to the rotor-type washer pump. A
seal fl ange wi th a barbed i nl et ni ppl e on the pump
housi ng passes through a rubber grommet seal
i nstal l ed i n a dedi cated mounti ng hol e i n the sump
area near the bottom of the washer reservoi r. The
rear washer pump/motor uni t i s al ways mounted i n
the rearward-most upper mounti ng hol e of the reser-
voi r. An i ntegral fi l ter screen i s l ocated wi thi n the
pump i nl et ni ppl e. When the pump i s i nstal l ed i n the
reservoi r a barbed outl et ni ppl e on the pump housi ng
connects the uni t to the washer system through the
front washer suppl y hose.
The washer pump/motor uni t i s retai ned on the
reservoi r by the i nterference fi t between the barbed
pump i nl et ni ppl e and the grommet seal , whi ch i s a
l i ght press fi t. An i ntegral connector receptacl e
between the motor housi ng and the pump housi ng
connects the uni t to the vehi cl e el ectri cal system. A
smal l capaci tor i nternal to the connector receptacl e
i nsul ator i s connected i n paral l el wi th the motor
l eads to control El ectroMagneti c I nterference (EMI )
Fig. 9 Rear Washer Nozzle Remove/Install
1 - LIFTGLASS (INSIDE)
2 - GROMMET
3 - PLASTIC NUT
4 - REAR WASHER SUPPLY HOSE
5 - REAR WIPER MOTOR
Fig. 10 Washer Pump/Motor
1 - MOTOR
2 - CONNECTOR RECEPTACLE
3 - OUTLET NIPPLE
4 - INLET NIPPLE
5 - PUMP
TJ REAR WIPERS/WASHERS 8R - 33
REAR WASHER NOZZLE (Continued)
created by washer motor operati on. The rear washer
pump/motor uni t cannot be repai red. I f faul ty or
damaged, the enti re washer pump/motor uni t must
be repl aced.
OPERATION
The rear washer pump/motor uni t features a smal l
Di rect Current (DC) el ectri c motor. The motor i s con-
nected to the vehi cl e el ectri cal system through a si n-
gl e take out and two-cavi ty connector of the body
wi re harness. The motor i s grounded at al l ti mes
through a take out of the body wi re harness wi th a
si ngl e eyel et termi nal connector that i s secured
under a ground screw to the l eft cowl si de i nner
panel bel ow the i nstrument panel i n the passenger
compartment. The motor recei ves battery current
through the cl osed contacts of the momentary rear
washer swi tch ci rcui try wi thi n the rear wi per and
washer swi tch uni t onl y when the bottom of the
swi tch rocker i s pushed towards the i nstrument
panel .
Washer fl ui d i s gravi ty-fed from the washer reser-
voi r to the i nl et si de of the washer pump. When the
pump motor i s energi zed, the motor spi ns the rotor
wi thi n the rotor-type washer pump. The spi nni ng
pump rotor pressuri zes the washer fl ui d and forces i t
through the pump outl et ni ppl e, the rear washer
pl umbi ng, and the rear washer nozzl e onto the l i ft-
gl ass. The rear washer pump/motor uni t can be di ag-
nosed usi ng conventi onal di agnosti c tool s and
methods.
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Di sconnect the washer suppl y hose from the
barbed outl et ni ppl e of the rear washer pump/motor
and al l ow the washer fl ui d from the washer reservoi r
to drai n i nto a cl ean contai ner for reuse (Fi g. 11).
(3) Di sconnect the body wi re harness connector
from the connector receptacl e for the rear washer
pump/motor.
(4) Usi ng a tri m sti ck or another sui tabl e wi de
fl at-bl aded tool , gentl y pry the barbed i nl et ni ppl e of
the rear washer pump/motor uni t out of the rubber
grommet seal i n the washer reservoi r. Care must be
taken not to damage the washer reservoi r.
(5) Remove the rear washer pump/motor uni t from
the washer reservoi r.
(6) Remove the rubber grommet seal from the rear
washer pump/motor mounti ng hol e i n the washer
reservoi r and di scard.
INSTALLATION
(1) I nstal l a new rubber grommet seal i nto the
rear washer pump/motor mounti ng hol e of the
washer reservoi r.
(2) Posi ti on the rear washer pump/motor i nl et ni p-
pl e to the mounti ng hol e i n the washer reservoi r
(Fi g. 11).
(3) Usi ng hand pressure, fi rml y and evenl y press
on the rear washer pump/motor to engage the i nl et
ni ppl e through the rubber grommet seal i nto the
washer reservoi r. Care must be taken not to damage
the washer reservoi r.
(4) Reconnect the body wi re harness connector for
the rear washer pump/motor to the washer pump/mo-
tor connector receptacl e.
(5) Reconnect the rear washer suppl y hose to the
barbed outl et ni ppl e of the rear washer pump/motor.
(6) Refi l l the washer reservoi r wi th the washer
fl ui d drai ned from the reservoi r duri ng the removal
procedure.
(7) Reconnect the battery negati ve cabl e.
REAR WIPER ARM
DESCRIPTION
The rear wi per arm i s the ri gi d member l ocated
between the rear wi per motor output shaft that pro-
trudes from the outsi de of the l i ftgl ass near the ri ght
l i ftgl ass hi nge and the rear wi per bl ade (Fi g. 12).
Thi s wi per arm features an over-center hi nge that
al l ows easy access to the l i ftgl ass for cl eani ng. The
wi per arm has a di e cast metal pi vot end wi th a
Fig. 11 Washer Pump/Motor Remove/Install
1 - REAR BODY WIRE HARNESS
2 - WASHER RESERVOIR
3 - REAR WASHER PUMP/MOTOR
4 - HEADLAMP & DASH WIRE HARNESS
5 - FRONT WASHER SUPPLY HOSE
6 - FRONT WASHER PUMP/MOTOR
7 - REAR WASHER SUPPLY HOSE
8R - 34 REAR WIPERS/WASHERS TJ
REAR WASHER PUMP MOTOR (Continued)
l arge tapered mounti ng hol e at one end. A mol ded
pl asti c pi vot cover i s secured l oosel y to and pi vots on
the wi per arm hi nge pi n to conceal the wi per arm
retai ni ng nut.
The wi de end of a tapered, stamped steel channel
i s secured wi th a hi nge pi n to the pi vot end of the
wi per arm. One end of a l ong, ri gi d, stamped steel
strap, wi th a smal l hol e near i ts pi vot end, i s ri veted
and cri mped wi thi n the narrow end of the stamped
steel channel . The ti p of the wi per bl ade end of thi s
strap i s bent back under i tsel f to form a smal l hook.
Conceal ed wi thi n the stamped steel channel , one end
of a l ong spri ng i s engaged wi th a wi re hook on the
undersi de of the di e cast pi vot end, whi l e the other
end of the spri ng i s hooked through the smal l hol e i n
the steel strap. The enti re wi per arm has a sati n
bl ack fi ni sh appl i ed to al l of i ts vi si bl e surfaces.
A wi per arm cannot be adjusted or repai red. I f
damaged or faul ty, the enti re wi per arm uni t must be
repl aced.
OPERATION
The rear wi per arm i s desi gned to mechani cal l y
transmi t the moti on from the rear wi per motor out-
put shaft to the rear wi per bl ade. The wi per arm
must be properl y i ndexed to the motor output shaft
i n order to mai ntai n the proper wi per bl ade travel on
the gl ass. The tapered hol e i n the wi per arm pi vot
end i nterl ocks wi th the serrati ons on the outer ci r-
cumference of the tapered motor output shaft, al l ow-
i ng posi ti ve engagement and fi ni te adjustment of thi s
connecti on. A hex nut secures the wi per arm pi vot
end to the threads on the rear wi per motor output
shaft and the pi vot cover hi nges and snaps over thi s
connecti on for a neat appearance. The spri ng-l oaded
wi per arm hi nge control s the down-force appl i ed
through the ti p of the wi per arm to the wi per bl ade
on the gl ass. The hook formati on on the ti p of the
wi per arm provi des a cradl e for securi ng and l atchi ng
the wi per bl ade pi vot bl ock to the wi per arm.
REMOVAL
(1) Li ft the rear wi per arm pi vot cover by l i fti ng i t
at the rear wi per motor output shaft end of the arm
(Fi g. 13).
(2) Remove the nut that secures the rear wi per
arm to the rear wi per motor output shaft.
(3) Li ft the rear wi per arm to i ts over-center posi -
ti on to hol d the wi per bl ade off of the gl ass and
rel i eve the spri ng tensi on on the wi per arm to rear
wi per motor output shaft connecti on.
(4) I f necessary, use a battery termi nal pul l er to
di sengage the wi per arm from the rear wi per motor
output shaft spl i nes (Fi g. 14).
(5) Remove the rear wi per arm pi vot end from the
motor output shaft.
INSTALLATION
NOTE: Be certain that the rear wiper motor is in the
park position before attempting to install the wiper
arm. Turn the ignition switch to the On position and
move the rear wiper and washer switch rocker to its
Off position. If the wiper motor output shaft moves,
wait until it stops moving, then turn the ignition
switch back to the Off position. The wiper motor is
now in its park position.
Fig. 12 Rear Wiper Arm
1 - HOOK
2 - STRAP
3 - CHANNEL
4 - HINGE PIN
5 - COVER
6 - PIVOT END
7 - TENSION SPRING
Fig. 13 Rear Wiper Arm Remove/Install
1 - LATCH
2 - WIPER ARM PIVOT END
TJ REAR WIPERS/WASHERS 8R - 35
REAR WIPER ARM (Continued)
(1) The rear wi per arm must be i ndexed to the
rear wi per motor output shaft wi th the motor i n the
park posi ti on to be properl y i nstal l ed. Posi ti on the
rear wi per arm pi vot end onto the motor output shaft
so that the wi per bl ade i s paral l el to the l ower edge
of the upper l i ftgl ass bl ackout area (Fi g. 15).
(2) Once the wi per bl ade i s i ndexed to the rear
wi per motor output shaft, l i ft the rear wi per arm to
i ts over-center posi ti on to hol d the wi per bl ade off of
the gl ass and rel i eve the spri ng tensi on on the wi per
arm to rear wi per motor output shaft connecti on.
Usi ng hand pressure, push the tapered hol e i n the
pi vot end of the wi per arm down fi rml y and evenl y
over the rear wi per motor output shaft (Fi g. 13).
(3) I nstal l and ti ghten the nut that secures the
wi per arm to the rear wi per motor output shaft.
Ti ghten the nut to 12 N·m (9 ft. l bs.). Do not over-
tighten.
(4) Gentl y l ower the wi per arm unti l the wi per
bl ade rests on the gl ass.
(5) Wet the l i ftgl ass, then operate the rear wi per.
Turn the wi per swi tch to the Off posi ti on, then check
for the correct wi per arm posi ti on and readjust as
requi red.
REAR WIPER BLADE
DESCRIPTION
The rear wi per bl ade i s secured by an i ntegral
l atchi ng pi vot bl ock to the hook formati on on the ti p
of the rear wi per arm, and rests i n a hori zontal posi -
ti on on the gl ass near the top of the l i ftgl ass when
the wi per i s not i n operati on (Fi g. 16). The wi per
bl ade consi sts of the fol l owi ng components:
• Superstructure - The superstructure i ncl udes
a stamped steel bri dge and pl asti c l i nks wi th cl aw
formati ons that gri p the wi per bl ade el ement. Al so
i ncl uded i n thi s uni t i s the l atchi ng, mol ded pl asti c
pi vot bl ock that secures the superstructure to the
wi per arm. Al l of the metal components of the wi per
bl ade have a sati n bl ack fi ni sh appl i ed.
• Element - The wi per el ement or squeegee i s the
resi l i ent rubber member of the wi per bl ade that con-
tacts the gl ass.
• Flexor - The fl exor i s a ri gi d metal component
runni ng al ong the l ength of each si de of the wi per
el ement where i t i s gri pped by the cl aws of the
superstructure.
Al l model s wi th the opti onal rear wi per and
washer system have a si ngl e 46.00 centi meter (18.00
i nch) rear wi per bl ade wi th a non-repl aceabl e rubber
el ement (squeegee). The wi per bl ade cannot be
Fig. 14 Wiper Arm Puller - Typical
1 - WIPER ARM
2 - WIPER PIVOT
3 - BATTERY TERMINAL PULLER
Fig. 15 Rear Wiper Arm Installation
1 - LIFTGLASS BLACKOUT AREA
Fig. 16 Rear Wiper Blade
1 - SUPERSTRUCTURE
2 - PIVOT PIN
3 - LATCH RELEASE
4 - PIVOT BLOCK
5 - CLAW
6 - FLEXOR
7 - ELEMENT
8R - 36 REAR WIPERS/WASHERS TJ
REAR WIPER ARM (Continued)
adjusted or repai red. I f faul ty, worn, or damaged the
enti re wi per bl ade uni t must be repl aced.
OPERATION
The rear wi per bl ade i s moved back and forth
across the gl ass by the wi per arm when the rear
wi per system i s i n operati on. The wi per bl ade super-
structure i s the fl exi bl e frame that gri ps the wi per
bl ade el ement and evenl y di stri butes the force of the
spri ng-l oaded wi per arm al ong the l ength of the el e-
ment. The combi nati on of the wi per arm force and
the fl exi bi l i ty of the superstructure makes the el e-
ment conform to and mai ntai n proper contact wi th
the l i ftgl ass, even as the bl ade i s moved over the var-
i ed curvature found across the gl ass surface.
The wi per el ement fl exor provi des the cl aws of the
bl ade superstructure wi th a ri gi d, yet fl exi bl e compo-
nent on the el ement whi ch can be gri pped. The rub-
ber el ement i s desi gned to be sti ff enough to
mai ntai n an even cl eani ng edge as i t i s drawn across
the gl ass, but resi l i ent enough to conform to the
gl ass surface and fl i p from one cl eani ng edge to the
other each ti me the wi per bl ade changes di recti ons.
REMOVAL
NOTE: The notched end of the wiper element flexor
should always be oriented towards the end of the
wiper blade that is nearest to the rear wiper motor
output shaft.
(1) Li ft the rear wi per arm to rai se the wi per bl ade
and el ement off of the l i ftgl ass.
(2) To remove the wi per bl ade from the wi per arm,
push the pi vot bl ock l atch rel ease tab under the ti p
of the arm and sl i de the bl ade away from the ti p
towards the rear wi per motor output shaft end of the
arm (Fi g. 17).
(3) Sl i de the rear wi per bl ade away from the ti p of
the arm towards the pi vot end of the arm far enough
to di sengage the pi vot bl ock from the hook formati on
on the end of the arm.
(4) Extract the hook formati on on the ti p of the
wi per arm from the openi ng i n the wi per bl ade
superstructure ahead of the wi per bl ade pi vot bl ock/
l atch uni t.
CAUTION: Do not allow the wiper arm to spring
back against the liftglass without the wiper blade in
place or the glass may be damaged.
(5) Gentl y l ower the wi per arm ti p onto the gl ass.
INSTALLATION
NOTE: The notched end of the wiper element flexor
should always be oriented towards the end of the
wiper blade that is nearest to the rear wiper motor
output shaft.
(1) Li ft the rear wi per arm off of the l i ftgl ass.
(2) Posi ti on the rear wi per bl ade near the hook for-
mati on on the ti p of the arm wi th the notched end of
the wi per el ement fl exor ori ented towards the end of
the wi per arm that i s nearest to the rear wi per motor
output shaft.
(3) I nsert the hook formati on on the ti p of the
wi per arm through the openi ng i n the wi per bl ade
superstructure ahead of the wi per bl ade pi vot bl ock/
l atch uni t far enough to engage the pi vot bl ock wi th
the hook (Fi g. 17).
(4) Sl i de the wi per bl ade pi vot bl ock/l atch up i nto
the hook formati on on the ti p of the wi per arm unti l
the l atch rel ease tab snaps i nto i ts l ocked posi ti on.
(5) Gentl y l ower the wi per bl ade onto the l i ftgl ass.
REAR WIPER MOTOR
DESCRIPTION
The rear wi per motor i s conceal ed behi nd a mol ded
pl asti c tri m cover on the i nsi de of the l i ftgl ass near
the ri ght l i ftgl ass hi nge at the top of the gl ass. A
l arge bl ackout area of the l i ftgl ass conceal s the uni t
from the exteri or of the vehi cl e. The end of the motor
output shaft that protrudes through a l arge rubber
grommet i n the l i ftgl ass to dri ve the rear wi per arm
and bl ade i s the onl y vi si bl e component of the rear
wi per motor (Fi g. 18). A l arge fl at washer and a nut
secure and seal the motor output shaft to the outsi de
of the l i ftgl ass, whi l e a rubber i nsul ator i n a sl ot on
the outboard upper corner of the motor bracket i s
secured by a stud and nut to the i nsi de of the l i ft-
gl ass near the ri ght l i ftgl ass hi nge. The connector of
a short pi gtai l harness i s secured to a tab on the
back of the motor bracket, and connects the rear
wi per motor to the vehi cl e el ectri cal system through
a dedi cated take out and connector of the hardtop
Fig. 17 Wiper Blade Remove/Install - Typical
1 - RELEASE TAB
TJ REAR WIPERS/WASHERS 8R - 37
REAR WIPER BLADE (Continued)
wi re harness. The rear wi per motor consi sts of the
fol l owi ng major components:
• Bracket - The rear wi per motor bracket consi sts
of a stamped steel mounti ng pl ate that i s secured
wi th screws to the wi per motor and transmi ssi on. A
rubber i nsul ator i n a sl ot on the upper outboard cor-
ner of the bracket i s secured by a nut and washer to
a stud on the i nsi de surface of the l i ftgl ass. An i nte-
gral tab on the back of the bracket supports the
wi per motor pi gtai l wi re connector.
• Motor - The si ngl e-speed permanent magnet
rear wi per motor i s secured wi th screws to the rear
wi per motor bracket. The wi per motor i ncl udes an
i ntegral transmi ssi on, a motor output shaft, a di ode,
and the rear wi per motor park swi tch.
The rear wi per motor cannot be adjusted or
repai red. I f any component of the motor i s faul ty or
damaged, the enti re rear wi per motor uni t must be
repl aced. The motor output shaft grommet, washer
and nut are avai l abl e for i ndi vi dual servi ce repl ace-
ment.
OPERATION
The rear wi per motor operati on i s control l ed by the
vehi cl e operator through battery current i nputs
recei ved by the rear wi per motor from the rear wi per
and washer swi tch on the i nstrument panel , and the
rear wi per motor park swi tch, whi ch control current
fl ow to the wi per motor brushes. An i nternal di ode
protects the motor from feedback through the park
swi tch when the swi tch i s cl osed to the fused i gni ti on
swi tch output (run) ci rcui t. An i nternal ci rcui t
breaker protects the motor from overl oads.
The park swi tch i s a si ngl e pol e, si ngl e throw,
momentary swi tch wi thi n the wi per motor that i s
mechani cal l y actuated by the wi per motor transmi s-
si on components. The park swi tch al ternatel y cl oses
the wi per motor brush to the rear wi per and washer
swi tch output or to a fused i gni ti on swi tch output
(run) ci rcui t, dependi ng upon the posi ti on of the
wi per on the gl ass. Thi s feature al l ows the motor to
compl ete i ts current wi pe cycl e after the wi per sys-
tem has been turned Off, and to park the wi per bl ade
i n the uppermost porti on of the wi pe pattern.
The wi per motor transmi ssi on converts the rotary
output of the wi per motor to the back and forth wi p-
i ng moti on of the rear wi per arm and bl ade on the
l i ftgl ass. The rear wi per motor may be di agnosed
usi ng conventi onal di agnosti c tool s and methods.
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the rear wi per arm from the rear
wi per motor output shaft. (Refer to 8 - ELECTRI -
CAL/REAR WI PERS/WASHERS/REAR WI PER ARM
- REMOVAL).
(3) Remove the nut that secures the threaded
sl eeve of the rear wi per motor output shaft to the
outsi de of the l i ftgl ass (Fi g. 19).
(4) Remove the washer from the rear wi per motor
output shaft sl eeve.
(5) Remove the tri m cover from the rear wi per
motor on the i nsi de of the l i ftgl ass. (Refer to 8 -
ELECTRI CAL/REAR WI PERS/WASHERS/REAR
WI PER MOTOR TRI M COVER - REMOVAL).
Fig. 18 Rear Wiper Motor
1 - OUTPUT SHAFT
2 - TRANSMISSION
3 - PIGTAIL CONNECTOR (ON BACK)
4 - INSULATOR
5 - BRACKET
6 - MOTOR
7 - PIGTAIL WIRES
Fig. 19 Rear Wiper Motor Output Shaft
1 - WASHER
2 - NUT
3 - GROMMET
4 - STUD
5 - LIFTGLASS
6 - REAR WASHER NOZZLE
7 - REAR WIPER MOTOR OUTPUT SHAFT
8R - 38 REAR WIPERS/WASHERS TJ
REAR WIPER MOTOR (Continued)
(6) Di sconnect the hardtop wi re harness connector
for the rear wi per motor from the motor pi gtai l wi re
connector.
(7) Remove the nut and washer that secures the
rear wi per motor bracket i nsul ator to the stud on the
l i ftgl ass (Fi g. 20).
(8) Remove the washer from the stud that secures
the rear wi per motor bracket i nsul ator to the l i ft-
gl ass.
(9) From the i nsi de of the l i ftgl ass, gentl y pul l the
rear wi per motor away from the l i ftgl ass unti l the
output shaft cl ears the rubber grommet i n the l i ft-
gl ass output shaft hol e.
(10) Remove the rear wi per motor and mounti ng
bracket from the l i ftgl ass as a uni t.
(11) Remove the rubber grommet from the outsi de
of the l i ftgl ass output shaft hol e.
INSTALLATION
(1) I nstal l the rubber grommet from the outsi de of
the l i ftgl ass output shaft hol e. Be certai n that the
al i gnment arrow mol ded i nto the outer fl ange of the
grommet i s al i gned wi th the arrowhead i mpri nted on
the gl ass bel ow the output shaft hol e.
(2) Posi ti on the rear wi per motor to the i nsi de of
the l i ftgl ass wi th the output shaft i nserted through
the rubber grommet and the mounti ng bracket i nsu-
l ator i nstal l ed over the stud on the i nsi de of the l i ft-
gl ass (Fi g. 20).
(3) Rei nstal l the washer onto the stud that secures
the rear wi per motor bracket i nsul ator to the l i ft-
gl ass.
(4) I nstal l and ti ghten the nut and washer that
secures the rear wi per motor bracket i nsul ator to the
stud on the l i ftgl ass. Ti ghten the nut to 6 N·m (54 i n.
l bs.).
(5) From the outsi de of the l i ftgl ass, rei nstal l the
washer over the rear wi per motor output shaft sl eeve
(Fi g. 19).
(6) I nstal l and ti ghten the nut that secures the
threaded sl eeve of the rear wi per motor output shaft
to the outsi de of the l i ftgl ass. Ti ghten the nut to 5
N·m (44 i n. l bs.).
(7) Reconnect the hardtop wi re harness connector
for the rear wi per motor to the motor pi gtai l wi re
connector.
(8) Rei nstal l the tri m cover over the rear wi per
motor on the i nsi de of the l i ftgl ass. (Refer to 8 -
ELECTRI CAL/REAR WI PERS/WASHERS/REAR
WI PER MOTOR TRI M COVER - I NSTALLATI ON).
(9) Rei nstal l the rear wi per arm onto the rear
wi per motor output shaft. (Refer to 8 - ELECTRI -
CAL/REAR WI PERS/WASHERS/REAR WI PER ARM
- I NSTALLATI ON).
(10) Reconnect the battery negati ve cabl e.
REAR WIPER MOTOR TRIM
COVER
REMOVAL
(1) From the i nsi de of the l i ftgl ass, remove the
three screws that secure the rear wi per motor tri m
cover to the motor mounti ng bracket (Fi g. 21).
(2) Remove the tri m cover from the rear wi per
motor mounti ng bracket.
Fig. 20 Rear Wiper Motor Bracket
1 - BRACKET
2 - INSULATOR
3 - RIGHT LIFTGLASS HINGE
4 - LIFTGLASS
5 - WASHER
6 - STUD
7 - NUT
Fig. 21 Rear Wiper Motor Trim Cover Remove/Install
1 - SCREW (3)
2 - TRIM COVER
3 - REAR WIPER MOTOR
4 - LIFTGLASS
TJ REAR WIPERS/WASHERS 8R - 39
REAR WIPER MOTOR (Continued)
INSTALLATION
(1) From the i nsi de of the l i ftgl ass, posi ti on the
tri m cover onto the rear wi per motor mounti ng
bracket (Fi g. 21).
(2) I nstal l and ti ghten the three screws that secure
the tri m cover to the rear wi per motor mounti ng
bracket. Ti ghten the screws to 1 N·m (10 i n. l bs.).
REAR WIPER/WASHER
SWITCH
DESCRIPTION
The rear wi per and washer swi tch i s l ocated i n the
accessory swi tch bezel near the bottom of the i nstru-
ment panel center stack area on the i nstrument
panel (Fi g. 22). Onl y the si ngl e swi tch toggl e button
i s vi si bl e through the openi ng of the accessory swi tch
bezel (Fi g. 23). The remai nder of the swi tch i s con-
ceal ed behi nd the accessory swi tch bezel wi thi n the
i nstrument panel . The si ngl e two-functi on swi tch
housi ng and swi tch toggl e button are mol ded from
bl ack pl asti c. The swi tch toggl e button i s cl earl y
i denti fi ed by a whi te graphi c of the I nternati onal
Control and Di spl ay Symbol i con for “Rear Wi per and
Washer,” maki ng i t cl earl y vi si bl e i n dayl i ght. When
i l l umi nated from behi nd by an i ntegral panel l amps
di mmer control l ed i l l umi nati on l amp wi th the exte-
ri or l amps turned On, the whi te graphi c appears
bl ue-green.
The rear wi per and washer swi tch i s secured by a
snap fi t wi thi n a dedi cated receptacl e mol ded i nto
the back of the accessory swi tch bezel . A si ngl e si x
pi n connector receptacl e i s mol ded i nto the back of
the swi tch housi ng. A dedi cated take out and connec-
tor of the i nstrument panel wi re harness connects
the swi tch to the vehi cl e el ectri cal system. The rear
wi per and washer swi tch contai ns swi tches and ci r-
cui try to control both the rear wi per and the rear
washer functi ons. The rear wi per and washer swi tch
cannot be repai red and, i f faul ty or damaged, the
enti re swi tch uni t must be repl aced. The i ncandes-
cent swi tch i l l umi nati on bul b and bul b hol der uni t i s
avai l abl e for i ndi vi dual servi ce repl acement.
OPERATION
The rear wi per and washer swi tch uses conventi on-
al l y swi tched outputs to control the functi ons and
features of the rear wi per and washer system. The
swi tch recei ves battery current on a fused i gni ti on
swi tch output (run) ci rcui t from a fuse i n the Power
Di stri buti on Center (PDC) through the rear wi per
and washer system fuse i n the fuse bl ock whenever
the i gni ti on swi tch i s i n the On posi ti on. The swi tch
recei ves a path to ground at al l ti mes through a
through a take out of the i nstrument panel wi re har-
ness wi th an eyel et termi nal connector that i s
secured by a ground screw to the support structure
near the dri ver si de end of the i nstrument panel .
The rear wi per and washer swi tch features detents
i n the Off and Wi pe posi ti ons, and a momentary
Wash posi ti on. When the swi tch toggl e button i s i n
the Off posi ti on i t provi des a ground path to the park
swi tch wi thi n the rear wi per motor. The park swi tch
uses thi s ground path to operate the rear wi per
motor unti l the wi per bl ade i s i n i ts parked posi ti on,
Fig. 22 Accessory Switch Bezel
1 - ACCESSORY SWITCH BEZEL
2 - REAR WINDOW DEFOGGER SWITCH (HARDTOP ONLY)
3 - REAR WIPER/WASHER SWITCH (HARDTOP ONLY)
4 - OVERDRIVE-OFF SWITCH (AUTOMATIC TRANSMISSION
ONLY)
5 - AXLE LOCK SWITCH (OFF ROAD PACKAGE ONLY)
6 - PASSENGER AIRBAG ON/OFF SWITCH (WITHOUT REAR
SEAT ONLY)
7 - ACCESSORY POWER OUTLET
8 - CIGAR LIGHTER
Fig. 23 Rear Wiper/Washer Switch
1 - CONNECTOR RECEPTACLE
2 - HOUSING
3 - TOGGLE BUTTON
8R - 40 REAR WIPERS/WASHERS TJ
REAR WIPER MOTOR TRIM COVER (Continued)
or unti l the i gni ti on swi tch i s turned to the Off posi -
ti on, whi chever occurs fi rst. When the swi tch toggl e
button i s depressed downward to i ts Wi pe detent
posi ti on, the swi tch provi des i gni ti on swi tched bat-
tery current to the rear wi per motor and the rear
wi per system operates. When the swi tch toggl e but-
ton i s depressed downward to the momentary Wash
posi ti on, the swi tch provi des i gni ti on swi tched bat-
tery current to both the rear wi per motor and the
rear washer pump motor for as l ong as the swi tch i s
hel d depressed. Refer to the owner’s manual i n the
vehi cl e gl ove box for more i nformati on on the fea-
tures, use and operati on of the rear wi per and
washer swi tch.
The i ncandescent swi tch i l l umi nati on l amp i s con-
trol l ed by a l amp dri ver output from the i nstrument
cl uster based upon the panel l amps di mmer i nput to
the cl uster from the l eft mul ti -functi on swi tch. The
rear wi per and washer swi tch can be di agnosed usi ng
conventi onal di agnosti c tool s and methods.
DIAGNOSIS AND TESTING - REAR WIPER &
WASHER SWITCH
Be certai n to perform the di agnosi s for the rear
wi per system and/or rear washer system before test-
i ng the rear wi per and washer swi tch. (Refer to 8 -
ELECTRI CAL/REAR WI PERS/WASHERS - DI AG-
NOSI S AND TESTI NG). Refer to the appropri ate
wi ri ng i nformati on. The wi ri ng i nformati on i ncl udes
wi ri ng di agrams, proper wi re and connector repai r
procedures, detai l s of wi re harness routi ng and
retenti on, connector pi n-out i nformati on and l ocati on
vi ews for the vari ous wi re harness connectors, spl i ces
and grounds.
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE SUPPLEMENTAL RESTRAINT SYS-
TEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, AIRBAG, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE BEFORE PERFORMING FURTHER DIAG-
NOSIS OR SERVICE. THIS IS THE ONLY SURE WAY
TO DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT.
(1) Di sconnect and i sol ate the battery negati ve
cabl e. Remove the accessory swi tch bezel from the
i nstrument panel and di sconnect the i nstrument
panel wi re harness connector for the rear wi per and
washer swi tch from the swi tch connector receptacl e.
(2) Usi ng an ohmmeter, check the rear wi per and
washer swi tch conti nui ty at the swi tch termi nal s as
shown i n the Rear Wi per & Washer Swi tch Conti nu-
i ty chart (Fi g. 24).
SWITCH POSITION CONTINUITY BETWEEN
OFF 1 & 4
WIPE 4 & 5
WASH 2 & 5, 4 & 5
LAMP 1 & 3
(3) I f the swi tch fai l s any of the conti nui ty checks,
repl ace the faul ty swi tch. I f the swi tch checks OK,
repai r the open or shorted rear wi per and/or rear
washer system ci rcui ts as requi red.
REMOVAL
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE SUPPLEMENTAL RESTRAINT SYS-
TEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, AIRBAG, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE BEFORE PERFORMING FURTHER DIAG-
NOSIS OR SERVICE. THIS IS THE ONLY SURE WAY
TO DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT.
Fig. 24 Rear Wiper & Washer Switch Continuity
TJ REAR WIPERS/WASHERS 8R - 41
REAR WIPER/WASHER SWITCH (Continued)
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the accessory swi tch bezel from the
i nstrument panel center bezel from the i nstrument
panel . (Refer to 23 - BODY/I NSTRUMENT PANEL/
ACCESSORY SWI TCH BEZEL - REMOVAL).
(3) Usi ng a tri m sti ck or another sui tabl e wi de
fl at-bl aded tool , gentl y pry the l atch tabs at the top
and bottom of the rear wi per and washer swi tch
receptacl e on the back of the accessory swi tch bezel
far enough to di sengage the snap features on the top
and bottom of the swi tch housi ng then pul l the
swi tch out of the receptacl e (Fi g. 25).
INSTALLATION
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE SUPPLEMENTAL RESTRAINT SYS-
TEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, AIRBAG, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE BEFORE PERFORMING FURTHER DIAG-
NOSIS OR SERVICE. THIS IS THE ONLY SURE WAY
TO DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT.
(1) Posi ti on the rear wi per and washer swi tch over
the proper receptacl e on the back of the accessory
swi tch bezel (Fi g. 25).
(2) Gentl y and evenl y push the rear wi per and
washer swi tch i nto the receptacl e unti l the snap fea-
tures on the top and bottom of the swi tch housi ng
are ful l y engaged by the l atch tabs at the top and
bottom of the receptacl e.
(3) Rei nstal l the accessory swi tch bezel onto the
i nstrument panel . (Refer to 23 - BODY/I NSTRU-
MENT PANEL/ACCESSORY SWI TCH BEZEL -
I NSTALLATI ON).
(4) Reconnect the battery negati ve cabl e.
Fig. 25 Rear Wiper/Washer Switch Remove
1 - TRIM STICK
2 - REAR WIPER/WASHER SWITCH
3 - OVERDRIVE-OFF SWITCH
4 - AXLE LOCKER SWITCH
5 - ACCESSORY SWITCH BEZEL
6 - REAR WINDOW DEFOGGER SWITCH
8R - 42 REAR WIPERS/WASHERS TJ
REAR WIPER/WASHER SWITCH (Continued)
WIRING
TABLE OF CONTENTS
page page
WIRING DIAGRAM INFORMATION. . . . . . . 8W-01-1
COMPONENT INDEX. . . . . . . . . . . . . . . . . . 8W-02-1
POWER DISTRIBUTION . . . . . . . . . . . . . . . 8W-10-1
FUSE BLOCK. . . . . . . . . . . . . . . . . . . . . . . . 8W-11-1
GROUND DISTRIBUTION . . . . . . . . . . . . . . 8W-15-1
BUS COMMUNICATIONS . . . . . . . . . . . . . . 8W-18-1
CHARGING SYSTEM . . . . . . . . . . . . . . . . . . 8W-20-1
STARTING SYSTEM . . . . . . . . . . . . . . . . . . 8W-21-1
FUEL/IGNITION SYSTEM . . . . . . . . . . . . . . 8W-30-1
TRANSMISSION CONTROL SYSTEM . . . . . 8W-31-1
VEHICLE SPEED CONTROL . . . . . . . . . . . . 8W-33-1
ANTILOCK BRAKES. . . . . . . . . . . . . . . . . . . 8W-35-1
VEHICLE THEFT SECURITY SYSTEM . . . . . 8W-39-1
INSTRUMENT CLUSTER. . . . . . . . . . . . . . . 8W-40-1
HORN/CIGAR LIGHTER/POWER OUTLET . . 8W-41-1
AIR CONDITIONING-HEATER . . . . . . . . . . . 8W-42-1
AIRBAG SYSTEM . . . . . . . . . . . . . . . . . . . . 8W-43-1
INTERIOR LIGHTING. . . . . . . . . . . . . . . . . . 8W-44-1
AUDIO SYSTEM . . . . . . . . . . . . . . . . . . . . . 8W-47-1
REAR WINDOW DEFOGGER. . . . . . . . . . . . 8W-48-1
FRONT LIGHTING . . . . . . . . . . . . . . . . . . . . 8W-50-1
REAR LIGHTING . . . . . . . . . . . . . . . . . . . . . 8W-51-1
TURN SIGNALS. . . . . . . . . . . . . . . . . . . . . . 8W-52-1
WIPERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-1
SPLICE INFORMATION . . . . . . . . . . . . . . . . 8W-70-1
CONNECTOR PIN-OUTS . . . . . . . . . . . . . . . 8W-80-1
CONNECTOR/GROUND/SPLICE
LOCATION . . . . . . . . . . . . . . . . . . . . . . . . 8W-91-1
POWER DISTRIBUTION . . . . . . . . . . . . . . . 8W-97-1
TJ WIRING 8W - 1
8W-01 WIRING DIAGRAM INFORMATION
TABLE OF CONTENTS
page page
WIRING DIAGRAM INFORMATION
DESCRIPTION
DESCRIPTION - HOW TO USE WIRING
DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DESCRIPTION - CIRCUIT INFORMATION . . . . 5
DESCRIPTION - CIRCUIT FUNCTIONS . . . . . . 6
DESCRIPTION - SECTION IDENTIFICATION
AND INFORMATION . . . . . . . . . . . . . . . . . . . . 6
DESCRIPTION - CONNECTOR, GROUND
AND SPLICE INFORMATION . . . . . . . . . . . . . . 7
WARNING
WARNINGS - GENERAL . . . . . . . . . . . . . . . . . 7
DIAGNOSIS AND TESTING - WIRING
HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
STANDARD PROCEDURE
STANDARD PROCEDURE -
ELECTROSTATIC DISCHARGE (ESD)
SENSITIVE DEVICES . . . . . . . . . . . . . . . . . . . 8
STANDARD PROCEDURE - TESTING OF
VOLTAGE POTENTIAL. . . . . . . . . . . . . . . . . . . 9
STANDARD PROCEDURE - TESTING FOR
CONTINUITY . . . . . . . . . . . . . . . . . . . . . . . . . . 9
STANDARD PROCEDURE - TESTING FOR A
SHORT TO GROUND . . . . . . . . . . . . . . . . . . . 9
STANDARD PROCEDURE - TESTING FOR A
SHORT TO GROUND ON FUSES
POWERING SEVERAL LOADS . . . . . . . . . . . 10
STANDARD PROCEDURE - TESTING FOR A
VOLTAGE DROP . . . . . . . . . . . . . . . . . . . . . . 10
SPECIAL TOOLS
WIRING/TERMINAL . . . . . . . . . . . . . . . . . . . . 10
CONNECTOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11
DIODE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14
TERMINAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14
WIRE
STANDARD PROCEDURE - WIRE SPLICING . . 15
WIRING DIAGRAM
INFORMATION
DESCRIPTION
DESCRIPTION - HOW TO USE WIRING
DIAGRAMS
Dai ml erChrysl er Corporati on wi ri ng di agrams are
desi gned to provi de i nformati on regardi ng the vehi -
cl es wi ri ng content. I n order to effecti vel y use the
wi ri ng di agrams to di agnose and repai r
Dai ml erChrysl er Corporati on vehi cl es, i t i s i mportant
to understand al l of thei r features and characteri s-
ti cs.
Di agrams are arranged such that the power (B+)
si de of the ci rcui t i s pl aced near the top of the page,
and the ground (B-) si de of the ci rcui t i s pl aced near
the bottom of the page (Fi g. 1).
Al l swi tches, components, and modul es are shown
i n the at rest posi ti on wi th the doors cl osed and the
key removed from the i gni ti on (Fi g. 2).
Components are shown two ways. A sol i d l i ne
around a component i ndi cates that the component i s
compl ete. A dashed l i ne around the component i ndi -
cates that the component i s bei ng shown i s not com-
pl ete. I ncompl ete components have a reference
number to i ndi cate the page where the component i s
shown compl ete.
I t i s i mportant to real i ze that no attempt i s made
on the di agrams to represent components and wi ri ng
as they appear on the vehi cl e. For exampl e, a short
pi ece of wi re i s treated the same as a l ong one. I n
addi ti on, swi tches and other components are shown
as si mpl y as possi bl e, wi th regard to functi on onl y.
SYMBOLS
I nternati onal symbol s are used throughout the wi r-
i ng di agrams. These symbol s are consi stent wi th
those bei ng used around the worl d (Fi g. 3).
TJ 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 1
Fig. 1 WIRING DIAGRAM EXAMPLE 1
8W - 01 - 2 8W-01 WIRING DIAGRAM INFORMATION TJ
WIRING DIAGRAM INFORMATION (Continued)
Fig. 2 WIRING DIAGRAM EXAMPLE 2
TJ 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 3
WIRING DIAGRAM INFORMATION (Continued)
Fig. 3 WIRING DIAGRAM SYMBOLS
8W - 01 - 4 8W-01 WIRING DIAGRAM INFORMATION TJ
WIRING DIAGRAM INFORMATION (Continued)
TERMINOLOGY
Thi s i s a l i st of terms and defi ni ti ons used i n the
wi ri ng di agrams.
LHD . . . . . . . . . . . . . . . . . Left Hand Dri ve Vehi cl es
RHD . . . . . . . . . . . . . . . Ri ght Hand Dri ve Vehi cl es
ATX . . Automati c Transmi ssi ons-Front Wheel Dri ve
MTX . . . Manual Transmi ssi ons-Front Wheel Dri ve
AT. . . . Automati c Transmi ssi ons-Rear Wheel Dri ve
MT . . . . . Manual Transmi ssi ons-Rear Wheel Dri ve
SOHC . . . . . . . . . . . Si ngl e Over Head Cam Engi ne
DOHC . . . . . . . . . . Doubl e Over Head Cam Engi ne
Bui l t-Up-Export . . . . . . . Vehi cl es Bui l t For Sal e I n
Markets Other Than North Ameri ca
Except Bui l t-Up-Export . . . . . . . . . . . Vehi cl es Bui l t
For Sal e I n North Ameri ca
DESCRIPTION - CIRCUIT INFORMATION
Each wi re shown i n the di agrams contai ns a code
whi ch i denti fi es the mai n ci rcui t, part of the mai n
ci rcui t, gage of wi re, and col or (Fi g. 4).
WIRE COLOR CODE CHART
COLOR CODE COLOR
BL BLUE
BK BLACK
BR BROWN
DB DARK BLUE
DG DARK GREEN
GY GRAY
LB LIGHT BLUE
LG LIGHT GREEN
OR ORANGE
PK PINK
RD RED
TN TAN
VT VIOLET
WT WHITE
YL YELLOW
* WITH TRACER
Fig. 4 WIRE CODE IDENTIFICATION
1 - COLOR OF WIRE (LIGHT BLUE WITH YELLOW TRACER
2 - GAGE OF WIRE (18 GAGE)
3 - PART OF MAIN CIRCUIT (VARIES DEPENDING ON
EQUIPMENT)
4 - MAIN CIRCUIT IDENTIFICATION
TJ 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 5
WIRING DIAGRAM INFORMATION (Continued)
DESCRIPTION - CIRCUIT FUNCTIONS
Al l ci rcui ts i n the di agrams use an al pha/numeri c
code to i denti fy the wi re and i t’s functi on. To i denti fy
whi ch ci rcui t code appl i es to a system, refer to the
Ci rcui t I denti fi cati on Code Chart. Thi s chart shows
the mai n ci rcui ts onl y and does not show the second-
ary codes that may appl y to some model s.
CIRCUIT IDENTIFICATION CODE CHART
CIRCUIT FUNCTION
A BATTERY FEED
B BRAKE CONTROLS
C CLIMATE CONTROLS
D DIAGNOSTIC CIRCUITS
E DIMMING ILLUMINATION
CIRCUITS
F FUSED CIRCUITS
G MONITORING CIRCUITS
(GAUGES)
H OPEN
I NOT USED
J OPEN
K POWERTRAIN CONTROL
MODULE
L EXTERIOR LIGHTING
M INTERIOR LIGHTING
N NOT USED
O NOT USED
P POWER OPTION (BATTERY
FEED)
Q POWER OPTIONS (IGNITION
FEED)
R PASSIVE RESTRAINT
S SUSPENSION/STEERING
T TRANSMISSION/TRANSAXLE/
TRANSFER CASE
U OPEN
V SPEED CONTROL, WIPER/
WASHER
W OPEN
X AUDIO SYSTEMS
Y OPEN
Z GROUNDS
DESCRIPTION - SECTION IDENTIFICATION AND
INFORMATION
The wi ri ng di agrams are grouped i nto i ndi vi dual
secti ons. I f a component i s most l i kel y found i n a par-
ti cul ar group, i t wi l l be shown compl ete (al l wi res,
connectors, and pi ns) wi thi n that group. For exam-
pl e, the Auto Shutdown Rel ay i s most l i kel y to be
found i n Group 30, so i t i s shown there compl ete. I t
can, however, be shown parti al l y i n another group i f
i t contai ns some associ ated wi ri ng.
Spl i ce di agrams i n Secti on 8W-70 show the enti re
spl i ce and provi de references to other secti ons the
spl i ces serves. Secti on 8W-70 onl y contai ns spl i ce di a-
grams that are not shown i n thei r enti rety some-
where el se i n the wi ri ng di agrams.
Secti on 8W-80 shows each connector and the ci r-
cui ts i nvol ved wi th that connector. The connectors
are i denti fi ed usi ng the name/number on the di a-
gram pages.
WIRING SECTION CHART
GROUP TOPIC
8W-01 thru
8W-09
General information and Diagram
Overview
8W-10 thru
8W-19
Main Sources of Power and
Vehicle Grounding
8W-20 thru
8W-29
Starting and Charging
8W-30 thru
8W-39
Powertrain/Drivetrain Systems
8W-40 thru
8W-49
Body Electrical items and A/C
8W-50 thru
8W-59
Exterior Lighting, Wipers and
Trailer Tow
8W-60 thru
8W-69
Power Accessories
8W-70 Splice Information
8W-80 Connector Pin Outs
8W-91 Connector, Ground and Splice
Locations
8W - 01 - 6 8W-01 WIRING DIAGRAM INFORMATION TJ
WIRING DIAGRAM INFORMATION (Continued)
DESCRIPTION - CONNECTOR, GROUND AND
SPLICE INFORMATION
CAUTION: Not all connectors are serviced. Some
connectors are serviced only with a harness. A typ-
ical example might be the Supplemental Restraint
System connectors. Always check parts availability
before attempting a repair.
IDENTIFICATION
I n-l i ne connectors are i denti fi ed by a number, as
fol l ows:
• I n-l i ne connectors l ocated i n the engi ne compart-
ment are C100 seri es numbers
• I n-l i ne connectors l ocated i n the I nstrument
Panel area are C200 seri es numbers.
• I n-l i ne connectors l ocated i n the body are C300
seri es numbers.
• Jumper harness connectors are C400 seri es
numbers.
• Grounds and ground connectors are i denti fi ed
wi th a “G” and fol l ow the same seri es numberi ng as
the i n-l i ne connectors.
• Spl i ces are i denti fi ed wi th an “S” and fol l ow the
same seri es numberi ng as the i n-l i ne connectors.
• Component connectors are i denti fi ed by the com-
ponent name i nstead of a number. Mul ti pl e connec-
tors on a component use a C1, C2, etc. i denti fi er.
LOCATIONS
Secti on 8W-91 contai ns connector/ground/spl i ce
l ocati on i l l ustrati ons. The i l l ustrati ons contai n the
connector name (or number)/ground number/spl i ce
number and component i denti fi cati on. Connector/
ground/spl i ce l ocati on charts i n secti on 8W-91 refer-
ence the fi gure numbers of the i l l ustrati ons.
The abbrevi ati on T/O i s used i n the component
l ocati on secti on to i ndi cate a poi nt i n whi ch the wi r-
i ng harness branches out to a component. The abbre-
vi ati on N/S means Not Shown i n the i l l ustrati ons
WARNING
WARNINGS - GENERAL
WARNINGS provi de i nformati on to prevent per-
sonal i njury and vehi cl e damage. Bel ow i s a l i st of
general warni ngs that shoul d be fol l owed any ti me a
vehi cl e i s bei ng servi ced.
WARNING: ALWAYS WEAR SAFETY GLASSES FOR
EYE PROTECTION.
WARNING: USE SAFETY STANDS ANYTIME A PRO-
CEDURE REQUIRES BEING UNDER A VEHICLE.
WARNING: BE SURE THAT THE IGNITION SWITCH
ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
WARNING: SET THE PARKING BRAKE WHEN
WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL
TRANSMISSION SHOULD BE IN NEUTRAL.
WARNING: OPERATE THE ENGINE ONLY IN A
WELL-VENTILATED AREA.
WARNING: KEEP AWAY FROM MOVING PARTS
WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
WARNING: TO PREVENT SERIOUS BURNS, AVOID
CONTACT WITH HOT PARTS SUCH AS THE RADIA-
TOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATA-
LYTIC CONVERTER AND MUFFLER.
WARNING: DO NOT ALLOW FLAME OR SPARKS
NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
WARNING: ALWAYS REMOVE RINGS, WATCHES,
LOOSE HANGING JEWELRY AND AVOID LOOSE
CLOTHING.
DIAGNOSIS AND TESTING - WIRING HARNESS
TROUBLESHOOTING TOOLS
When di agnosi ng a probl em i n an el ectri cal ci rcui t
there are several common tool s necessary. These tool s
are l i sted and expl ai ned bel ow.
• Jumper Wi re - Thi s i s a test wi re used to con-
nect two poi nts of a ci rcui t. I t can be used to bypass
an open i n a ci rcui t.
WARNING: NEVER USE A JUMPER WIRE ACROSS
A LOAD, SUCH AS A MOTOR, CONNECTED
BETWEEN A BATTERY FEED AND GROUND.
• Vol tmeter - Used to check for vol tage on a ci r-
cui t. Al ways connect the bl ack l ead to a known good
ground and the red l ead to the posi ti ve si de of the
ci rcui t.
CAUTION: Most of the electrical components used
in today’s vehicles are Solid State. When checking
voltages in these circuits, use a meter with a 10 -
megohm or greater impedance rating.
TJ 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 7
WIRING DIAGRAM INFORMATION (Continued)
• Ohmmeter - Used to check the resi stance
between two poi nts of a ci rcui t. Low or no resi stance
i n a ci rcui t means good conti nui ty.
CAUTION: Most of the electrical components used
in today’s vehicles are Solid State. When checking
resistance in these circuits use a meter with a 10 -
megohm or greater impedance rating. In addition,
make sure the power is disconnected from the cir-
cuit. Circuits that are powered up by the vehicle’s
electrical system can cause damage to the equip-
ment and provide false readings.
• Probi ng Tool s - These tool s are used for probi ng
termi nal s i n connectors (Fi g. 5). Sel ect the proper
si ze tool from Speci al Tool Package 6807, and i nsert
i t i nto the termi nal bei ng tested. Use the other end
of the tool to i nsert the meter probe.
INTERMITTENT AND POOR CONNECTIONS
Most i ntermi ttent el ectri cal probl ems are caused
by faul ty el ectri cal connecti ons or wi ri ng. I t i s al so
possi bl e for a sti cki ng component or rel ay to cause a
probl em. Before condemni ng a component or wi ri ng
assembl y, check the fol l owi ng i tems.
• Connectors are ful l y seated
• Spread termi nal s, or termi nal push out
• Termi nal s i n the wi ri ng assembl y are ful l y
seated i nto the connector/component and l ocked i nto
posi ti on
• Di rt or corrosi on on the termi nal s. Any amount of
corrosi on or di rt coul d cause an i ntermi ttent probl em
• Damaged connector/component casi ng exposi ng
the i tem to di rt or moi sture
• Wi re i nsul ati on that has rubbed through causi ng
a short to ground
• Some or al l of the wi ri ng strands broken i nsi de
of the i nsul ati on
• Wi ri ng broken i nsi de of the i nsul ati on
TROUBLESHOOTING WIRING PROBLEMS
When troubl eshooti ng wi ri ng probl ems there are
si x steps whi ch can ai d i n the procedure. The steps
are l i sted and expl ai ned bel ow. Al ways check for non-
factory i tems added to the vehi cl e before doi ng any
di agnosi s. I f the vehi cl e i s equi pped wi th these i tems,
di sconnect them to veri fy these add-on i tems are not
the cause of the probl em.
(1) Veri fy the probl em.
(2) Veri fy any rel ated symptoms. Do thi s by per-
formi ng operati onal checks on components that are
i n the same ci rcui t. Refer to the wi ri ng di agrams.
(3) Anal yze the symptoms. Use the wi ri ng di a-
grams to determi ne what the ci rcui t i s doi ng, where
the probl em most l i kel y i s occurri ng and where the
di agnosi s wi l l conti nue.
(4) I sol ate the probl em area.
(5) Repai r the probl em area.
(6) Veri fy the proper operati on. For thi s step,
check for proper operati on of al l i tems on the
repai red ci rcui t. Refer to the wi ri ng di agrams.
STANDARD PROCEDURE
STANDARD PROCEDURE - ELECTROSTATIC
DISCHARGE (ESD) SENSITIVE DEVICES
Al l ESD sensi ti ve components are sol i d state and a
symbol (Fi g. 6) i s used to i ndi cate thi s. When han-
dl i ng any component wi th thi s symbol , compl y wi th
the fol l owi ng procedures to reduce the possi bi l i ty of
el ectrostati c charge bui l d up on the body and i nad-
vertent di scharge i nto the component. I f i t i s not
known whether the part i s ESD sensi ti ve, assume
that i t i s.
(1) Al ways touch a known good ground before han-
dl i ng the part. Thi s shoul d be repeated whi l e han-
dl i ng the part and more frequentl y after sl i di ng
across a seat, si tti ng down from a standi ng posi ti on,
or wal ki ng a di stance.
(2) Avoi d touchi ng el ectri cal termi nal s of the part,
unl ess i nstructed to do so by a wri tten procedure.
(3) When usi ng a vol tmeter, be sure to connect the
ground l ead fi rst.
(4) Do not remove the part form i t’s protecti ve
packi ng unti l i t i s ti me to i nstal l the part.
(5) Before removi ng the part from i t’s pakage,
ground the pakage to a known good ground on the
vehi cl e.
Fig. 5 PROBING TOOL
1 - SPECIAL TOOL 6801
2 - PROBING END
Fig. 6 ELECTROSTATIC DISCHARGE SYMBOL
8W - 01 - 8 8W-01 WIRING DIAGRAM INFORMATION TJ
WIRING DIAGRAM INFORMATION (Continued)
STANDARD PROCEDURE - TESTING OF
VOLTAGE POTENTIAL
(1) Connect the ground l ead of a vol tmeter to a
known good ground (Fi g. 7).
(2) Connect the other l ead of the vol tmeter to the
sel ected test poi nt. The vehi cl e i gni ti on may need to
be turned ON to check vol tage. Refer to the appropri -
ate test procedure.
STANDARD PROCEDURE - TESTING FOR
CONTINUITY
(1) Remove the fuse for the ci rcui t bei ng checked
or, di sconnect the battery.
(2) Connect one l ead of the ohmmeter to one si de
of the ci rcui t bei ng tested (Fi g. 8).
(3) Connect the other l ead to the other end of the
ci rcui t bei ng tested. Low or no resi stance means good
conti nui ty.
STANDARD PROCEDURE - TESTING FOR A
SHORT TO GROUND
(1) Remove the fuse and di sconnect al l i tems
i nvol ved wi th the fuse.
(2) Connect a test l i ght or a vol tmeter across the
termi nal s of the fuse.
(3) Starti ng at the fuse bl ock, wi ggl e the wi ri ng
harness about si x to ei ght i nches apart and watch
the vol tmeter/test l amp.
(4) I f the vol tmeter regi sters vol tage or the test
l amp gl ows, there i s a short to ground i n that gen-
eral area of the wi ri ng harness.
Fig. 7 TESTING FOR VOLTAGE POTENTIAL
Fig. 8 TESTING FOR CONTINUITY
1 - FUSE REMOVED FROM CIRCUIT
TJ 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 9
WIRING DIAGRAM INFORMATION (Continued)
STANDARD PROCEDURE - TESTING FOR A
SHORT TO GROUND ON FUSES POWERING
SEVERAL LOADS
(1) Refer to the wi ri ng di agrams and di sconnect or
i sol ate al l i tems on the suspected fused ci rcui ts.
(2) Repl ace the bl own fuse.
(3) Suppl y power to the fuse by turni ng ON the
i gni ti on swi tch or re-connecti ng the battery.
(4) Start connecti ng or energi zi ng the i tems i n the
fuse ci rcui t one at a ti me. When the fuse bl ows the
ci rcui t wi th the short to ground has been i sol ated.
STANDARD PROCEDURE - TESTING FOR A
VOLTAGE DROP
(1) Connect the posi ti ve l ead of the vol tmeter to
the si de of the ci rcui t cl osest to the battery (Fi g. 9).
(2) Connect the other l ead of the vol tmeter to the
other si de of the swi tch, component or ci rcui t.
(3) Operate the i tem.
(4) The vol tmeter wi l l show the di fference i n vol t-
age between the two poi nts.
SPECIAL TOOLS
WIRING/TERMINAL
Fig. 9 TESTING FOR VOLTAGE DROP
PROBING TOOL PACKAGE 6807
TERMINAL PICK TOOL SET 6680
TERMINAL REMOVING TOOLS 6932 AND 8638
TERMINAL REMOVING TOOL 6934
8W - 01 - 10 8W-01 WIRING DIAGRAM INFORMATION TJ
WIRING DIAGRAM INFORMATION (Continued)
CONNECTOR
REMOVAL
(1) Di sconnect battery.
(2) Rel ease Connector Lock (Fi g. 10).
(3) Di sconnect the connector bei ng repai red from
i ts mati ng hal f/component.
(4) Remove the dress cover (i f appl i cabl e) (Fi g. 10).
(5) Rel ease the Secondary Termi nal Lock, i f
requi red (Fi g. 11).
(6) Posi ti on the connector l ocki ng fi nger away from
the termi nal usi ng the proper speci al tool . Pul l on
the wi re to remove the termi nal from the connector
(Fi g. 12).
INSTALLATION
(1) I nsert the removed termi nal i n the same cavi ty
on the repai r connector.
(2) Repeat steps for each termi nal i n the connec-
tor, bei ng sure that al l wi res are i nserted i nto the
proper cavi ti es. For addi ti onal connector pi n-out
i denti fi cati on, refer to the wi ri ng di agrams.
(3) When the connector i s re-assembl ed, the sec-
ondary termi nal l ock must be pl aced i n the l ocked
posi ti on to prevent termi nal push out.
(4) Repl ace dress cover (i f appl i cabl e).
(5) Connect connector to i ts mati ng hal f/compo-
nent.
(6) Connect battery and test al l affected systems.
Fig. 10 REMOVAL OF DRESS COVER
1 - DRESS COVER
2 - CONNECTOR LOCK
3 - CONNECTOR
TJ 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 11
Fig. 11 EXAMPLES OF CONNECTOR SECONDARY TERMINAL LOCKS
1 - Secondary Terminal Lock
8W - 01 - 12 8W-01 WIRING DIAGRAM INFORMATION TJ
CONNECTOR (Continued)
Fig. 12 TERMINAL REMOVAL
1 - TYPICAL CONNECTOR
2 - PICK FROM SPECIAL TOOL KIT 6680
3 - APEX CONNECTOR
4 - PICK FROM SPECIAL TOOL KIT 6680
5 - AUGAT CONNECTOR
6 - SPECIAL TOOL 6932
7 - MOLEX CONNECTOR
8 - SPECIAL TOOL 6742
9 - THOMAS AND BETTS CONNECTOR
10 - SPECIAL TOOL 6934
11 - TYCO CONNECTOR
12 - SPECIAL TOOL 8638
TJ 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 13
CONNECTOR (Continued)
DIODE
REMOVAL
(1) Di sconnect the battery.
(2) Locate the di ode i n the harness, and remove
the protecti ve coveri ng.
(3) Remove the di ode from the harness, pay atten-
ti on to the current fl ow di recti on (Fi g. 13).
INSTALLATION
(1) Remove the i nsul ati on from the wi res i n the
harness. Onl y remove enough i nsul ati on to sol der i n
the new di ode.
(2) I nstal l the new di ode i n the harness, maki ng
sure current fl ow i s correct. I f necessary, refer to the
appropri ate wi ri ng di agram for current fl ow (Fi g. 13).
(3) Sol der the connecti on together usi ng rosi n core
type sol der onl y. Do not use acid core solder.
(4) Tape the di ode to the harness usi ng el ectri cal
tape. Make sure the di ode i s compl etel y seal ed from
the el ements.
(5) Re-connect the battery and test affected sys-
tems.
TERMINAL
REMOVAL
(1) Fol l ow steps for removi ng termi nal s descri bed
i n the connector removal secti on.
(2) Cut the wi re 6 i nches from the back of the con-
nector.
INSTALLATION
(1) Sel ect a wi re from the termi nal repai r ki t that
best matches the col or and gage of the wi re bei ng
repai red.
(2) Cut the repai r wi re to the proper l ength and
remove one–hal f (1/2) i nch of i nsul ati on.
(3) Spl i ce the repai r wi re to the wi re harness (see
wi re spl i ci ng procedure).
(4) I nsert the repai red wi re i nto the connector.
(5) I nstal l the connector l ocki ng wedge, i f requi red,
and reconnect the connector to i ts mati ng hal f/compo-
nent.
(6) Re-tape the wi re harness starti ng at 1–1/2
i nches behi nd the connector and 2 i nches past the
repai r.
(7) Connect battery and test al l affected systems.
Fig. 13 DIODE IDENTIFICATION
1 - CURRENT FLOW
2 - BAND AROUND DIODE INDICATES CURRENT FLOW
3 - DIODE AS SHOWN IN THE DIAGRAMS
8W - 01 - 14 8W-01 WIRING DIAGRAM INFORMATION TJ
WIRE
STANDARD PROCEDURE - WIRE SPLICING
When spl i ci ng a wi re, i t i s i mportant that the cor-
rect gage be used as shown i n the wi ri ng di agrams.
(1) Remove one-hal f (1/2) i nch of i nsul ati on from
each wi re that needs to be spl i ced.
(2) Pl ace a pi ece of adhesi ve l i ned heat shri nk tub-
i ng on one si de of the wi re. Make sure the tubi ng wi l l
be l ong enough to cover and seal the enti re repai r
area.
(3) Pl ace the strands of wi re overl appi ng each
other i nsi de of the spl i ce cl i p (Fi g. 14).
(4) Usi ng cri mpi ng tool , Mopar p/n 05019912AA,
cri mp the spl i ce cl i p and wi res together (Fi g. 15).
(5) Sol der the connecti on together usi ng rosi n core
type sol der onl y (Fi g. 16).
CAUTION: DO NOT USE ACID CORE SOLDER.
(6) Center the heat shri nk tubi ng over the joi nt
and heat usi ng a heat gun. Heat the joi nt unti l the
tubi ng i s ti ghtl y seal ed and seal ant comes out of both
ends of the tubi ng (Fi g. 17).
Fig. 14 SPLICE BAND
1 - SPLICE BAND
Fig. 15 CRIMPING TOOL
1 - CRIMPING TOOL
Fig. 16 SOLDER SPLICE
1 - SOLDER
2 - SPLICE BAND
3 - SOLDERING IRON
Fig. 17 HEAT SHRINK TUBE
1 - SEALANT
2 - HEAT SHRINK TUBE
TJ 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 15
8W-02 COMPONENT INDEX
Component Page
A/C Compressor Cl utch Rel ay . . . . . . . . . . . . 8W-42
A/C Compressor Cl utch . . . . . . . . . . . . . . . . . 8W-42
A/C Pressure Swi tches . . . . . . . . . . . . . . . . . 8W-42
A/C Pressure Transducer . . . . . . . . . . . . . . . . 8W-42
A/C-Heater Control . . . . . . . . . . . . . . . . . . . . 8W-42
Ai rbag Control Modul e . . . . . . . . . . . . . . . . . 8W-43
Ai rbag On-Off Swi tch . . . . . . . . . . . . . . . . . . 8W-43
Ai rbag Squi bs . . . . . . . . . . . . . . . . . . . . . . . . 8W-43
Ambi ent Temperature Sensor . . . . . . . . . . . . 8W-44
Anti l ock Brake Rel ay . . . . . . . . . . . . . . . . . . 8W-35
Automati c Shut Down Rel ay . . . . . . . . . . . . . 8W-30
Axl e Lock Swi tch . . . . . . . . . . . . . . . . . . . . . . 8W-31
Back-Up Lamp Swi tch . . . . . . . . . . . . . . . . . . 8W-51
Battery Temperature Sensor . . . . . . . . . . . . . 8W-30
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20
Bl end Door Actuator . . . . . . . . . . . . . . . . . . . 8W-42
Bl ower Motor Rel ay . . . . . . . . . . . . . . . . . . . . 8W-42
Bl ower Motor Resi stor Bl ock . . . . . . . . . . . . . 8W-42
Bl ower Motor . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42
Brake Lamp Swi tch . . . . . . . . . . . . . . . . . . . . 8W-51
Brake Transmi ssi on Shi ft I nterl ock
Sol enoi d . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31
Brake Warni ng I ndi cator Swi tch . . . . . . . . . . 8W-40
Camshaft Posi ti on Sensor . . . . . . . . . . . . . . . 8W-30
Capaci tor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30
Center Hi gh Mounted Stop Lamp . . . . . . . . . 8W-51
Ci gar Li ghter/Power Outl et . . . . . . . . . . . . . . 8W-41
Ci rcui t Breaker . . . . . . . . . . . . . . . . . . . . . . . 8W-50
Cl ockspri ng . . . . . . . . . . . . . . . . . . . . 8W-33, 41, 43
Cl utch Pedal Posi ti on Swi tch . . . . . . . . . . . . 8W-21
Coi l Capaci tor . . . . . . . . . . . . . . . . . . . . . . . . 8W-30
Compass/Temperature Mi rror . . . . . . . . . . . . 8W-44
Control l er Anti l ock Brake . . . . . . . . . . . . . . . 8W-35
Courtesy Lamps . . . . . . . . . . . . . . . . . . . . . . 8W-44
Crankshaft Posi ti on Sensor . . . . . . . . . . . . . . 8W-30
Data Li nk Connector . . . . . . . . . . . . . . . . 8W-18, 31
Dayti me Runni ng Lamp Modul e . . . . . . . . . . 8W-50
Dome Lamps . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44
Door Ajar Swi tches . . . . . . . . . . . . . . . . . . . . 8W-44
Engi ne Cool ant Temperature Sensor . . . . . . . 8W-30
Engi ne Oi l Pressure Sensor . . . . . . . . . . . . . . 8W-30
Engi ne Oi l Pressure Swi tch . . . . . . . . . . . . . . 8W-30
Engi ne Starter Motor Rel ay . . . . . . . . . . . . . 8W-21
Engi ne Starter Motor . . . . . . . . . . . . . . . . . . 8W-21
EVAP/Purge Sol enoi d . . . . . . . . . . . . . . . . . . 8W-30
Fog Lamp Rel ay . . . . . . . . . . . . . . . . . . . . . . 8W-50
Fog Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50
Fuel I njectors . . . . . . . . . . . . . . . . . . . . . . . . 8W-30
Fuel Pump Modul e . . . . . . . . . . . . . . . . . . . . 8W-30
Fuel Pump Rel ay . . . . . . . . . . . . . . . . . . . . . . 8W-30
Fuse Bl ock . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10, 11
Component Page
Fusi bl e Li nk . . . . . . . . . . . . . . . . . . . . . . 8W-10, 20
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20
Grounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15
G-Swi tch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-35
Headl amp Level i ng Motors . . . . . . . . . . . . . . 8W-50
Headl amp Level i ng Swi tch . . . . . . . . . . . . . . 8W-50
Headl amps . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50
Heater Control . . . . . . . . . . . . . . . . . . . . . . . 8W-42
Horn Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41
Horn Swi tch . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41
I dl e Ai r Control Motor . . . . . . . . . . . . . . . . . . 8W-30
I gni ti on Coi l Pack . . . . . . . . . . . . . . . . . . . . . 8W-30
I gni ti on Swi tch . . . . . . . . . . . . . . . . . . . . . . . 8W-10
I nstrument Cl uster . . . . . . . . . . . . . . . . . . . . 8W-40
I ntake Ai r Temperature Sensor . . . . . . . . . . . 8W-30
Lamp Assembl i es . . . . . . . . . . . . . . . . . . . . . . 8W-51
Leak Detecti on Pump . . . . . . . . . . . . . . . . . . 8W-30
Li cense Lamps . . . . . . . . . . . . . . . . . . . . . . . 8W-51
Locker I ndi cator Swi tches . . . . . . . . . . . . . . . 8W-31
Locker Pumps . . . . . . . . . . . . . . . . . . . . . . . . 8W-31
Locker Rel ays . . . . . . . . . . . . . . . . . . . . . . . . 8W-31
Mani fol d Absol ute Pressure Sensor . . . . . . . . 8W-30
Mul ti -Functi on Swi tch . . . 8W-40, 44, 50, 51, 52, 53
Overdri ve Off Swi tch . . . . . . . . . . . . . . . . . . . 8W-31
Oxygen Sensor Downstream Heater Rel ay . . 8W-30
Oxygen Sensors . . . . . . . . . . . . . . . . . . . . . . . 8W-30
Park Brake Swi tch . . . . . . . . . . . . . . . . . . . . 8W-40
Park/Turn Si gnal Lamps . . . . . . . . . . . . . . . . 8W-52
Posi ti on Lamps . . . . . . . . . . . . . . . . . . . . . . . 8W-50
Power Di stri buti on Center . . . . . . . . . . . . . . 8W-10
Power Outl et . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41
Power Steeri ng Pressure Swi tch . . . . . . . . . . 8W-30
Powertrai n Control Modul e . . . . . . . . . . . . . . 8W-30
Radi ator Fan Motor Ci rcui t Breaker . . . . 8W-15, 42
Radi ator Fan Motor . . . . . . . . . . . . . . . . . . . . 8W-42
Radi ator Fan Rel ays . . . . . . . . . . . . . . . . . . . 8W-42
Radi o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47
Rear Fog Lamp . . . . . . . . . . . . . . . . . . . . . . . 8W-51
Rear Wi ndow Defogger Rel ay . . . . . . . . . . . . 8W-48
Rear Wi ndow Defogger Swi tch . . . . . . . . . . . 8W-48
Rear Wi ndow Defogger . . . . . . . . . . . . . . . . . 8W-48
Rear Wi per/Washer Swi tch . . . . . . . . . . . . . . 8W-53
Seat Bel t Swi tch . . . . . . . . . . . . . . . . . . . . . . 8W-40
Sentry Key I mmobi l i zer Modul e . . . . . . . . . . 8W-39
Si de Marker Lamps . . . . . . . . . . . . . . . . . 8W-50, 52
Si de Repeater Lamps . . . . . . . . . . . . . . . . . . 8W-52
Speakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47
Speed Control Servo . . . . . . . . . . . . . . . . . . . 8W-33
Speed Control Swi tches . . . . . . . . . . . . . . . . . 8W-33
Speed Sensors . . . . . . . . . . . . . . . . . . . . . . . . 8W-31
Spl i ces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70
TJ 8W-02 COMPONENT INDEX 8W - 02 - 1
Component Page
Subwoofer . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47
Throttl e Posi ti on Sensor . . . . . . . . . . . . . . . . 8W-30
Transfer Case Swi tch . . . . . . . . . . . . . . . . . . 8W-31
Transmi ssi on Control Modul e . . . . . . . . . . . . 8W-31
Transmi ssi on Control Rel ay . . . . . . . . . . . . . 8W-31
Transmi ssi on Range I ndi cator I l l umi nati on . 8W-44
Transmi ssi on Range Sensor . . . . . . . . . . . 8W-31, 51
Transmi ssi on Sol enoi d/Pressure Swi tch
Assembl y . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31
Component Page
Turn Si gnal Lamps . . . . . . . . . . . . . . . . . . . . 8W-52
Underhood Lamp . . . . . . . . . . . . . . . . . . . . . . 8W-44
Vehi cl e Speed Sensor . . . . . . . . . . . . . . . . . . . 8W-30
Washer Pumps . . . . . . . . . . . . . . . . . . . . . . . 8W-53
Wheel Speed Sensors . . . . . . . . . . . . . . . . . . . 8W-35
Wi per Motors . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53
8W - 02 - 2 8W-02 COMPONENT INDEX TJ
8W-10 POWER DISTRIBUTION
Component Page
A/C Compressor Cl utch . . . . . . . . . . . . . . 8W-10-19
A/C Compressor Cl utch Rel ay . . . . . . . . 8W-10-9, 19
Automati c Shut Down Rel ay . . . . 8W-10-8, 9, 15, 16
Axl e Lock Swi tch . . . . . . . . . . . . . . . . . . . 8W-10-20
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-8
Bl ower Motor Rel ay . . . . . . . . . . . . . . . 8W-10-8, 11
Capaci tor . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-17
Ci rcui t Breaker . . . . . . . . . . . . . . . . . . . 8W-10-8, 12
Cl utch Pedal Posi ti on Swi tch . . . . . . . . . . 8W-10-13
Coi l Capaci tor . . . . . . . . . . . . . . . . . . . . . . 8W-10-18
Compass/Temperature Mi rror . . . . . . . . . . 8W-10-20
Control l er Anti l ock Brake . . . . . . . . . . . 8W-10-8, 12
Data Li nk Connector . . . . . . . . . . . . . . . . 8W-10-20
Engi ne Starter Motor . . . . . . . . . . . . . . 8W-10-8, 13
Engi ne Starter Motor Rel ay . . . . . . . . . . . 8W-10-13
Fog Lamp Rel ay . . . . . . . . . . . . . . . . . . . . 8W-10-19
Front Locker Pump . . . . . . . . . . . . . . . . . 8W-10-22
Front Locker Rel ay . . . . . . . . . . . . . . . . . . 8W-10-22
Fuel I njector No. 1 . . . . . . . . . . . . . . . 8W-10-17, 18
Fuel I njector No. 2 . . . . . . . . . . . . . . . 8W-10-17, 18
Fuel I njector No. 3 . . . . . . . . . . . . . . . 8W-10-17, 18
Fuel I njector No. 4 . . . . . . . . . . . . . . . 8W-10-17, 18
Fuel I njector No. 5 . . . . . . . . . . . . . . . . . . 8W-10-17
Fuel I njector No. 6 . . . . . . . . . . . . . . . . . . 8W-10-17
Fuel Pump Modul e . . . . . . . . . . . . . . . . . . 8W-10-19
Fuel Pump Rel ay . . . . . . . . . . . . . . . . . 8W-10-9, 19
Fuse 1 . . . . . . . . . . . . . . . . . . . . . . . 8W-10-8, 11, 12
Fuse 2 . . . . . . . . . . . . . . . . . . . . . . . 8W-10-8, 11, 12
Fuse 3 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-8, 12
Fuse 4 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-8, 12
Fuse 5 . . . . . . . . . . . . . . . . . . . . 8W-10-9, 10, 13, 21
Fuse 6 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-8, 13
Fuse 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-13
Fuse 8 . . . . . . . . . . . . . . . . . . . . . . . 8W-10-8, 12, 13
Fuse 9 . . . . . . . . . . . . . . . . . . . . . . . 8W-10-8, 14, 16
Fuse 10 . . . . . . . . . . . . . . . . . . . . 8W-10-8, 9, 12, 14
Fuse 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-14
Fuse 12 . . . . . . . . . . . . . . . . . . . . . . 8W-10-8, 12, 14
Fuse 13 . . . . . . . . . . . . . . . . . . . . 8W-10-8, 9, 14, 15
Fuse 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-14
Fuse 15 . . . . . . . . . . . . . . . . . . . . . . 8W-10-9, 11, 20
Fuse 16 . . . . . . . . . . . . . . . . . . . . . . 8W-10-9, 15, 16
Fuse 17 . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-10, 21
Fuse 18 . . . . . . . . . . . . . . . . . . . . . . 8W-10-9, 15, 19
Fuse 19 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-9, 19
Component Page
Fuse 20 . . . . . . . . . . . . . . . . . . . . . 8W-10-10, 13, 21
Fuse 21 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-9, 19
Fuse 22 . . . . . . . . . . . . . . . . . . . . . . 8W-10-9, 13, 14
Fuse 23 . . . . . . . . . . . . . . . . . . . . . . 8W-10-9, 10, 19
Fuse 24 . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-10, 22
Fuse 26 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-9, 20
Fuse 27 . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-10, 21
Fuse 28 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-9, 16
Fuse Bl ock . . . . . . . . . . . 8W-10-8, 11, 12, 13, 14, 15
Fusi bl e Li nk . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-8
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-14
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-8
Hi gh Speed Radi ator Fan Rel ay . . . . . . . . 8W-10-12
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-19
Horn Rel ay . . . . . . . . . . . . . . . . . . . . . . 8W-10-9, 19
I gni ti on Coi l Pack . . . . . . . . . . . . . . . . 8W-10-17, 18
I gni ti on Swi tch . . . . . . . . . . . . . 8W-10-9, 13, 14, 15
I nstrument Cl uster . . . . . . . . . . . . . . . 8W-10-14, 20
Left Courtesy Lamp . . . . . . . . . . . . . . . . . 8W-10-20
Left Dome Lamp . . . . . . . . . . . . . . . . . . . . 8W-10-20
Left Fog Lamp . . . . . . . . . . . . . . . . . . . . . 8W-10-19
Low Speed Radi ator Fan Rel ay . . . . . . . . 8W-10-12
Mul ti -Functi on Swi tch . . . . . . . 8W-10-9, 10, 19, 21
Oxygen Sensor 1/1 Upstream . . . . . . . . . . 8W-10-16
Oxygen Sensor 1/2 Downstream . . . . . 8W-10-15, 16
Oxygen Sensor 2/2 Downstream . . . . . . . . 8W-10-15
Oxygen Sensor Downstream Heater
Rel ay . . . . . . . . . . . . . . . . . . . . . . 8W-10-9, 15, 16
Power Di stri buti on Center . . . 8W-10-2, 8, 9, 10, 11,
12, 13, 14, 15, 16, 19, 20, 21, 22
Power Outl et . . . . . . . . . . . . . . . . . . . . 8W-10-10, 21
Powertrai n Control Modul e . . . . . . . . . 8W-10-8, 16
Radi o . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-21
Rear Locker Pump . . . . . . . . . . . . . . . . . . 8W-10-22
Rear Locker Rel ay . . . . . . . . . . . . . . . 8W-10-10, 22
Rear Wi ndow Defogger . . . . . . . . . . . . . . . 8W-10-11
Rear Wi ndow Defogger Rel ay . . . . . . . . 8W-10-8, 11
Ri ght Courtesy Lamp . . . . . . . . . . . . . . . . 8W-10-20
Ri ght Dome Lamp . . . . . . . . . . . . . . . . . . 8W-10-20
Ri ght Fog Lamp . . . . . . . . . . . . . . . . . . . . 8W-10-19
Transmi ssi on Control Modul e . . . . . . . . . . 8W-10-21
Transmi ssi on Control Rel ay . . . . . . . . 8W-10-10, 21
Transmi ssi on Sol enoi d/Pressure Swi tch
Assembl y . . . . . . . . . . . . . . . . . . . . . . . 8W-10-21
Underhood Lamp . . . . . . . . . . . . . . . . . . . 8W-10-20
TJ 8W-10 POWER DISTRIBUTION 8W - 10 - 1
8W-11 FUSE BLOCK
Component Page
A/C Compressor Cl utch Rel ay . . . . . . . . . . . 8W-11-8
A/C-Heater Control . . . . . . . . . . . . . . . . . . . 8W-11-6
Ai rbag Control Modul e . . . . . . . . . . . . . . 8W-11-5, 7
Anti l ock Brake Rel ay . . . . . . . . . . . . . . . . . 8W-11-6
Automati c Shut Down Rel ay . . . . . . . . . . . 8W-11-7
Back-Up Lamp Swi tch . . . . . . . . . . . . . . . . 8W-11-6
Bl end Door Actuator . . . . . . . . . . . . . . . . . . 8W-11-6
Bl ower Motor Rel ay . . . . . . . . . . . . . . . . . . 8W-11-6
Brake Lamp Swi tch . . . . . . . . . . . . . . . . . . 8W-11-4
Brake Transmi ssi on Shi ft I nterl ock
Sol enoi d . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-7
Ci gar Li ghter/Power Outl et . . . . . . . . . . . 8W-11-10
Cl utch Pedal Posi ti on Swi tch . . . . . . . . . . . 8W-11-9
Compass/Temperature Mi rror . . . . . . . . . . . 8W-11-7
Control l er Anti l ock Brake . . . . . . . . . . . . . . 8W-11-6
Dayti me Runni ng Lamp Modul e . . . . . . 8W-11-8, 10
Dri ver Door Ajar Swi tch . . . . . . . . . . . . . . . 8W-11-4
Engi ne Starter Motor Rel ay . . . . . . . . . . . 8W-11-11
EVAP/Purge Sol enoi d . . . . . . . . . . . . . . . . . 8W-11-8
Front Wi per Motor . . . . . . . . . . . . . . . . . . 8W-11-10
Fuel Pump Rel ay . . . . . . . . . . . . . . . . . . . . 8W-11-7
Fuse 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-4
Fuse 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-4
Fuse 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-4
Fuse 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-4
Fuse 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-5
Fuse 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-5
Fuse 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-6
Fuse 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-6
Fuse 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-7
Fuse 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-7
Fuse 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-8
Fuse 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-7
Component Page
Fuse 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-9
Fuse 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-9
Fuse 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-9
Fuse 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-10
Fuse 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-10
Fuse 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-10
Fuse 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-9
Fuse Bl ock . . . . . . . . . . . 8W-11-2, 4, 5, 6, 7, 8, 9, 10
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-4
Headl amp Level i ng Swi tch . . . . . . . . . . . . 8W-11-10
Heater Control . . . . . . . . . . . . . . . . . . . . . . 8W-11-6
Hi gh Speed Radi ator Fan Rel ay . . . . . . . . . 8W-11-6
I gni ti on Swi tch . . . . . . . . . . . . . . . . . . . . . 8W-11-10
I nstrument Cl uster . . . . . . . . . . . . . . . . . . . 8W-11-7
Left Headl amp . . . . . . . . . . . . . . . . . . . . . 8W-11-10
Left Headl amp Level i ng Motor . . . . . . . . . 8W-11-10
Low Speed Radi ator Fan Rel ay . . . . . . . . . 8W-11-6
Mul ti -Functi on Swi tch . . . . . . . . . . . 8W-11-4, 9, 10
Passenger Ai rbag On-Off Swi tch . . . . . . . . 8W-11-7
Passenger Door Ajar Swi tch . . . . . . . . . . . . 8W-11-4
Powertrai n Control Modul e . . . . . . . . . . 8W-11-7, 11
Radi o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-9
Rear Wi ndow Defogger Rel ay . . . . . . . . . 8W-11-6, 9
Rear Wi ndow Defogger Swi tch . . . . . . . . . . 8W-11-9
Rear Wi per Motor . . . . . . . . . . . . . . . . . . . . 8W-11-5
Rear Wi per/Washer Swi tch . . . . . . . . . . . . . 8W-11-5
Ri ght Headl amp . . . . . . . . . . . . . . . . . . . . 8W-11-10
Ri ght Headl amp Level i ng Motor . . . . . . . . 8W-11-10
Sentry Key I mmobi l i zer Modul e . . . . . . . 8W-11-4, 7
Subwoofer . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-4
Transmi ssi on Control Modul e . . . . . . . . . . 8W-11-11
Transmi ssi on Range Sensor . . . . . . . . . . . . 8W-11-6
TJ 8W-11 FUSE BLOCK 8W - 11 - 1
8W-15 GROUND DISTRIBUTION
Component Page
A/C Compressor Cl utch . . . . . . . . . . . 8W-15-7, 8, 9
A/C-Heater Control . . . . . . . . . . . . . . . 8W-15-11, 12
Ai rbag Control Modul e . . . . . . . . . . . . . . . 8W-15-14
Anti l ock Brake Rel ay . . . . . . . . . . . . . . . . . 8W-15-2
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-10
Bl end Door Actuator . . . . . . . . . . . . . . 8W-15-11, 12
Bl ower Motor Rel ay . . . . . . . . . . . . . . 8W-15-11, 12
Brake Lamp Swi tch . . . . . . . . . . . . . . . . . 8W-15-13
Center Hi gh Mounted Stop Lamp . . . . . . . 8W-15-14
Ci gar Li ghter/Power Outl et . . . . . . . . . 8W-15-11, 12
Compass/Temperature Mi rror . . . . . . . 8W-15-11, 12
Control l er Anti l ock Brake . . . . . . . . . . . . . . 8W-15-2
Data Li nk Connector . . . . . . . . . . . . 8W-15-6, 11, 12
Dayti me Runni ng Lamp Modul e . . . . . . . . 8W-15-2
Dri ver Door Ajar Swi tch . . . . . . . . . . . . . . 8W-15-13
Engi ne Starter Motor Rel ay . . . . . . . . 8W-15-7, 8, 9
Fog Lamp Rel ay . . . . . . . . . . . . . . . . . . . . . 8W-15-2
Front Locker I ndi cator Swi tch . . . . . . . . . . 8W-15-8
Front Locker Pump . . . . . . . . . . . . . . . . . . 8W-15-8
Front Washer Pump . . . . . . . . . . . . . . . . 8W-15-3, 4
Front Wi per Motor . . . . . . . . . . . . . . . . . . 8W-15-13
Fuel Pump Modul e . . . . . . . . . . . . . . . 8W-15-7, 8, 9
Fuse 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-13
Fuse Bl ock . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-13
G100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-2
G101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-2
G102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-3, 4
G103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-5
G104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-6
G105 . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-6, 7, 8, 9
G106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-10
G107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-10
G190 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-10
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-11, 12
G201 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-11, 12
G202 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-11, 12
G203 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-11, 12
G204 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-11, 12
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-13
G301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-14
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-14
G303 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-14
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-6
Headl amp Level i ng Swi tch . . . . . . . . . 8W-15-11, 12
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-3, 4
I gni ti on Swi tch . . . . . . . . . . . . . . . . . . . . . 8W-15-13
Component Page
I nstrument Cl uster . . . . . . . . . . . . . . . 8W-15-11, 12
Left Fog Lamp . . . . . . . . . . . . . . . . . . . . . . 8W-15-3
Left Front Park/Turn Si gnal Lamp . . . . . . . 8W-15-3
Left Front Posi ti on Lamp . . . . . . . . . . . . . . 8W-15-4
Left Front Turn Si gnal Lamp . . . . . . . . . . . 8W-15-4
Left Headl amp . . . . . . . . . . . . . . . . . . . . 8W-15-3, 4
Left Headl amp Level i ng Motor . . . . . . . . . . 8W-15-4
Left Li cense Lamp . . . . . . . . . . . . . . . . . . 8W-15-14
Left Si de Repeater Lamp . . . . . . . . . . . . . . 8W-15-4
Mul ti -Functi on Swi tch . . . . . . . . . . . . . . . 8W-15-13
Overdri ve Off Swi tch . . . . . . . . . . . . . 8W-15-11, 12
Oxygen Sensor 1/2 Downstream . . . . . . . 8W-15-7, 8
Passenger Door Ajar Swi tch . . . . . . . . . . . 8W-15-13
Power Outl et . . . . . . . . . . . . . . . . . . . . 8W-15-11, 12
Power Steeri ng Pressure Swi tch . . . . . . . . . 8W-15-9
Powertrai n Control Modul e . . . . . . 8W-15-6, 7, 8, 9
Radi ator Fan Motor . . . . . . . . . . . . . . . . . 8W-15-10
Radi ator Fan Motor Ci rcui t Breaker . . . . 8W-15-10
Radi o . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-11, 12
Rear Fog Lamp . . . . . . . . . . . . . . . . . . . . . 8W-15-14
Rear Locker I ndi cator Swi tch . . . . . . . . . . . 8W-15-8
Rear Locker Pump . . . . . . . . . . . . . . . . . . . 8W-15-8
Rear Washer Pump . . . . . . . . . . . . . . . . . . 8W-15-14
Rear Wi ndow Defogger . . . . . . . . . . . . . . . 8W-15-14
Rear Wi ndow Defogger Swi tch . . . . . . 8W-15-11, 12
Rear Wi per Motor . . . . . . . . . . . . . . . . . . . 8W-15-14
Rear Wi per/Washer Swi tch . . . . . . . . . 8W-15-11, 12
Ri ght Fog Lamp . . . . . . . . . . . . . . . . . . . . . 8W-15-5
Ri ght Front Park/Turn Si gnal Lamp . . . . . 8W-15-5
Ri ght Front Posi ti on Lamp . . . . . . . . . . . . . 8W-15-5
Ri ght Front Turn Si gnal Lamp . . . . . . . . . . 8W-15-5
Ri ght Headl amp . . . . . . . . . . . . . . . . . . . . . 8W-15-5
Ri ght Headl amp Level i ng Motor . . . . . . . . 8W-15-5
Ri ght Li cense Lamp . . . . . . . . . . . . . . . . . 8W-15-14
Ri ght Si de Repeater Lamp . . . . . . . . . . . . . 8W-15-5
Seat Bel t Swi tch . . . . . . . . . . . . . . . . . . . . 8W-15-14
Sentry Key I mmobi l i zer Modul e . . . . . . . . 8W-15-14
Speed Control Servo . . . . . . . . . . . . . . . . . . 8W-15-2
Subwoofer . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-14
Transfer Case Swi tch . . . . . . . . . . . . . . . 8W-15-7, 9
Transmi ssi on Control Modul e . . . . . . . . . . . 8W-15-9
Transmi ssi on Control Rel ay . . . . . . . . . . . . 8W-15-2
Transmi ssi on Range I ndi cator
I l l umi nati on . . . . . . . . . . . . . . . . . . . . . 8W-15-13
Underhood Lamp . . . . . . . . . . . . . . . . . . . . 8W-15-2
TJ 8W-15 GROUND DISTRIBUTION 8W - 15 - 1
8W-18 BUS COMMUNICATIONS
Component Page
Ai rbag Control Modul e . . . . . . . . . . . . . . . . 8W-18-2
Control l er Anti l ock Brake . . . . . . . . . . . . . . 8W-18-4
Data Li nk Connector . . . . . . . . . . . . . 8W-18-2, 3, 4
Fuse 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-18-3
G105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-18-3
G201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-18-3
Component Page
I nstrument Cl uster . . . . . . . . . . . . . . . . . . . 8W-18-2
Power Di stri buti on Center . . . . . . . . . . . . . 8W-18-3
Powertrai n Control Modul e . . . . . . . . 8W-18-2, 3, 4
Radi o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-18-2
Sentry Key I mmobi l i zer Modul e . . . . . . . . . 8W-18-2
Transmi ssi on Control Modul e . . . . . . . . . 8W-18-3, 4
TJ 8W-18 BUS COMMUNICATIONS 8W - 18 - 1
8W-20 CHARGING SYSTEM
Component Page
Automati c Shut Down Rel ay . . . . . . . . . . . 8W-20-2
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2
Battery Temperature Sensor . . . . . . . . . . . 8W-20-3
Engi ne Starter Motor . . . . . . . . . . . . . . . . . 8W-20-2
Fuel Pump Rel ay . . . . . . . . . . . . . . . . . . 8W-20-2, 3
Fuse 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2
Fuse 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-3
Fuse Bl ock . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-3
Component Page
Fusi bl e Li nk . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2
G104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2
G106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2
G107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2
Power Di stri buti on Center . . . . . . . . . . . . . 8W-20-2
Powertrai n Control Modul e . . . . . . . . . . 8W-20-2, 3
TJ 8W-20 CHARGING SYSTEM 8W - 20 - 1
8W-21 STARTING SYSTEM
Component Page
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-21-2, 3
Cl utch Pedal Posi ti on Swi tch . . . . . . . . . . . 8W-21-2
Engi ne Starter Motor . . . . . . . . . . . . . . . 8W-21-2, 3
Engi ne Starter Motor Rel ay . . . . . . . . . . 8W-21-2, 3
Fuse 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-21-2
Fuse 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-21-2
Component Page
Fuse Bl ock . . . . . . . . . . . . . . . . . . . . . . . . . 8W-21-2
G105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-21-3
I gni ti on Swi tch . . . . . . . . . . . . . . . . . . . . . . 8W-21-2
Power Di stri buti on Center . . . . . . . . . . . . . 8W-21-2
Transmi ssi on Range Sensor . . . . . . . . . . . . 8W-21-3
TJ 8W-21 STARTING SYSTEM 8W - 21 - 1
8W-30 FUEL/IGNITION SYSTEM
Component Page
A/C Compressor Cl utch Rel ay . . . . . . . . . . 8W-30-3
A/C Hi gh Pressure Swi tch . . . . . . . . . . . . 8W-30-18
A/C Low Pressure Swi tch . . . . . . . . . . 8W-30-12, 18
A/C Pressure Transducer . . . . . . . . . . . . . . 8W-30-4
A/C-Heater Control . . . . . . . . . . . . . . . 8W-30-12, 18
Automati c Shut Down
Rel ay . . . . . . . . . . . . . . . . 8W-30-2, 3, 7, 8, 13, 14
Battery Temperature Sensor . . . . . . . . 8W-30-10, 16
Brake Lamp Swi tch . . . . . . . . . . . . 8W-30-6, 12, 18
Brake Transmi ssi on Shi ft I nterl ock
Sol enoi d . . . . . . . . . . . . . . . . . . . . . 8W-30-12, 18
Camshaft Posi ti on Sensor . . . . . . . . . . . 8W-30-7, 13
Capaci tor . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-13
Cl ockspri ng . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-6
Coi l Capaci tor . . . . . . . . . . . . . . . . . . . . . . . 8W-30-7
Crankshaft Posi ti on Sensor . . . . . . . . . 8W-30-7, 13
Data Li nk Connector . . . . . . . . . . . . . . . . . 8W-30-5
Dayti me Runni ng Lamp Modul e . . . . . 8W-30-10, 16
Engi ne Cool ant Temperature Sensor . . 8W-30-9, 15
Engi ne Oi l Pressure Sensor . . . . . . . . . . . 8W-30-15
Engi ne Oi l Pressure Swi tch . . . . . . . . . . . . 8W-30-9
Engi ne Starter Motor Rel ay . . . . . . . . . . . . 8W-30-4
EVAP/Purge Sol enoi d . . . . . . . . . . . . . 8W-30-11, 17
Fuel I njector No. 1 . . . . . . . . . . . . . . . . 8W-30-8, 14
Fuel I njector No. 2 . . . . . . . . . . . . . . . . 8W-30-8, 14
Fuel I njector No. 3 . . . . . . . . . . . . . . . . 8W-30-8, 14
Fuel I njector No. 4 . . . . . . . . . . . . . . . . 8W-30-8, 14
Fuel I njector No. 5 . . . . . . . . . . . . . . . . . . 8W-30-14
Fuel I njector No. 6 . . . . . . . . . . . . . . . . . . 8W-30-14
Fuel Pump Modul e . . . . . . . . . . . . . . . . . . . 8W-30-3
Fuel Pump Rel ay . . . . . . . . . . . . . . . . . . 8W-30-2, 3
Fuse 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-20
Fuse 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-20
Fuse 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-2
Fuse 11 . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-11, 17
Fuse 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-3
Component Page
Fuse 16 . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-19, 21
Fuse 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-4
Fuse 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-3
Fuse 28 . . . . . . . . . . . . . . . . . . . . 8W-30-7, 8, 13, 14
Fuse Bl ock . . . . . . . . . . . . . . . 8W-30-3, 4, 11, 17, 20
G105 . . . . . . . . . . . . . . . . . . . 8W-30-2, 3, 12, 18, 24
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-12, 18
Generator . . . . . . . . . . . . . . . . 8W-30-11, 12, 17, 18
Hi gh Speed Radi ator Fan Rel ay . . . . . . . . 8W-30-20
I dl e Ai r Control Motor . . . . . . . . . . . . 8W-30-11, 17
I gni ti on Coi l Pack . . . . . . . . . . . . . . . . . 8W-30-7, 13
I ntake Ai r Temperature Sensor . . . . . . 8W-30-9, 15
Leak Detecti on Pump . . . . . . . . . . . . . 8W-30-11, 17
Left Speed Control Swi tch . . . . . . . . . . . . . 8W-30-6
Low Speed Radi ator Fan Rel ay . . . . . . . . 8W-30-20
Mani fol d Absol ute Pressure Sensor . . . 8W-30-9, 15
Oxygen Sensor 1/1 Upstream . . . . 8W-30-19, 22, 23
Oxygen Sensor 1/2 Downstream . . 8W-30-19, 22, 24
Oxygen Sensor 2/1 Upstream . . . . . . . . . . 8W-30-23
Oxygen Sensor 2/2 Downstream . . . . . . . . 8W-30-24
Oxygen Sensor Downstream Heater
Rel ay . . . . . . . . . . . . . . . . . . 8W-30-21, 22, 23, 24
Power Di stri buti on
Center . . . . . . 8W-30-2, 3, 7, 8, 13, 14, 19, 20, 21
Power Steeri ng Pressure Swi tch . . . . . . . . 8W-30-12
Powertrai n Control Modul e . . 8W-30-2, 3, 4, 5, 6, 7,
8, 9, 10, 11, 12, 13, 14, 15,
16, 17, 18, 19, 20, 21, 22, 23, 24
Speed Control Servo . . . . . . . . . . . . . . . . . . 8W-30-6
Throttl e Posi ti on Sensor . . . . . . . . . . . 8W-30-10, 16
Transfer Case Swi tch . . . . . . . . . . . . . . . . 8W-30-15
Transmi ssi on Control Modul e . . . . . . . . . 8W-30-2, 5
Transmi ssi on Range Sensor . . . . . . . . 8W-30-12, 18
Vehi cl e Speed Sensor . . . . . . . . . . . . . 8W-30-10, 16
TJ 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 1
8W-31 TRANSMISSION CONTROL SYSTEM
Component Page
A/C Compressor Cl utch Rel ay . . . . . . . . . . 8W-31-2
Axl e Lock Swi tch . . . . . . . . . . . . . . . . 8W-31-14, 15
Brake Lamp Swi tch . . . . . . . . . . . . . . . . . . 8W-31-2
Brake Transmi ssi on Shi ft I nterl ock
Sol enoi d . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-2
Crankshaft Posi ti on Sensor . . . . . . . . . . . . 8W-31-8
Data Li nk Connector . . . . . . . . . . . . . . . . 8W-31-11
Front Locker I ndi cator Swi tch . . . . . . . . . 8W-31-13
Front Locker Pump . . . . . . . . . . . . . . . . . 8W-31-12
Front Locker Rel ay . . . . . . . . . . . . . . . . . . 8W-31-12
Fuse 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-3
Fuse 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-7
Fuse 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-2
Fuse 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-2
Fuse Bl ock . . . . . . . . . . . . . . . . . . . . . . . 8W-31-2, 7
G100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-3
G105 . . . . . . . . . . . . . . . . . . . . . . 8W-31-2, 8, 12, 13
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-10, 15
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-2
Component Page
I nput Speed Sensor . . . . . . . . . . . . . . . . . . 8W-31-9
I nstrument Cl uster . . . . . . . 8W-31-2, 10, 13, 14, 15
Left Rear Lamp Assembl y . . . . . . . . . . . . . 8W-31-7
Output Speed Sensor . . . . . . . . . . . . . . . . . 8W-31-9
Overdri ve Off Swi tch . . . . . . . . . . . . . . . . 8W-31-10
Power Di stri buti on Center . . . . . . 8W-31-3, 4, 5, 12
Powertrai n Control Modul e . . . 8W-31-2, 6, 8, 11, 15
Rear Locker I ndi cator Swi tch . . . . . . . . . . 8W-31-13
Rear Locker Pump . . . . . . . . . . . . . . . . . . 8W-31-12
Rear Locker Rel ay . . . . . . . . . . . . . . . . . . 8W-31-12
Ri ght Rear Lamp Assembl y . . . . . . . . . . . . 8W-31-7
Throttl e Posi ti on Sensor . . . . . . . . . . . . . . 8W-31-11
Transfer Case Swi tch . . . . . . . . . . . . . . 8W-31-2, 15
Transmi ssi on Control
Modul e . . . . . . . . . . . 8W-31-3, 4, 5, 6, 8, 9, 10, 11
Transmi ssi on Control Rel ay . . . . . . . . 8W-31-3, 4, 5
Transmi ssi on Range Sensor . . . . . . . . 8W-31-6, 7, 9
Transmi ssi on Sol enoi d/Pressure Swi tch
Assembl y . . . . . . . . . . . . . . . . . . . . . . 8W-31-4, 5
TJ 8W-31 TRANSMISSION CONTROL SYSTEM 8W - 31 - 1
8W-33 VEHICLE SPEED CONTROL
Component Page
Brake Lamp Swi tch . . . . . . . . . . . . . . . . . . 8W-33-2
Brake Transmi ssi on Shi ft I nterl ock
Sol enoi d . . . . . . . . . . . . . . . . . . . . . . . . . 8W-33-2
Cl ockspri ng . . . . . . . . . . . . . . . . . . . . . . . . 8W-33-3
G100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-33-2
Component Page
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-33-2
Left Speed Control Swi tch . . . . . . . . . . . . . 8W-33-3
Powertrai n Control Modul e . . . . . . . . . . 8W-33-2, 3
Ri ght Speed Control Swi tch . . . . . . . . . . . . 8W-33-3
Speed Control Servo . . . . . . . . . . . . . . . . . . 8W-33-2
TJ 8W-33 VEHICLE SPEED CONTROL 8W - 33 - 1
8W-35 ANTILOCK BRAKES
Component Page
Anti l ock Brake Rel ay . . . . . . . . . . . . . . . . . 8W-35-2
Brake Lamp Swi tch . . . . . . . . . . . . . . . . . . 8W-35-3
Brake Transmi ssi on Shi ft I nterl ock
Sol enoi d . . . . . . . . . . . . . . . . . . . . . . . . . 8W-35-2
Center Hi gh Mounted Stop Lamp . . . . . . . 8W-35-3
Control l er Anti l ock Brake . . . . . . . . . . 8W-35-2, 3, 4
Fuse 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-35-3
Fuse 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-35-2
Fuse 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-35-2
Fuse 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-35-2
Fuse 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-35-2
Fuse Bl ock . . . . . . . . . . . . . . . . . . . . . . . 8W-35-2, 3
Component Page
G-Swi tch . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-35-3
G100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-35-2
G101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-35-2
I nstrument Cl uster . . . . . . . . . . . . . . . . . . . 8W-35-2
Left Front Wheel Speed Sensor . . . . . . . . . 8W-35-4
Left Rear Wheel Speed Sensor . . . . . . . . . . 8W-35-4
Mul ti -Functi on Swi tch . . . . . . . . . . . . . . . . 8W-35-3
Power Di stri buti on Center . . . . . . . . . . . . . 8W-35-2
Powertrai n Control Modul e . . . . . . . . . . . . 8W-35-3
Ri ght Front Wheel Speed Sensor . . . . . . . . 8W-35-4
Ri ght Rear Wheel Speed Sensor . . . . . . . . . 8W-35-4
TJ 8W-35 ANTILOCK BRAKES 8W - 35 - 1
8W-39 VEHICLE THEFT SECURITY SYSTEM
Component Page
Data Li nk Connector . . . . . . . . . . . . . . . . . 8W-39-2
Fuse 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-2
Fuse 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-2
Fuse Bl ock . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-2
Component Page
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-2
Mul ti -Functi on Swi tch . . . . . . . . . . . . . . . . 8W-39-2
Sentry Key I mmobi l i zer Modul e . . . . . . . . . 8W-39-2
TJ 8W-39 VEHICLE THEFT SECURITY SYSTEM 8W - 39 - 1
8W-40 INSTRUMENT CLUSTER
Component Page
Ai rbag Control Modul e . . . . . . . . . . . . . . . . 8W-40-4
Anti l ock Brake Rel ay . . . . . . . . . . . . . . . . . 8W-40-7
Axl e Lock Swi tch . . . . . . . . . . . . . . . . . . . . 8W-40-6
Brake Warni ng I ndi cator Swi tch . . . . . . . . 8W-40-7
Data Li nk Connector . . . . . . . . . . . . . 8W-40-3, 4, 9
Dayti me Runni ng Lamp Modul e . . . . . . 8W-40-5, 10
Dri ver Door Ajar Swi tch . . . . . . . . . . . . . . . 8W-40-8
Engi ne Cool ant Temperature Sensor . . . . . 8W-40-3
Engi ne Oi l Pressure Swi tch . . . . . . . . . . . . 8W-40-3
Front Locker I ndi cator Swi tch . . . . . . . . . . 8W-40-6
Fuel Pump Modul e . . . . . . . . . . . . . . . . . . . 8W-40-3
Fuse 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-8
Fuse 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-2
Fuse 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-2
Fuse Bl ock . . . . . . . . . . . . . . . . . . . . . . . 8W-40-2, 8
G105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-5
Component Page
G201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-2
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-8
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-4
I gni ti on Swi tch . . . . . . . . . . . . . . . . . . . . . . 8W-40-8
I nstrument Cl uster . . 8W-40-2, 3, 4, 5, 6, 7, 8, 9, 10
Mul ti -Functi on Swi tch . . . . . . . . . 8W-40-4, 5, 8, 10
Park Brake Swi tch . . . . . . . . . . . . . . . . . . . 8W-40-7
Passenger Door Ajar Swi tch . . . . . . . . . . . . 8W-40-8
Power Di stri buti on Center . . . . . . . . . . . . . 8W-40-2
Powertrai n Control Modul e . . . . . . . . . . 8W-40-3, 4
Rear Locker I ndi cator Swi tch . . . . . . . . . . . 8W-40-6
Rear Wi ndow Defogger Rel ay . . . . . . . . . . . 8W-40-9
Rear Wi ndow Defogger Swi tch . . . . . . . . . . 8W-40-9
Seat Bel t Swi tch . . . . . . . . . . . . . . . . . . . . . 8W-40-4
Transfer Case Swi tch . . . . . . . . . . . . . . . . . 8W-40-5
Vehi cl e Speed Sensor . . . . . . . . . . . . . . . . . 8W-40-3
TJ 8W-40 INSTRUMENT CLUSTER 8W - 40 - 1
8W-41 HORN/CIGAR LIGHTER/POWER OUTLET
Component Page
Ci gar Li ghter/Power Outl et . . . . . . . . . . . . 8W-41-2
Cl ockspri ng . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-3
Fuse 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-2
Fuse 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-2
Fuse 18 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-2, 3
Fuse Bl ock . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-2
G102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-3
Component Page
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-2
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-3
Horn Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-3
Horn Swi tch . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-3
I gni ti on Swi tch . . . . . . . . . . . . . . . . . . . . . . 8W-41-2
Power Di stri buti on Center . . . . . . . . . . . 8W-41-2, 3
Power Outl et . . . . . . . . . . . . . . . . . . . . . . . 8W-41-2
TJ 8W-41 HORN/CIGAR LIGHTER/POWER OUTLET 8W - 41 - 1
8W-42 AIR CONDITIONING-HEATER
Component Page
A/C Compressor Cl utch . . . . . . . . . . . . . 8W-42-6, 8
A/C Compressor Cl utch Rel ay . . . . . . . 8W-42-6, 7, 8
A/C Hi gh Pressure Swi tch . . . . . . . . . . . . . 8W-42-6
A/C Low Pressure Swi tch . . . . . . . . . . . . 8W-42-6, 7
A/C Pressure Transducer . . . . . . . . . . . . . 8W-42-10
A/C-Heater Control . . . . . . . . . . . . . 8W-42-4, 5, 6, 7
Bl end Door Actuator . . . . . . . . . . . . . . 8W-42-3, 4, 5
Bl ower Motor . . . . . . . . . . . . . . . . . 8W-42-2, 3, 4, 5
Bl ower Motor Rel ay . . . . . . . . . . . . 8W-42-2, 3, 4, 5
Bl ower Motor Resi stor Bl ock . . . . . . . . . 8W-42-2, 4
Fuse 1 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-3, 5
Fuse 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-9
Fuse 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-9
Fuse 8 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-2, 4
Component Page
Fuse 11 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-6, 7
Fuse 21 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-6, 7
Fuse Bl ock . . . . . . . . . . . . . 8W-42-2, 3, 4, 5, 6, 7, 9
G105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-6, 8
G190 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-9
G200 . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-2, 3, 4, 5
G202 . . . . . . . . . . . . . . . . . . . . 8W-42-2, 3, 4, 5, 6, 7
Heater Control . . . . . . . . . . . . . . . . . . . . 8W-42-2, 3
Hi gh Speed Radi ator Fan Rel ay . . . . . . . . . 8W-42-9
Low Speed Radi ator Fan Rel ay . . . . . . . . . 8W-42-9
Power Di stri buti on Center . . . . . 8W-42-3, 5, 6, 7, 9
Powertrai n Control Modul e . . . . . . 8W-42-6, 7, 9, 10
Radi ator Fan Motor . . . . . . . . . . . . . . . . . . 8W-42-9
Radi ator Fan Motor Ci rcui t Breaker . . . . . 8W-42-9
TJ 8W-42 AIR CONDITIONING-HEATER 8W - 42 - 1
8W-43 AIRBAG SYSTEM
Component Page
Ai rbag Control Modul e . . . . . . . . . . . . . . 8W-43-2, 3
Brake Transmi ssi on Shi ft I nterl ock
Sol enoi d . . . . . . . . . . . . . . . . . . . . . . . . . 8W-43-3
Cl ockspri ng . . . . . . . . . . . . . . . . . . . . . . . . 8W-43-2
Data Li nk Connector . . . . . . . . . . . . . . . . . 8W-43-3
Dri ver Ai rbag Squi b 1 . . . . . . . . . . . . . . . . 8W-43-2
Fuse 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-43-2
Component Page
Fuse 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-43-2
Fuse 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-43-3
Fuse Bl ock . . . . . . . . . . . . . . . . . . . . . . . 8W-43-2, 3
G301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-43-2
I nstrument Cl uster . . . . . . . . . . . . . . . . . . . 8W-43-3
Passenger Ai rbag On-Off Swi tch . . . . . . . . 8W-43-2
Passenger Ai rbag Squi b 1 . . . . . . . . . . . . . . 8W-43-2
TJ 8W-43 AIRBAG SYSTEM 8W - 43 - 1
8W-44 INTERIOR LIGHTING
Component Page
A/C-Heater Control . . . . . . . . . . . . . . . . . . . 8W-44-5
Ambi ent Temperature Sensor . . . . . . . . . . . 8W-44-7
Axl e Lock Swi tch . . . . . . . . . . . . . . . . . . 8W-44-3, 5
Back-Up Lamp Swi tch . . . . . . . . . . . . . . . . 8W-44-6
Compass/Temperature Mi rror . . . . . . . 8W-44-3, 6, 7
Data Li nk Connector . . . . . . . . . . . . . . . . . 8W-44-3
Dri ver Door Ajar Swi tch . . . . . . . . . . . . . . . 8W-44-4
Fuse 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-4
Fuse 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-6
Fuse 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-6
Fuse 26 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-2, 6
Fuse Bl ock . . . . . . . . . . . . . . . . . . . . . . . 8W-44-4, 6
G100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-2
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-5, 7
G201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-5
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-4, 5
I gni ti on Swi tch . . . . . . . . . . . . . . . . . . . . . . 8W-44-4
Component Page
I nstrument Cl uster . . . . . . . . . . . . . 8W-44-3, 4, 5, 7
Left Courtesy Lamp . . . . . . . . . . . . . . . . . . 8W-44-3
Left Dome Lamp . . . . . . . . . . . . . . . . . . . . 8W-44-3
Mul ti -Functi on Swi tch . . . . . . . . . . . . . . . . 8W-44-5
Overdri ve Off Swi tch . . . . . . . . . . . . . . . . . 8W-44-5
Passenger Door Ajar Swi tch . . . . . . . . . . . . 8W-44-4
Power Di stri buti on Center . . . . . . . . . . . 8W-44-2, 6
Radi o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-5
Rear Wi ndow Defogger Swi tch . . . . . . . . . . 8W-44-5
Rear Wi per/Washer Swi tch . . . . . . . . . . . . . 8W-44-5
Ri ght Courtesy Lamp . . . . . . . . . . . . . . . . . 8W-44-3
Ri ght Dome Lamp . . . . . . . . . . . . . . . . . . . 8W-44-3
Transmi ssi on Range I ndi cator
I l l umi nati on . . . . . . . . . . . . . . . . . . . . . . 8W-44-5
Transmi ssi on Range Sensor . . . . . . . . . . . . 8W-44-6
Underhood Lamp . . . . . . . . . . . . . . . . . . . . 8W-44-2
TJ 8W-44 INTERIOR LIGHTING 8W - 44 - 1
8W-47 AUDIO SYSTEM
Component Page
Fuse 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-5
Fuse 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-2
Fuse 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-2
Fuse Bl ock . . . . . . . . . . . . . . . . . . . . . . . 8W-47-2, 5
G204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-2
G303 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-4, 5
I nstrument Cl uster . . . . . . . . . . . . . . . . . . . 8W-47-2
Left Front Speaker . . . . . . . . . . . . . . . . . 8W-47-3, 4
Component Page
Left Rear Speaker . . . . . . . . . . . . . . . . . 8W-47-3, 5
Power Di stri buti on Center . . . . . . . . . . . . . 8W-47-2
Radi o . . . . . . . . . . . . . . . . . . . . . . . 8W-47-2, 3, 4, 5
Ri ght Front Speaker . . . . . . . . . . . . . . . . 8W-47-3, 4
Ri ght Rear Speaker . . . . . . . . . . . . . . . . 8W-47-3, 5
Subwoofer . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-4, 5
TJ 8W-47 AUDIO SYSTEM 8W - 47 - 1
8W-48 REAR WINDOW DEFOGGER
Component Page
Fuse 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-48-2
Fuse 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-48-2
Fuse 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-48-2
Fuse Bl ock . . . . . . . . . . . . . . . . . . . . . . . 8W-48-2, 3
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-48-3
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-48-3
Component Page
I nstrument Cl uster . . . . . . . . . . . . . . . . . 8W-48-2, 3
Power Di stri buti on Center . . . . . . . . . . . . . 8W-48-2
Rear Wi ndow Defogger . . . . . . . . . . . . . . 8W-48-2, 3
Rear Wi ndow Defogger Rel ay . . . . . . . . . . . 8W-48-2
Rear Wi ndow Defogger Swi tch . . . . . . . . . . 8W-48-3
TJ 8W-48 REAR WINDOW DEFOGGER 8W - 48 - 1
8W-50 FRONT LIGHTING
Component Page
Ci rcui t Breaker . . . . . . . . . . . . . . . . . . . 8W-50-2, 11
Dayti me Runni ng Lamp Modul e . . 8W-50-2, 3, 9, 11
Fog Lamp Rel ay . . . . . . . . . . . . . . 8W-50-3, 8, 9, 10
Fuse 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-2
Fuse 10 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-2, 11
Fuse 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-11
Fuse 16 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-2, 7
Fuse 19 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-8, 9
Fuse Bl ock . . . . . . . . . . . . . . . . . . . . 8W-50-2, 7, 11
G100 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-8, 9, 11
G102 . . . . . . . . . . . . . . . . . . . 8W-50-3, 4, 5, 6, 7, 10
G103 . . . . . . . . . . . . . . . . . . . 8W-50-3, 4, 5, 6, 7, 10
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-7
Headl amp Level i ng Swi tch . . . . . . . . . . . . . 8W-50-7
I nstrument Cl uster . . . . . 8W-50-3, 4, 5, 6, 9, 10, 11
Left Fog Lamp . . . . . . . . . . . . . . . . . . . . . 8W-50-10
Left Front Park/Turn Si gnal Lamp . . . . . . . 8W-50-4
Left Front Posi ti on Lamp . . . . . . . . . . . . . . 8W-50-6
Left Front Turn Si gnal Lamp . . . . . . . . . . . 8W-50-5
Component Page
Left Headl amp . . . . . . . . . . . . . . . . . . . . . . 8W-50-3
Left Headl amp Level i ng Motor . . . . . . . . . . 8W-50-7
Left Si de Marker Lamp . . . . . . . . . . . . . . . 8W-50-4
Left Si de Repeater Lamp . . . . . . . . . . . . . . 8W-50-5
Mul ti -Functi on Swi tch . . . . 8W-50-2, 4, 5, 6, 7, 8, 9
Power Di stri buti on Center . . . . . . 8W-50-2, 8, 9, 11
Powertrai n Control Modul e . . . . . . . . . . . 8W-50-11
Ri ght Fog Lamp . . . . . . . . . . . . . . . . . . . . 8W-50-10
Ri ght Front Park/Turn Si gnal Lamp . . . . . 8W-50-4
Ri ght Front Posi ti on Lamp . . . . . . . . . . . . . 8W-50-6
Ri ght Front Turn Si gnal Lamp . . . . . . . . . . 8W-50-5
Ri ght Headl amp . . . . . . . . . . . . . . . . . . . . . 8W-50-3
Ri ght Headl amp Level i ng Motor . . . . . . . . 8W-50-7
Ri ght Si de Marker Lamp . . . . . . . . . . . . . . 8W-50-4
Ri ght Si de Repeater Lamp . . . . . . . . . . . . . 8W-50-5
Transmi ssi on Control Rel ay . . . . . . . . . . 8W-50-8, 9
Vehi cl e Speed Sensor . . . . . . . . . . . . . . . . 8W-50-11
TJ 8W-50 FRONT LIGHTING 8W - 50 - 1
8W-51 REAR LIGHTING
Component Page
Back-Up Lamp Swi tch . . . . . . . . . . . . . . 8W-51-2, 4
Brake Lamp Swi tch . . . . . . . . . . . . . . . . 8W-51-5, 7
Brake Transmi ssi on Shi ft I nterl ock
Sol enoi d . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-7
Center Hi gh Mounted Stop Lamp . . . . . . 8W-51-5, 7
Compass/Temperature Mi rror . . . . . . . . . 8W-51-3, 4
Control l er Anti l ock Brake . . . . . . . . . . . . 8W-51-5, 7
Fuse 2 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-5, 7
Fuse 7 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-2, 4
Fuse Bl ock . . . . . . . . . . . . . . . . . . . 8W-51-2, 4, 5, 7
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-7
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-5, 8
Component Page
I nstrument Cl uster . . . . . . . . . . . . . . . 8W-51-2, 4, 8
Left Li cense Lamp . . . . . . . . . . . . . . . . . . . 8W-51-8
Left Rear Lamp Assembl y . . . . . . 8W-51-3, 4, 5, 6, 7
Mul ti -Functi on Swi tch . . . . 8W-51-2, 3, 4, 5, 6, 7, 8
Powertrai n Control Modul e . . . . . . . . . . 8W-51-2, 7
Rear Fog Lamp . . . . . . . . . . . . . . . . . . . . . . 8W-51-8
Ri ght Li cense Lamp . . . . . . . . . . . . . . . . . . 8W-51-8
Ri ght Rear Lamp Assembl y . . 8W-51-2, 3, 4, 5, 6, 7
Speed Control Servo . . . . . . . . . . . . . . . . . . 8W-51-7
Transmi ssi on Range Sensor . . . . . . . . . . 8W-51-2, 4
TJ 8W-51 REAR LIGHTING 8W - 51 - 1
8W-52 TURN SIGNALS
Component Page
Brake Lamp Swi tch . . . . . . . . . . . . . . . . . . 8W-52-2
Fuse 13 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-2, 3
Fuse 27 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-2, 3
Fuse Bl ock . . . . . . . . . . . . . . . . . . . . . . . 8W-52-2, 3
G102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-4, 5
G103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-4, 5
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-2
I nstrument Cl uster . . . . . . . . . . . . . . . . . 8W-52-4, 5
Left Front Park/Turn Si gnal Lamp . . . . . . . 8W-52-4
Left Front Turn Si gnal Lamp . . . . . . . . . . . 8W-52-5
Left Rear Lamp Assembl y . . . . . . . . . . . 8W-52-2, 3
Component Page
Left Si de Marker Lamp . . . . . . . . . . . . . . . 8W-52-4
Left Si de Repeater Lamp . . . . . . . . . . . . . . 8W-52-5
Mul ti -Functi on Swi tch . . . . . . . . . . 8W-52-2, 3, 4, 5
Power Di stri buti on Center . . . . . . . . . . . 8W-52-2, 3
Ri ght Front Park/Turn Si gnal Lamp . . . . . 8W-52-4
Ri ght Front Turn Si gnal Lamp . . . . . . . . . . 8W-52-5
Ri ght Rear Lamp Assembl y . . . . . . . . . . 8W-52-2, 3
Ri ght Si de Marker Lamp . . . . . . . . . . . . . . 8W-52-4
Ri ght Si de Repeater Lamp . . . . . . . . . . . . . 8W-52-5
TJ 8W-52 TURN SIGNALS 8W - 52 - 1
8W-53 WIPERS
Component Page
Front Washer Pump . . . . . . . . . . . . . . . . . . 8W-53-2
Front Wi per Motor . . . . . . . . . . . . . . . . . . . 8W-53-2
Fuse 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-4
Fuse 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-2
Fuse Bl ock . . . . . . . . . . . . . . . . . . . . . . . 8W-53-2, 4
G102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-2
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-3
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-2
Component Page
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-4
I nstrument Cl uster . . . . . . . . . . . . . . . . . . . 8W-53-3
Mul ti -Functi on Swi tch . . . . . . . . . . . . . . . . 8W-53-2
Rear Washer Pump . . . . . . . . . . . . . . . . . 8W-53-3, 4
Rear Wi per Motor . . . . . . . . . . . . . . . . . . 8W-53-3, 4
Rear Wi per/Washer Swi tch . . . . . . . . . . . . . 8W-53-3
TJ 8W-53 WIPERS 8W - 53 - 1
8W-70 SPLICE INFORMATION
Component Page
S101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-16
S102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-8
S103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-6, 7
S105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-3
S106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-2
S108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-6, 9
S111 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-13
S113 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-11, 17
S116 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-19
S117 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-3, 4
S118 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-2, 3
S121 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-6, 7, 8
S122 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-3
S123 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-10
S124 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-16
S125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-5
S126 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-17
S127 . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-5, 6, 7, 8
S128 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-17, 18
S129 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-4
S130 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-6
S132 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-7, 8, 9
S133 . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-5, 6, 7, 8
S134 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-7, 8, 9
S135 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-10
S136 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-8
S137 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-7, 8
S138 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-7
S140 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-15
S141 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-4, 5
S142 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-4, 5
S143 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-2
S144 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-2
S145 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-4
S147 . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-5, 6, 7, 8
S150 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-5
S151 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-10
S152 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-3, 10
S153 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-17
S155 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-9
S156 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-10
S157 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-8
S158 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-11
S159 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-21
S160 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-9
S161 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-2
Component Page
S162 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-11
S163 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-16
S164 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-8
S170 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-18-4
S171 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-18-3
S172 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-11
S173 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-20
S173 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-2
S176 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-5
S177 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-9
S178 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-18
S180 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-12
S180 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-9
S202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-3
S204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-20
S206 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-5
S207 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-11, 12
S208 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-2, 4
S209 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-18-2
S210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-21
S215 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-7
S216 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-14
S217 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-14
S302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-13
S304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-2
S309 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-14
S310 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-2, 3
S311 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-4
S315 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-7
S316 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-14
S317 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-8
S320 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-11
S331 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-13
S335 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-3
S351 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-20
S352 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-3
S353 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-4, 5
S354 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-8
S355 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-18-2
S356 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-5
S357 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-5
S358 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-5
S359 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-5
S360 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-14
S361 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-5
TJ 8W-70 SPLICE INFORMATION 8W - 70 - 1
8W-80 CONNECTOR PIN-OUTS
Component Page
A/C Compressor Cl utch . . . . . . . . . . . . . . . 8W-80-3
A/C Hi gh Pressure Swi tch (4.0L) . . . . . . . . 8W-80-3
A/C Low Pressure Swi tch (2.4L) . . . . . . . . . 8W-80-3
A/C Low Pressure Swi tch (4.0L) . . . . . . . . . 8W-80-3
A/C Pressure Transducer (2.4L) . . . . . . . . . 8W-80-3
A/C-Heater Control C1 . . . . . . . . . . . . . . . . 8W-80-4
A/C-Heater Control C2 . . . . . . . . . . . . . . . . 8W-80-4
A/C-Heater Control C3 . . . . . . . . . . . . . . . . 8W-80-4
Ai rbag Control Modul e . . . . . . . . . . . . . . . . 8W-80-4
Ambi ent Temperature Sensor . . . . . . . . . . . 8W-80-5
Axl e Lock Swi tch (Off-Road Package) . . . . . 8W-80-5
Back-Up Lamp Swi tch (M/T) . . . . . . . . . . . 8W-80-5
Battery Temperature Sensor . . . . . . . . . . . 8W-80-5
Bl end Door Actuator . . . . . . . . . . . . . . . . . . 8W-80-6
Bl ower Motor . . . . . . . . . . . . . . . . . . . . . . . 8W-80-6
Bl ower Motor Rel ay . . . . . . . . . . . . . . . . . . 8W-80-6
Bl ower Motor Resi stor Bl ock . . . . . . . . . . . 8W-80-6
Brake Lamp Swi tch . . . . . . . . . . . . . . . . . . 8W-80-6
Brake Transmi ssi on Shi ft I nterl ock
Sol enoi d . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-7
Brake Warni ng I ndi cator Swi tch . . . . . . . . 8W-80-7
C103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-7
C103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-8
C104 (LHD) . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-8
C104 (LHD) . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-9
C104 (RHD) . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-9
C104 (RHD) . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-9
C107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-10
C107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-11
C109 (A/T) . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-12
C109 (A/T) . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-12
C110 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-12
C110 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-13
C115 (Off-Road Package) . . . . . . . . . . . . . 8W-80-13
C115 (Off-Road Package) . . . . . . . . . . . . . 8W-80-13
C116 (Off-Road Package) . . . . . . . . . . . . . 8W-80-13
C116 (Off-Road Package) . . . . . . . . . . . . . 8W-80-14
C120 (2.4L) . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-14
C120 (2.4L) . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-14
C170 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-14
C170 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-15
C181 (2.4L) . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-15
C181 (2.4L) . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-16
C182 (2.4L) . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-16
C182 (2.4L) . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-16
C202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-17
C202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-18
C203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-19
C203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-19
C205 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-19
C205 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-19
C324 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-20
Component Page
C324 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-20
C325 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-20
C325 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-20
C326 (Hard Top) . . . . . . . . . . . . . . . . . . . . 8W-80-20
C326 (Hard Top) . . . . . . . . . . . . . . . . . . . . 8W-80-21
C329 (Export) . . . . . . . . . . . . . . . . . . . . . . 8W-80-21
C329 (Export) . . . . . . . . . . . . . . . . . . . . . . 8W-80-21
C380 (Except Export) . . . . . . . . . . . . . . . . 8W-80-21
C380 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-21
Camshaft Posi ti on Sensor (2.4L) . . . . . . . 8W-80-22
Camshaft Posi ti on Sensor (4.0L) . . . . . . . 8W-80-22
Ci gar Li ghter/Power Outl et . . . . . . . . . . . 8W-80-22
Ci rcui t Breaker . . . . . . . . . . . . . . . . . . . . . 8W-80-22
Cl ockspri ng C1 . . . . . . . . . . . . . . . . . . . . . 8W-80-22
Cl ockspri ng C2 . . . . . . . . . . . . . . . . . . . . . 8W-80-23
Cl utch Pedal Posi ti on Swi tch (M/T) . . . . . 8W-80-23
Compass/Temperature Mi rror . . . . . . . . . . 8W-80-23
Control l er Anti l ock Brake . . . . . . . . . . . . . 8W-80-23
Crankshaft Posi ti on Sensor
(2.4L/4.0L A/T) . . . . . . . . . . . . . . . . . . . 8W-80-24
Crankshaft Posi ti on Sensor (4.0L M/T) . . . 8W-80-24
Data Li nk Connector . . . . . . . . . . . . . . . . 8W-80-24
Dayti me Runni ng Lamp Modul e (Except
Export) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-25
Dri ver Ai rbag Squi b 1 . . . . . . . . . . . . . . . . 8W-80-25
Dri ver Door Ajar Swi tch . . . . . . . . . . . . . . 8W-80-25
Engi ne Cool ant Temperature Sensor . . . . 8W-80-25
Engi ne Oi l Pressure Swi tch . . . . . . . . . . . 8W-80-26
EVAP/Purge Sol enoi d . . . . . . . . . . . . . . . . 8W-80-26
Front Locker I ndi cator Swi tch (Off-Road
Package) . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-26
Front Locker Pump (Off-Road Package) . . 8W-80-26
Front Washer Pump . . . . . . . . . . . . . . . . . 8W-80-27
Front Wi per Motor . . . . . . . . . . . . . . . . . . 8W-80-27
Fuel I njector No. 1 (2.4L) . . . . . . . . . . . . . 8W-80-27
Fuel I njector No. 1 (4.0L) . . . . . . . . . . . . . 8W-80-27
Fuel I njector No. 2 (2.4L) . . . . . . . . . . . . . 8W-80-27
Fuel I njector No. 2 (4.0L) . . . . . . . . . . . . . 8W-80-28
Fuel I njector No. 3 (2.4L) . . . . . . . . . . . . . 8W-80-28
Fuel I njector No. 3 (4.0L) . . . . . . . . . . . . . 8W-80-28
Fuel I njector No. 4 (2.4L) . . . . . . . . . . . . . 8W-80-28
Fuel I njector No. 4 (4.0L) . . . . . . . . . . . . . 8W-80-28
Fuel I njector No. 5 (4.0L) . . . . . . . . . . . . . 8W-80-28
Fuel I njector No. 6 (4.0L) . . . . . . . . . . . . . 8W-80-29
Fuel Pump Modul e . . . . . . . . . . . . . . . . . . 8W-80-29
G-Swi tch (LHD) . . . . . . . . . . . . . . . . . . . . 8W-80-29
Generator . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-29
Headl amp Level i ng Swi tch (Export) . . . . . 8W-80-29
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-30
I dl e Ai r Control Motor . . . . . . . . . . . . . . . 8W-80-30
I gni ti on Coi l Pack (2.4L) . . . . . . . . . . . . . . 8W-80-30
I gni ti on Coi l Pack (4.0L) . . . . . . . . . . . . . . 8W-80-30
TJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 1
Component Page
I gni ti on Swi tch . . . . . . . . . . . . . . . . . . . . . 8W-80-30
I nput Speed Sensor . . . . . . . . . . . . . . . . . 8W-80-31
I nstrument Cl uster C1 . . . . . . . . . . . . . . . 8W-80-31
I nstrument Cl uster C2 . . . . . . . . . . . . . . . 8W-80-31
I ntake Ai r Temperature Sensor . . . . . . . . 8W-80-32
Leak Detecti on Pump . . . . . . . . . . . . . . . . 8W-80-32
Left Courtesy Lamp . . . . . . . . . . . . . . . . . 8W-80-32
Left Dome Lamp . . . . . . . . . . . . . . . . . . . . 8W-80-32
Left Fog Lamp (Except Export) . . . . . . . . 8W-80-32
Left Front Park/Turn Si gnal Lamp (Except
Export) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-33
Left Front Posi ti on Lamp (Export) . . . . . . 8W-80-33
Left Front Speaker . . . . . . . . . . . . . . . . . . 8W-80-33
Left Front Turn Si gnal Lamp (Export) . . . 8W-80-33
Left Front Wheel Speed Sensor . . . . . . . . 8W-80-33
Left Headl amp . . . . . . . . . . . . . . . . . . . . . 8W-80-34
Left Headl amp Level i ng Motor (Export) . . 8W-80-34
Left Li cense Lamp (Export) . . . . . . . . . . . 8W-80-34
Left Rear Lamp Assembl y . . . . . . . . . . . . 8W-80-34
Left Rear Speaker . . . . . . . . . . . . . . . . . . 8W-80-35
Left Rear Wheel Speed Sensor . . . . . . . . . 8W-80-35
Left Si de Marker Lamp (Except Export) . . 8W-80-35
Left Si de Repeater Lamp (Export) . . . . . . 8W-80-35
Mani fol d Absol ute Pressure Sensor
(2.4L) . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-35
Mani fol d Absol ute Pressure Sensor
(4.0L) . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-36
Mul ti -Functi on Swi tch C1 . . . . . . . . . . . . 8W-80-36
Mul ti -Functi on Swi tch C2 . . . . . . . . . . . . 8W-80-36
Output Speed Sensor . . . . . . . . . . . . . . . . 8W-80-37
Overdri ve Off Swi tch . . . . . . . . . . . . . . . . 8W-80-37
Oxygen Sensor 1/1 Upstream . . . . . . . . . . 8W-80-37
Oxygen Sensor 1/2 Downstream . . . . . . . . 8W-80-37
Oxygen Sensor 2/1 Upstream (Except Export/Japan
Low Emi ssi on Vehi cl e) . . . . . . . . . . . . . 8W-80-38
Oxygen Sensor 2/2 Downstream (Except Export/
Japan Low Emi ssi on Vehi cl e) . . . . . . . . 8W-80-38
Passenger Ai rbag On-Off Swi tch (LHD) . . 8W-80-38
Passenger Ai rbag Squi b 1 . . . . . . . . . . . . . 8W-80-38
Passenger Door Ajar Swi tch . . . . . . . . . . . 8W-80-39
Power Outl et . . . . . . . . . . . . . . . . . . . . . . 8W-80-39
Power Steeri ng Pressure Swi tch (2.4L) . . . 8W-80-39
Powertrai n Control Modul e C1 . . . . . . . . . 8W-80-40
Powertrai n Control Modul e C2 . . . . . . . . . 8W-80-41
Powertrai n Control Modul e C3 . . . . . . . . . 8W-80-42
Radi ator Fan Motor (2.4L) . . . . . . . . . . . . 8W-80-42
Radi ator Fan Motor Ci rcui t Breaker
(2.4L) . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-43
Component Page
Radi o . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-43
Rear Fog Lamp (Export) . . . . . . . . . . . . . . 8W-80-43
Rear Locker I ndi cator Swi tch (Off-Road
Package) . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-44
Rear Locker Pump (Off-Road Package) . . . 8W-80-44
Rear Washer Pump (Hard Top) . . . . . . . . . 8W-80-44
Rear Wi ndow Defogger Swi tch (Hard
Top) . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-44
Rear Wi per Motor (Hard Top) . . . . . . . . . . 8W-80-45
Rear Wi per/washer Swi tch (Hard Top) . . . 8W-80-45
Ri ght Courtesy Lamp . . . . . . . . . . . . . . . . 8W-80-45
Ri ght Dome Lamp . . . . . . . . . . . . . . . . . . 8W-80-45
Ri ght Fog Lamp (Except Export) . . . . . . . 8W-80-45
Ri ght Front Park/Turn Si gnal Lamp (Except
Export) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-46
Ri ght Front Posi ti on Lamp (Export) . . . . . 8W-80-46
Ri ght Front Speaker . . . . . . . . . . . . . . . . . 8W-80-46
Ri ght Front Turn Si gnal Lamp (Export) . . 8W-80-46
Ri ght Front Wheel Speed Sensor . . . . . . . 8W-80-46
Ri ght Headl amp . . . . . . . . . . . . . . . . . . . . 8W-80-47
Ri ght Headl amp Level i ng Motor (Export) . 8W-80-47
Ri ght Li cense Lamp (Export) . . . . . . . . . . 8W-80-47
Ri ght Rear Lamp Assembl y . . . . . . . . . . . 8W-80-47
Ri ght Rear Speaker . . . . . . . . . . . . . . . . . 8W-80-48
Ri ght Rear Wheel Speed Sensor . . . . . . . . 8W-80-48
Ri ght Si de Marker Lamp (Except
Export) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-48
Ri ght Si de Repeater Lamp (Export) . . . . . 8W-80-48
Seat Bel t Swi tch (Except LHD Export) . . . 8W-80-48
Sentry Key I mmobi l i zer Modul e . . . . . . . . 8W-80-49
Speed Control Servo . . . . . . . . . . . . . . . . . 8W-80-49
Subwoofer . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-49
Throttl e Posi ti on Sensor (2.4L) . . . . . . . . . 8W-80-49
Throttl e Posi ti on Sensor (4.0L) . . . . . . . . . 8W-80-50
Torque Converter Cl utch Sol enoi d . . . . . . 8W-80-50
Transfer Case Swi tch (Except Off-Road
Package) . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-50
Transfer Case Swi tch (Off-Road
Package) . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-50
Transmi ssi on Control Modul e . . . . . . . . . . 8W-80-51
Transmi ssi on Range I ndi cator I l l umi nati on
(PRNDL) . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-52
Transmi ssi on Range Sensor . . . . . . . . . . . 8W-80-52
Transmi ssi on Sol enoi d/Pressure Swi tch
Assembl y . . . . . . . . . . . . . . . . . . . . . . . 8W-80-53
Underhood Lamp . . . . . . . . . . . . . . . . . . . 8W-80-53
Vehi cl e Speed Sensor . . . . . . . . . . . . . . . . 8W-80-53
8W - 80 - 2 8W-80 CONNECTOR PIN-OUTS TJ
A/C COMPRESSOR CLUTCH - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 C3 18DB/BK (2.4L) A/C CLUTCH RELAY OUTPUT
1 C3 20DB/BK (4.0L) A/C COMPRESSOR CLUTCH RELAY OUTPUT
2 Z246 18BK/OR (2.4L) GROUND
2 Z1 20BK (4.0L) GROUND
A/C HIGH PRESSURE SWITCH (4.0L) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 C90 20LG A/C SELECT SIGNAL
2 C22 20DB/WT A/C SWITCH SIGNAL
A/C LOW PRESSURE SWITCH (2.4L) - GREEN 2 WAY
CAV CIRCUIT FUNCTION
1 C21 18DB/OR A/C SWITCH SENSE
2 C90 20LG A/C SELECT INPUT
A/C LOW PRESSURE SWITCH (4.0L) - GREEN 2 WAY
CAV CIRCUIT FUNCTION
1 C21 20DB/OR A/C REQUEST SIGNAL
2 C22 20DB/WT A/C SWITCH SIGNAL
A/C PRESSURE TRANSDUCER (2.4L) - 4 WAY
CAV CIRCUIT FUNCTION
1 K4 20BK/LB SENSOR GROUND 1
2 K6 20VT/WT 5 VOLT SUPPLY
3 C18 18DB A/C PRESSURE SIGNAL
4 - -
TJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 3
A/C-HEATER CONTROL C1 - 5 WAY
CAV CIRCUIT FUNCTION
1 C7 12BR/TN BLOWER MOTOR HIGH SPEED
2 C6 14LB BLOWER MOTOR M2 SPEED
3 C5 16LG/LB BLOWER MOTOR M1 SPEED
4 C4 18TN BLOWER MOTOR LOW SPEED
5 C1 12DG BLOWER MOTOR FEED
A/C-HEATER CONTROL C2 - 5 WAY
CAV CIRCUIT FUNCTION
1 Z11 20BK/WT (LHD) GROUND
1 F24 20RD/DG (RHD) FUSED IGNITION SWITCH OUTPUT (RUN)
2 C36 20DB/RD BLEND DOOR FEEDBACK SIGNAL
3 F24 20RD/DG (LHD) FUSED IGNITION SWITCH OUTPUT (RUN)
3 Z11 20BK/WT (RHD) GROUND
4 E2 20OR FUSED PANEL LAMPS DIMMER SWITCH SIGNAL
5 Z1 20BK GROUND
A/C-HEATER CONTROL C3 - 3 WAY
CAV CIRCUIT FUNCTION
1 C90 20LG A/C SELECT INPUT
2 C1 12DG BLOWER MOTOR FEED
3 Z1 12BK GROUND
AIRBAG CONTROL MODULE - YELLOW 22 WAY
CAV CIRCUIT FUNCTION
1 R45 18DG/LB DRIVER SQUIB 1 LINE 2
2 R43 18BK/LB DRIVER SQUIB 1 LINE 1
3 - -
4 - -
5 R42 18BK/YL PASSENGER SQUIB 1 LINE 1
6 R44 18DG/YL PASSENGER SQUIB 1 LINE 2
7 - -
8 R166 18LG/BR (PAD) PASSENGER AIRBAG INDICATOR DRIVER
9 - -
10 Z6 18BK/PK GROUND
11 R65 18LG/OR (PAD) PASSENGER AIRBAG MUX SWITCH SENSE
12 - -
13 - -
14 - -
15 - -
16 - -
17 F14 18LG/YL FUSED IGNITION SWITCH OUTPUT (RUN)
18 D25 18VT/YL PCI BUS
19 - -
20 F23 18DB/YL FUSED IGNITION SWITCH OUTPUT (RUN)
21 - -
22 R66 18YL/LG (PAD) PASSENGER AIRBAG MUX SWITCH RETURN
8W - 80 - 4 8W-80 CONNECTOR PIN-OUTS TJ
AMBIENT TEMPERATURE SENSOR - GRAY 2 WAY
CAV CIRCUIT FUNCTION
1 G31 20VT/LG AMBIENT TEMPERATURE SENSOR SIGNAL
2 G32 20BK/LB SENSOR GROUND
AXLE LOCK SWITCH (OFF-ROAD PACKAGE) - 8 WAY
CAV CIRCUIT FUNCTION
1 Z1 20BK GROUND
2 E2 20OR PANEL LAMPS FEED
3 M1 20PK/WT FUSED B(+)
4 G302 20RD/WT LOCKER ENABLE SIGNAL 1
5 G303 20VT/DG LOCKER ENABLE SIGNAL 2
6 G305 20VT/LG REAR LOCKER REQUEST
7 G304 20VT/DB FRONT LOCKER REQUEST
8 - -
BACK-UP LAMP SWITCH (M/T) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 F20 20VT/WT FUSED IGNITION SWITCH OUTPUT (RUN)
2 L1 20VT/BK BACK-UP LAMP FEED
BATTERY TEMPERATURE SENSOR - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 K118 18PK/YL BATTERY TEMPERATURE SENSOR SIGNAL
2 K4 20BK/LB SENSOR GROUND 1
TJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 5
BLEND DOOR ACTUATOR - 6 WAY
CAV CIRCUIT FUNCTION
5 - -
6 - -
7 Z11 20DB/WT GROUND
8 C36 20YL BLEND DOOR FEEDBACK SIGNAL
9 - -
10 F24 20OR FUSED IGNITION SWITCH OUTPUT (RUN)
BLOWER MOTOR - 2 WAY
CAV CIRCUIT FUNCTION
A C1 12DG BLOWER MOTOR RELAY OUTPUT
B C7 12BK/TN BLOWER MOTOR HIGH DRIVER
BLOWER MOTOR RELAY - BLACK
CAV CIRCUIT FUNCTION
1 C1 12DG BLOWER MOTOR RELAY OUTPUT
2 Z1 20BK GROUND
3 - -
4 A111 12RD/LG FUSED B(+)
5 F24 20DB/WT FUSED IGNITION SWITCH OUTPUT (RUN)
BLOWER MOTOR RESISTOR BLOCK - 4 WAY
CAV CIRCUIT FUNCTION
1 C4 14TN BLOWER MOTOR LOW DRIVER
2 C5 14LG BLOWER MOTOR M1 DRIVER
3 C6 14LB BLOWER MOTOR M2 DRIVER
4 C7 12BK/TN BLOWER MOTOR HIGH DRIVER
BRAKE LAMP SWITCH - GRAY 6 WAY
CAV CIRCUIT FUNCTION
1 K29 20WT/PK BRAKE LAMP SWITCH SENSE
1 K29 20WT/PK BRAKE LAMP SWITCH SENSE
2 Z1 20BK/WT GROUND
3 V32 20YL/RD SPEED CONTROL ON/OFF SWITCH SENSE
4 V30 20DB/RD SPEED CONTROL BRAKE LAMP SWITCH OUTPUT
5 F32 18PK/DB FUSED B(+)
6 L50 18WT/TN BRAKE LAMP SWITCH OUTPUT
8W - 80 - 6 8W-80 CONNECTOR PIN-OUTS TJ
BRAKE TRANSMISSION SHIFT INTERLOCK SOLENOID - WHITE 2 WAY
CAV CIRCUIT FUNCTION
1 K29 20WT/PK BRAKE LAMP SWITCH SENSE
2 G5 20DB/WT FUSED IGNITION SWITCH OUTPUT (RUN-START)
BRAKE WARNING INDICATOR SWITCH - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 G9 20GY/BK BRAKE WARNING INDICATOR DRIVER
2 G99 20GY/WT BRAKE WARNING INDICATOR DRIVER
C103 - BLACK (DASH SIDE)
CAV CIRCUIT
1 F142 18OR/DG
2 K125 18WT/DB
3 K6 20VT/WT (2.4L A/C)
3 C90 20LG (4.0L)
4 K99 18BR/OR
5 K299 18BR/WT
7 A242 18VT/OR (4.0L)
8 K4 20BK/LB
9 F15 20DB
10 -
11 Z12 20BK/TN
12 G7 20WT/OR (DRL)
13 T141 18YL/RD
14 C3 20DB/BK (A/C)
TJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 7
C103 - BLACK (ENGINE SIDE)
CAV CIRCUIT
1 F142 18OR/DG
2 K125 18WT/DB
3 K6 20VT/WT (2.4L)
3 C90 20LG (4.0L)
4 K99 18BR/OR
5 K299 18BR/WT
6 -
7 A242 18VT/OR (4.0L EXCEPT EXPORT/
4.0L J APAN LOW EMISSION VEHICLE)
8 K4 20BK/LB
9 F15 18DB/WT
10 - -
11 Z12 20BK/TN
12 G7 20WT/OR (DRL)
13 T141 18YL/RD
14 C3 20DB/BK
C104 (LHD) - (ENGINE SIDE)
CAV CIRCUIT
1 A14 14RD/WT
2 C18 18DB (2.4L)
2 C21 20DB/OR (4.0L)
3 B1 18YL/DB (4.0L ABS)
3 G301 20VT/LB (4.0L OFF-ROAD PACK-
AGE)
4 B2 18YL (4.0L ABS)
4 A850 18RD/WT (4.0L OFF-ROAD PACK-
AGE)
5 T41 20BK/WT
6 B3 18LG/DB (4.0L ABS)
6 G300 20VT/WT (4.0L OFF-ROAD PACK-
AGE)
7 B4 18LG (4.0L ABS)
7 A750 18TN/RD (4.0L OFF-ROAD PACK-
AGE)
8 K226 20DB/LG
9 L1 20VT/BK
10 F20 20VT/WT
11 F42 18DG/LG
12 T40 12BR
13 G107 20BK/RD (4X4)
14 A141 18DG/WT
8W - 80 - 8 8W-80 CONNECTOR PIN-OUTS TJ
C104 (LHD) - GRAY (DASH SIDE)
CAV CIRCUIT
1 A14 14RD/WT
2 C18 18DB (2.4L A/C)
2 C21 18DB/OR (4.0L)
3 B1 18YL/DB (ABS)
3 G301 20VT/LB (OFF-ROAD PACKAGE)
4 B2 18YL (ABS)
4 A850 18RD/WT (OFF-ROAD PACKAGE)
5 T41 20BR/LB
6 B3 18LG/DB (ABS)
6 G300 20VT/WT (OFF-ROAD PACKAGE)
7 B4 18LG (ABS)
7 A750 18TN/RD (OFF-ROAD PACKAGE)
8 K226 18DB/LG
9 L1 20VT/BK
10 F20 20VT/WT
11 F42 18DG/LG
12 T40 14BR
13 G107 20BK/RD
14 A141 18DG/WT
C104 (RHD) - BLACK (DASH SIDE)
CAV CIRCUIT
1 A14 14RD/WT
2 C21 18DB/OR
3 A141 18DG/WT
4 F42 18DG/LG
5 T41 20BR/LB
6 T40 14BR
7 G107 20BK/RD
8 K226 18DB/LG
9 L1 20VT/BK
10 F20 20VT/WT
C104 (RHD) - BLACK (ENGINE SIDE)
CAV CIRCUIT
1 A14 14RD/WT
2 C21 20DB/OR
3 A141 18DG/WT
4 F42 18DG/LG
5 T41 20BK/WT
6 T40 12BR
7 G107 20BK/RD
8 K226 20DB/LG
9 L1 20VT/BK
10 F20 20VT/WT
TJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 9
C107 - (BODY SIDE)
CAV CIRCUIT
A1 V32 20YL/RD
A2 B41 20YL/VT (LHD)
A3 L3 14RD/OR
A4 L4 14VT/WT
A5 F3 14LB/OR
A6 F30 12RD/PK
A7 K125 18WT/DB (EXCEPT EXPORT)
A8 K4 20BK/LB
B1 V37 20RD/LG (EXCEPT RHD HARDTOP
SUBWOOFER)
B1 V37 20RD/LB (RHD HARDTOP SUB-
WOOFER)
B2 L9 18BK/WT
B3 M1 20PK/WT
B4 K29 20WT/PK
B5 G107 20BK/RD
B6 L60 18TN
B7 A1 18RD
B8 L1 20VT/BK
B9 L61 18GY
B10 L7 18BK/YL
B11 L50 18WT/TN
B12 X3 20RD/YL
C1 V10 16BR
C2 F61 16WT/OR (LHD EXCEPT EXPORT)
C3 V30 20DB/RD
C4 K106 18WT/DG (EXCEPT EXPORT)
C5 K107 18OR (EXCEPT EXPORT)
C6 L22 20LG/DG (EXPORT)
C7 F20 20VT/WT
C8 F15 20DB
C9 F39 16PK/LG (EXCEPT POSTAL)
C10 F12 20RD/LG
C11 G9 20GY/BK (LHD)
C12 B43 20PK/OR (LHD)
D1 T141 18YL/RD
D2 B42 20TN/WT (LHD)
D3 A6 12RD/BK
D4 A3 12RD/WT
D5 C15 12BK/WT (HARD TOP)
D6 A2 14BK/PK
D7 D25 20VT/YL
D8 -
8W - 80 - 10 8W-80 CONNECTOR PIN-OUTS TJ
C107 - (DASH SIDE)
CAV CIRCUIT
A1 V32 18YL/RD (SPEED CONTROL)
A2 B41 18YL/VT (ABS)
A3 L3 14RD/OR
A4 L4 14VT/WT
A5 F3 14LB/OR (DRL)
A6 F30 12RD/PK
A7 K125 18WT/DB
A8 K4 20 BK/LB
B1 V37 18RD/LB (SPEED CONTROL)
B2 L9 18BK/WT
B3 M1 20PK/WT
B3 M1 20PK/WT (ABS EXCEPT CANADA)
B4 K29 18WT/PK
B5 G107 20BK/RD
B6 L60 18TN
B7 A1 18RD
B8 L1 20VT/BK
B9 L61 18GY
B10 L7 18BK/YL
B11 L50 18WT/TN (ABS)
B12 X3 20RD/YL
C1 V10 16BR
C2 F61 16WT/OR (4.0L)
C3 V30 20DB/RD (SPEED CONTROL)
C4 K106 18WT/DG
C5 K107 18OR
C6 L22 20 LG/DG (EXCEPT CANADA)
C7 F20 20VT/WT
C8 F15 20DB
C9 F39 16PK/LG
C10 F12 20RD/LG
C11 G9 20GY/BK
C12 B43 18PK/OR (ABS)
D1 T141 18YL/RD
D2 B42 18TN/WT (ABS)
D3 A6 12RD/BK
D4 A3 12RD/WT
D5 C15 12BK/WT
D6 A2 14PK/BK
D7 D25 18VT/YL
D8 -
TJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 11
C109 (A/T) - LT GRAY (DASH SIDE)
CAV CIRCUIT
1 A30 16RD/WT
2 K30 18PK
3 T16 16RD
4 D21 18PK
5 D20 18LG/PK
6 D25 18VT/YL
7 T56 18DG/LB
8 -
9 T10 18YL/DG
10 T6 18OR/WT
C109 (A/T) - LT GRAY (ENGINE SIDE)
CAV CIRCUIT
1 A30 16RD/WT
2 K30 18PK
3 T16 14RD
4 D21 18PK
5 D20 18LG
6 D25 18VT/YL
7 T56 18DG/LB
8 -
9 T10 18YL/DG
10 T6 18OR/WT
C110 - BLACK (DASH SIDE)
CAV CIRCUIT
1 L7 18BK/YL
2 L60 18TN
3 L61 18GY
4 L3 14RD/OR
5 L4 14VT/WT
6 X2 18WT/RD
7 -
8 V10 16BR
9 L22 20LG/DG (HEADLAMP LEVELING)
10 G31 20VT/LG
11 G32 20BK/LB
12 -
13 L39 16LB (FRONT FOG LAMPS)
14 L13 20BR/YL (HEADLAMP LEVELING)
8W - 80 - 12 8W-80 CONNECTOR PIN-OUTS TJ
C110 - BLACK (HEADLAMP SIDE)
CAV CIRCUIT
1 L7 18BK/YL
2 L60 18TN
3 L61 18GY
4 L3 14RD/OR
5 L4 14VT/WT
6 X2 18WT/RD
7 -
8 V10 16BR
9 L22 20LG/DG (EXPORT)
10 G31 20VT/LG
11 G32 20BK/LB
12 -
13 L39 16LB (FRONT FOG LAMPS)
14 L13 20BR/YL (EXPORT)
C115 (OFF-ROAD PACKAGE) - BLACK (ENGINE
SIDE)
CAV CIRCUIT
1 Z1 20BK
2 G300 20VT/WT
C115 (OFF-ROAD PACKAGE) - BLACK (FRONT
FEEDBACK OVERLAY SIDE)
CAV CIRCUIT
1 Z1 16BK
2 G300 16VT/WT
C116 (OFF-ROAD PACKAGE) - LT GRAY (ENGINE
SIDE)
CAV CIRCUIT
1 Z1 20BK
2 G301 20VT/LB
TJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 13
C116 (OFF-ROAD PACKAGE) - LT GRAY (REAR
FEEDBACK OVERLAY SIDE)
CAV CIRCUIT
1 Z1 16BK
2 G301 16VT/LB
C120 (2.4L) - (DASH SIDE)
CAV CIRCUIT
1 C23 12DG
2 Z213 12BK
3 C25 12YL
C120 (2.4L) - BLACK (ELECTRIC FAN J UMPER)
CAV CIRCUIT
1 C25 12DG
2 Z213 12BK
3 C23 12DB
C170 - WHITE (DASH SIDE)
CAV CIRCUIT
1 L13 20BR/YL (HEADLAMP LEVELING)
2 C81 20LB/WT
3 A111 12RD/LB
4 F60 16RD/WT
5 T56 18DG/LB (A/T)
6 C90 20LG (A/C)
7 T6 18OR/WT (A/T)
8 G31 20VT/LG
9 D32 18LG/WT
10 D21 18PK
11 F70 16PK/BK
12 G34 14RD/GY (CANADA)
12 L3 14RD/OR (EXCEPT CANADA)
13 G305 20VT/LG (OFF-ROAD PACKAGE)
14 Z12 20BK/TN
15 L3 14RD/OR
16 G300 20VT/WT (OFF-ROAD PACKAGE)
17 G301 20VT/LB (OFF-ROAD PACKAGE)
18 G32 20BK/LB
19 G19 20LG/OR (ABS)
20 L39 16LB
21 -
22 G99 20GY/WT
23 D20 18LG/PK (A/T)
24 G304 20VT/DB (OFF-ROAD PACKAGE)
8W - 80 - 14 8W-80 CONNECTOR PIN-OUTS TJ
C170 - WHITE (I/P SIDE)
CAV CIRCUIT
1 L13 20BR/YL (EXPORT)
2 C81 20LB/WT (HARD TOP)
3 A111 12RD/LB
4 F60 16RD/WT
5 T56 18DG/LB
6 C90 20LG
7 T6 18OR/WT
8 G31 20VT/LG
9 D32 20LG/WT
10 D21 20PK
11 F70 16PK/BK
12 G34 16RD/GY (EXCEPT RHD EXPORT)
12 L3 16RD/OR (RHD EXPORT)
13 G305 20VT/LG (OFF-ROAD PACKAGE)
14 Z12 20BK/TN
15 G34 16RD/GY
16 G300 20VT/WT (OFF-ROAD PACKAGE)
17 G301 20VT/LB (OFF-ROAD PACKAGE)
18 G32 20BK/LB
19 G19 20LG/OR (ABS)
20 Z12 20BK/TN
21 L39 16LB (EXCEPT EXPORT)
22 G99 20GY/WT
23 D20 20LG/PK
24 G304 20VT/DB (OFF-ROAD PACKAGE)
C181 (2.4L) - BLACK (ENGINE INTAKE SIDE)
CAV CIRCUIT
1 F142 18OR/DG
2 C3 18DB/BK
3 Z246 18BK/GR
4 K11 18WT/DB
5 K12 18TN
6 K13 18YL/WT
7 K14 18LB/BR
8 K44 18TN/YL
9 K4 18BK/LB
10 -
TJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 15
C181 (2.4L) - BLACK (ENGINE SIDE)
CAV CIRCUIT
1 F42 18DG/LG
2 C3 20DB/BK
3 Z1 20BK
4 K11 18WT/DB
5 K12 18TN
6 K13 18YL/WT
7 K14 18LB/BR
8 K44 18TN/YL
9 K4 18TN/YL
10 -
C182 (2.4L) - BLACK (ENGINE INTAKE SIDE)
CAV CIRCUIT
1 K59 18VT/BK
2 K40 18BR/WT
3 K60 18YL/BK
4 K39 18GY/RD
5 K21 18BK/RD
6 K2 18TN/BK
7 K1 18DG/RD
8 K22 18OR/DB
9 -
10 G60 18GY/YL
11 K24 18GY/BK
12 K7 18OR
13 -
14 -
C182 (2.4L) - BLACK (ENGINE SIDE)
CAV CIRCUIT
1 K59 18VT/BK
2 K40 18BR/WT
3 K60 18/YL/BK
4 K39 18GY/RD
5 K21 18BK/RD
6 K2 18TN/BK
7 K1 18DG/RD
8 K22 18OR/DB
9 K6 18VT/WT
10 G60 18GY/YL
11 K24 18GY/BK
12 K7 18OR
13 -
14 -
8W - 80 - 16 8W-80 CONNECTOR PIN-OUTS TJ
C202 - (BODY SIDE)
CAV CIRCUIT
A1 -
A2 G75 20TN
A3 X55 18BR/RD (SUBWOOFER)
A4 X53 18DG (SUBWOOFER)
A5 L7 18BK/YL
A5 L7 18BK/YL
A6 L61 18GY
A6 L61 18GY
A7 L1 20VT/BK
A8 F38 16LB/WT
B1 F14 18LG/YL (RHD)
B2 G5 20DB/WT
B3 X52 18GY/DB
B4 X58 18DB/PK
B5 L60 18TN
B6 -
B7 G26 20LB
B8 R166 18LG/BR (PAD)
B9 V20 18VT/OR (HARD TOP)
B10 G107 20BK/RD
B11 F81 20DB/RD (HARD TOP)
B12 L38 18BR/WT (EXPORT)
C1 X12 20PK
C2 X16 20LG (SUBWOOFER)
C3 V13 18BR/LG (HARD TOP)
C4 G10 20LG/RD (EXCEPT LHD EXPORT)
C5 M2 20YL
C6 V23 18BR/PK (HARD TOP)
C7 E19 20RD
C8 -
C9 R66 18YL/LG (PAD)
C10 X51 18BR/YL
C11 X57 18BR/LB
C12 D25 20VT/YL
D1 L22 20LG/DG (EXPORT)
D2 G76 20TN/YL
D3 M1 20PK/WT
D3 M1 20PK/WT
D4 F24 20RD/DG
D5 X54 18VT (SUBWOOFER)
D6 X56 18DB (SUBWOOFER)
D7 E2 20OR
D8 R65 18LG/OR (PAD)
TJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 17
C202 - (I/P SIDE)
CAV CIRCUIT
A1 -
A2 G75 20TN
A3 X55 18BR/RD (EXCEPT POSTAL)
A3 X55 18BR/RD (EXCEPT POSTAL)
A4 X53 18DG (EXCEPT POSTAL)
A4 X53 18DG (EXCEPT POSTAL)
A5 L7 18BK/YL
A6 L61 18GY
A7 L1 20VT/BK (EXCEPT POSTAL)
A8 F38 16LB/WT
B1 F14 18LG/YL (PAD)
B2 G5 20DB/WT
B3 X52 18DB/WT
B4 X58 18DB/PK
B5 L60 18TN
B6 -
B7 G26 20LB
B8 R166 18LG/BR (PAD)
B9 V20 18VT/OR (HARD TOP)
B10 G107 20BK/RD (4X4)
B11 F81 20DB/RD (HARD TOP)
B12 L38 16BR/WT (EXPORT)
C1 X12 20PK
C2 X16 20LG
C3 V13 18BR/LG (HARD TOP)
C4 G10 20LG/RD
C5 M2 20YL
C6 V23 18BR/PK (HARD TOP)
C7 E19 20RD
C8 -
C9 R66 18YL/DG (PAD)
C10 X51 18BR/YL
C11 X57 18BR/LB
C12 D25 20VT/YL
D1 L22 20LG/DG (EXPORT)
D2 G76 20TN/YL
D3 M1 20PK/WT
D4 F24 20RD/DG
D4 F24 20RD/DG
D5 X54 18VT (EXCEPT POSTAL)
D5 X54 18VT (EXCEPT POSTAL)
D6 X56 18DB (EXCEPT POSTAL)
D6 X56 18DB (EXCEPT POSTAL)
D7 E2 20OR
D8 R65 18LG/OR (PAD)
8W - 80 - 18 8W-80 CONNECTOR PIN-OUTS TJ
C203 - (I/P SIDE)
CAV CIRCUIT
1 G5 20DB/WT
2 Z10 20BK
3 L1 20VT/BK
4 G31 20VT/LG
5 G32 20BK/LB
6 M2 20YL
7 M1 20PK/WT
C203 - (MIRROR SIDE)
CAV CIRCUIT
1 G5 20DB/WT
2 Z2 20BK/LG
3 L1 20VT/BK
4 G31 20VT/LG
5 G32 20BK/LB
6 M2 20YL
7 M1 20PK/WT
C205 - (HVAC SIDE)
CAV CIRCUIT
1 Z11 20DB/WT
2 C4 14TN
3 C5 14LG
4 C6 14LB
5 F24 20OR
6 C36 20YL
7 C7 12BK/TN
8 A111 12RD/LG
9 F24 20DB/WT
10 Z1 20BK
C205 - LT GREEN (I/P SIDE)
CAV CIRCUIT
1 Z11 20BK/WT
2 C4 18TN
3 C5 16LG/LB
4 C6 14LB
5 F24 20RD/DG
5 F24 20RD/DG
6 C36 20DB/RD
7 C7 12BR/TN
8 A111 12RD/LB
9 F24 20RD/DG
10 Z1 20BK
TJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 19
C324 - (BODY SIDE)
CAV CIRCUIT
1 M1 20PK/WT
2 M2 20YL
3 X58 18DB/PK
4 X52 18GY/DB
C324 - BLACK (SPEAKER POD J UMPER)
CAV CIRCUIT
A M1 20PK/WT
B M2 20YL
C X58 18DB/PK
D X52 18GY/DB
C325 - BLACK (SPEAKER POD J UMPER)
CAV CIRCUIT
A M1 20PK/WT
B M2 20YL
C X57 18BR/LB
D X51 18BR/YL
C325 - WHITE (BODY SIDE)
CAV CIRCUIT
A M1 20PK/WT
B M2 20YL
C X57 18BR/LB
D X51 18BR/YL
C326 (HARD TOP) - (BODY SIDE)
CAV CIRCUIT
1 C15 12BK/WT
2 -
3 V13 18BR/LG
4 V23 18BR/PK
5 V23 18BR/PK
6 Z1 12BK
8W - 80 - 20 8W-80 CONNECTOR PIN-OUTS TJ
C326 (HARD TOP) - BLACK (HARD TOP SIDE)
CAV CIRCUIT
1 C15 12BK/WT
2 -
3 V13 18BR/LG
4 V23 18BR/PK
5 V23 18BR/PK
6 Z1 12BK
C329 (EXPORT) - BLACK (BODY SIDE)
CAV CIRCUIT
1 L38 18BR/WT
2 L7 18BK/YL
3 Z1 20BK
C329 (EXPORT) - BLACK (BUMPER SIDE)
CAV CIRCUIT
1 L38 18BR/WT
2 L7 18BK/YL
3 Z1 20BK
C380 - BLACK (LEAK DETECTION PUMP)
CAV CIRCUIT
1 K107 18OR
2 K106 18WT/DG
3 K125 18WT/DB
C380 (EXCEPT EXPORT) - BLACK (BODY SIDE)
CAV CIRCUIT
1 K107 18OR
2 K106 18WT/DG
3 K125 18WT/DB
TJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 21
CAMSHAFT POSITION SENSOR (2.4L) - BLACK 3 WAY
CAV CIRCUIT FUNCTION
1 K7 18OR 5 VOLT SUPPLY
2 K4 18BK/LB SENSOR GROUND 1
3 K44 18TN/YL CMP SIGNAL
CAMSHAFT POSITION SENSOR (4.0L) - 3 WAY
CAV CIRCUIT FUNCTION
1 K44 18TN/YL CMP SIGNAL
2 K4 20BK/LB SENSOR GROUND 1
3 K7 20OR 5V SUPPLY
CIGAR LIGHTER/POWER OUTLET - RED 3 WAY
CAV CIRCUIT FUNCTION
1 F38 16LB/WT FUSED CIGAR LIGHTER/ACCESSORY RELAY OUTPUT
2 - -
3 Z1 16BK/WT GROUND
CIRCUIT BREAKER - GRAY 2 WAY
CAV CIRCUIT FUNCTION
1 A3 12RD/WT HEADLAMP SWITCH RELAY FEED
2 F3 14LB/OR DAYTIME RUNNING LAMP MODULE
CLOCKSPRING C1 - 4 WAY
CAV CIRCUIT FUNCTION
1 X3 20RD/YL HORN RELAY CONTROL
2 V37 20RD/LG (EXCEPT RHD HARDTOP
SUBWOOFER)
SPEED CONTROL SWITCH SIGNAL
2 V37 20RD/LB (RHD HARDTOP SUB-
WOOFER)
SPEED CONTROL SWITCH SIGNAL
3 K4 20BK/LB SENSOR GROUND 1
4 - -
8W - 80 - 22 8W-80 CONNECTOR PIN-OUTS TJ
CLOCKSPRING C2 - YELLOW 2 WAY
CAV CIRCUIT FUNCTION
1 R45 18DG/LB DRIVER SQUIB 1 LINE 2
2 R43 18BK/LB DRIVER SQUIB 1 LINE 1
CLUTCH PEDAL POSITION SWITCH (M/T) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 T141 18YL/RD FUSED IGNITION SWITCH OUTPUT (START)
2 A41 18YL FUSED IGNITION SWITCH OUTPUT (START)
COMPASS/TEMPERATURE MIRROR - BLACK 7 WAY
CAV CIRCUIT FUNCTION
1 G5 20DB/WT FUSED IGNITION SWITCH OUTPUT (RUN-START)
2 Z2 20BK/LG GROUND
3 L1 20VT/BK BACK-UP LAMP FEED
4 G31 20VT/LG AMBIENT TEMPERATURE SENSOR SIGNAL
5 G32 20BK/LB SENSOR GROUND
6 M2 20YL COURTESY LAMPS DRIVER
7 M1 20PK/WT FUSED B(+)
CONTROLLER ANTILOCK BRAKE - 25 WAY
CAV CIRCUIT FUNCTION
1 B1 18YL/DB RIGHT REAR WHEEL SPEED SENSOR (-)
2 B3 18LG/DB LEFT REAR WHEEL SPEED SENSOR (-)
3 B7 18WT RIGHT FRONT WHEEL SPEED SENSOR (+)
4 B9 18RD LEFT FRONT WHEEL SPEED SENSOR (+)
5 - -
6 B41 18YL/VT G-SWITCH NO. 1 SENSE
7 B42 18TN/WT G-SWITCH NO. 2 SENSE
8 Z22 12BK/PK GROUND
9 A20 12RD/DB FUSED B(+)
10 B4 18LG LEFT REAR WHEEL SPEED SENSOR (+)
11 B8 18RD/DB LEFT FRONT WHEEL SPEED SENSOR (-)
12 L50 18WT/TN BRAKE LAMP SWITCH OUTPUT
13 B43 18PK/OR G-SWITCH TEST SIGNAL
14 - -
15 - -
16 G83 18GY/BK ABS RELAY CONTROL
17 B2 18YL RIGHT REAR WHEEL SPEED SENSOR (+)
18 B6 18WT/DB RIGHT FRONT WHEEL SPEED SENSOR (-)
19 - -
20 D21 18PK SCI TRANSMIT
21 - -
22 - -
23 F20 18VT/WT FUSED IGNITION SWITCH OUTPUT (RUN)
24 Z22 12BK/PK GROUND
25 A10 12RD/DG FUSED B(+)
TJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 23
CRANKSHAFT POSITION SENSOR (2.4L/4.0L A/T) - BLACK 3 WAY
CAV CIRCUIT FUNCTION
1 K24 18GY/BK (2.4L) CRANKSHAFT POSITION SENSOR SIGNAL
1 K7 20OR (4.0L) 5V SUPPLY
2 K4 18BK/LB (2.4L) SENSOR GROUND 1
2 K4 20BK/LB (4.0L) SENSOR GROUND 1
3 K7 18OR (2.4L) 5V SUPPLY
3 K24 18GY/BK (4.0L) CRANKSHAFT POSITION SENSOR SIGNAL
CRANKSHAFT POSITION SENSOR (4.0L M/T) - 3 WAY
CAV CIRCUIT FUNCTION
1 K24 18GY/BK CRANKSHAFT POSITION SENSOR SIGNAL
2 K4 20BK/LB SENSOR GROUND 1
3 K7 20OR 5 VOLT SUPPLY
DATA LINK CONNECTOR - BLACK 16 WAY
CAV CIRCUIT FUNCTION
1 - -
2 D25 20VT/YL PCI BUS
3 - -
4 Z2 20BK/LG GROUND
5 Z12 20BK/TN GROUND
6 D32 20LG/WT SCI RECEIVE
7 D21 20PK SCI TRANSMIT
8 - -
9 D23 20WT/BR FLASH PROGRAM ENABLE
10 - -
11 - -
12 - -
13 - -
14 D20 20LG/PK SCI RECEIVE
15 - -
16 M1 20PK/WT FUSED B(+)
8W - 80 - 24 8W-80 CONNECTOR PIN-OUTS TJ
DAYTIME RUNNING LAMP MODULE (EXCEPT EXPORT) - BLACK 10 WAY
CAV CIRCUIT FUNCTION
1 L3 14RD/OR HIGH BEAM INDICATOR DRIVER
2 - -
3 - -
4 G34 14RD/GY HIGH BEAM INDICATOR DRIVER
5 F12 20RD/LG FUSED IGNITION SWITCH OUTPUT (RUN-START)
6 F3 14LB/OR FUSED B(+)
7 G7 20WT/OR VEHICLE SPEED SENSOR SIGNAL
8 Z1 18BK GROUND
9 - -
10 L4 14VT/WT DIMMER SWITCH LOW BEAM OUTPUT
DRIVER AIRBAG SQUIB 1 - YELLOW 2 WAY
CAV CIRCUIT FUNCTION
1 R45 18DG/LB DRIVER SQUIB 1 LINE 2
2 R43 18BK/LB DRIVER SQUIB 1 LINE 1
DRIVER DOOR AJ AR SWITCH - NATURAL 3 WAY
CAV CIRCUIT FUNCTION
1 M23 20YL/BK DOOR AJ AR SWITCH OUTPUT
2 - -
3 G75 20TN DRIVER DOOR AJ AR SWITCH SENSE
ENGINE COOLANT TEMPERATURE SENSOR - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 K4 18BK/LB (2.4L) SENSOR GROUND 1
1 K4 20BK/LB (4.0L) SENSOR GROUND 1
2 K2 18TN/BK ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
TJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 25
ENGINE OIL PRESSURE SWITCH - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 G60 18GY/YL OIL PRESSURE SIGNAL
2 - -
EVAP/PURGE SOLENOID - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 K52 18PK/BK EVAP/PURGE SOLENOID CONTROL
2 F12 20RD/LG FUSED IGNITION SWITCH OUTPUT (RUN-START)
FRONT LOCKER INDICATOR SWITCH (OFF-ROAD PACKAGE) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 Z1 16BK GROUND
2 G300 16VT/WT FRONT LOCKER INDICATOR SWITCH SENSE
FRONT LOCKER PUMP (OFF-ROAD PACKAGE) - LT GRAY 3 WAY
CAV CIRCUIT FUNCTION
1 Z1 18BK GROUND
2 - -
3 A750 18TN/RD FRONT LOCKER RELAY OUTPUT
8W - 80 - 26 8W-80 CONNECTOR PIN-OUTS TJ
FRONT WASHER PUMP - BLACK 2 WAY
CAV CIRCUIT FUNCTION
A V10 16BR WASHER PUMP CONTROL SWITCH OUTPUT
B Z1 18BK GROUND
FRONT WIPER MOTOR - BLACK 6 WAY
CAV CIRCUIT FUNCTION
1 V6 16PK/BK FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
2 V5 16DG/YL WIPER PARK SWITCH SENSE
3 - -
4 Z1 18BK GROUND
5 V3 16BR/WT LOW SPEED WIPER SWITCH OUTPUT
6 V4 16RD/YL WIPER SWITCH HIGH SPEED OUTPUT
FUEL INJ ECTOR NO. 1 (2.4L) - 2 WAY
CAV CIRCUIT FUNCTION
1 F142 18OR/DG FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT
2 K11 18WT/DB FUEL INJ ECTOR NO. 1 DRIVER
FUEL INJ ECTOR NO. 1 (4.0L) - 2 WAY
CAV CIRCUIT FUNCTION
1 F42 18DG/LG FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT
2 K11 18WT/DB FUEL INJ ECTOR NO. 1 DRIVER
FUEL INJ ECTOR NO. 2 (2.4L) - 2 WAY
CAV CIRCUIT FUNCTION
1 F142 18OR/DG FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT
2 K12 18TN FUEL INJ ECTOR NO. 2 DRIVER
TJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 27
FUEL INJ ECTOR NO. 2 (4.0L) - 2 WAY
CAV CIRCUIT FUNCTION
1 F42 18DG/LG FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT
2 K12 18TN FUEL INJ ECTOR NO. 2 DRIVER
FUEL INJ ECTOR NO. 3 (2.4L) - 2 WAY
CAV CIRCUIT FUNCTION
1 F142 18OR/DG FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT
2 K13 18YL/WT FUEL INJ ECTOR NO. 3 DRIVER
FUEL INJ ECTOR NO. 3 (4.0L) - 2 WAY
CAV CIRCUIT FUNCTION
1 F42 18DG/LG FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT
2 K13 18YL/WT FUEL INJ ECTOR NO. 3 DRIVER
FUEL INJ ECTOR NO. 4 (2.4L) - 2 WAY
CAV CIRCUIT FUNCTION
1 F142 18OR/DG FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT
2 K14 18LB/BR FUEL INJ ECTOR NO. 4 DRIVER
FUEL INJ ECTOR NO. 4 (4.0L) - 2 WAY
CAV CIRCUIT FUNCTION
1 F42 18DG/LG FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT
2 K14 18LB/BR FUEL INJ ECTOR NO. 4 DRIVER
FUEL INJ ECTOR NO. 5 (4.0L) - 2 WAY
CAV CIRCUIT FUNCTION
1 F42 18DG/LG FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT
2 K38 18GY FUEL INJ ECTOR NO. 5 DRIVER
8W - 80 - 28 8W-80 CONNECTOR PIN-OUTS TJ
FUEL INJ ECTOR NO. 6 (4.0L) - 2 WAY
CAV CIRCUIT FUNCTION
1 F42 18DG/LG FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT
2 K58 18BR/DB FUEL INJ ECTOR NO. 6 DRIVER
FUEL PUMP MODULE - 4 WAY
CAV CIRCUIT FUNCTION
1 A141 18DG/WT FUEL PUMP RELAY OUTPUT
2 K226 20DB/LG FUEL LEVEL SENSOR SIGNAL
3 K4 20BK/LB SENSOR GROUND 1
4 Z1 18BK GROUND
G-SWITCH (LHD) - 3 WAY
CAV CIRCUIT FUNCTION
1 B42 20TN/WT G-SWITCH NO. 2 SENSE
2 B41 20YL/VT G-SWITCH NO. 1 SENSE
3 B43 20PK/OR G-SWITCH TEST SIGNAL
GENERATOR - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 K125 18WT/DB GENERATOR SOURCE
2 K20 18DG GENERATOR FIELD
HEADLAMP LEVELING SWITCH (EXPORT) - 6 WAY
CAV CIRCUIT FUNCTION
1 - -
2 L22 20LG/DG FUSED HEADLAMP SWITCH OUTPUT
3 - -
4 Z1 20BK GROUND
5 L13 20BR/YL HEADLAMP ADJ UST SIGNAL
6 - -
TJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 29
HORN - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 Z1 18BK GROUND
2 X2 18WT/RD HORN RELAY OUTPUT
IDLE AIR CONTROL MOTOR - BLACK 4 WAY
CAV CIRCUIT FUNCTION
1 K59 18VT/BK IDLE AIR CONTROL NO. 4 DRIVER
2 K40 18BR/WT IDLE AIR CONTROL NO. 3 DRIVER
3 K60 18YL/BK IDLE AIR CONTROL NO. 2 DRIVER
4 K39 18GY/RD IDLE AIR CONTROL NO. 1 DRIVER
IGNITION COIL PACK (2.4L) - BLACK 3 WAY
CAV CIRCUIT FUNCTION
1 K17 18DB/TN IGNITION COIL NO. 2 DRIVER
2 F42 18DG/LG FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT
3 K19 18GY IGNITION COIL NO. 1 DRIVER
IGNITION COIL PACK (4.0L) - BLACK 4 WAY
CAV CIRCUIT FUNCTION
1 K19 18BK/GY IGNITION COIL NO. 1 DRIVER
2 F42 18DG/LG FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT
3 K17 18DB/TN IGNITION COIL NO. 2 DRIVER
4 K18 18RD/YL IGNITION COIL NO. 3 DRIVER
IGNITION SWITCH - 10 WAY
CAV CIRCUIT FUNCTION
1 A1 18RD FUSED B(+)
2 A21 18DB IGNITION SWITCH OUTPUT (RUN-START)
3 F22 12WT/PK IGNITION SWITCH OUTPUT (RUN-ACC)
4 F30 12RD/PK FUSED B(+)
5 G26 20LB KEY-IN IGNITION SWITCH SENSE
6 A41 18YL IGNITION SWITCH OUTPUT (START)
7 A31 18BK/DG IGNITION SWITCH OUTPUT (RUN-ACC)
8 A22 14BK/OR IGNITION SWITCH OUTPUT (RUN)
9 A2 14PK/BK FUSED B(+)
10 Z1 16BK GROUND
8W - 80 - 30 8W-80 CONNECTOR PIN-OUTS TJ
INPUT SPEED SENSOR - 2 WAY
CAV CIRCUIT FUNCTION
1 T52 18RD/BK INPUT SPEED SENSOR SIGNAL
2 T13 18DB/BK SPEED SENSOR GROUND
INSTRUMENT CLUSTER C1 - 12 WAY
CAV CIRCUIT FUNCTION
1 L61 18GY LEFT TURN SIGNAL
2 L60 18TN RIGHT TURN SIGNAL
3 G34 16RD/GY (LHD) HIGH BEAM INDICATOR DRIVER
3 L3 16RD/OR (RHD) HIGH BEAM INDICATOR DRIVER
4 L39 16LB (EXCEPT EXPORT) FOG LAMP FEED
4 L38 16BR/WT (EXPORT) REAR FOG LAMP FEED
5 L7 18BK/YL HEADLAMP SWITCH OUTPUT
6 G305 20VT/LG (OFF-ROAD PACKAGE) REAR LOCKER REQUEST
7 G301 20VT/LB (OFF-ROAD PACKAGE) REAR LOCKER INDICATOR SWITCH SENSE
8 Z2 18BK/LG GROUND
9 G303 20VT/DG (OFF-ROAD PACKAGE) LOCKER ENABLE SIGNAL 2
10 D23 20WT/BR -
11 G5 20DB/WT FUSED IGNITION SWITCH OUTPUT (RUN-START)
12 M1 20PK/WT FUSED B(+)
INSTRUMENT CLUSTER C2 - 16 WAY
CAV CIRCUIT FUNCTION
1 C80 20DB/WT (HARD TOP) REAR WINDOW DEFOGGER SWITCH SENSE
2 G10 20LG/RD SEAT BELT SWITCH SENSE
3 G76 20TN/YL PASSENGER DOOR AJ AR SWITCH SENSE
4 G75 20TN DRIVER DOOR AJ AR SWITCH SENSE
5 M2 20YL COURTESY LAMP FEED
6 E2 20OR PANEL LAMPS FEED
7 C81 20LB/WT (HARD TOP) REAR WINDOW DEFOGGER RELAY CONTROL
8 G19 20LG/OR (ABS) ABS WARNING INDICATOR DRIVER
9 G99 20GY/WT BRAKE WARNING INDICATOR DRIVER
10 G304 20VT/DB (OFF-ROAD PACKAGE) FRONT LOCKER REQUEST
11 G107 20BK/RD (4X4) 4WD INDICATOR
12 D25 20VT/YL PCI BUS
13 G26 20LB KEY-IN IGNITION SWITCH SENSE
14 G302 20RD/WT (OFF-ROAD PACKAGE) LOCKER ENABLE SIGNAL 1
15 E19 20RD PANEL LAMPS DIMMER SIGNAL
16 G300 20VT/WT (OFF-ROAD PACKAGE) FRONT LOCKER INDICATOR SWITCH SENSE
TJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 31
INTAKE AIR TEMPERATURE SENSOR - GRAY 2 WAY
CAV CIRCUIT FUNCTION
1 K4 18BK/LB (2.4L) SENSOR GROUND 1
1 K4 20BK/LB (4.0L) SENSOR GROUND 1
2 K21 18BK/RD INTAKE AIR TEMPERATURE SENSOR SIGNAL
LEAK DETECTION PUMP - BLACK 4 WAY
CAV CIRCUIT FUNCTION
1 - -
2 K125 18WT/DB GENERATOR SOURCE
3 K106 18WT/DG LEAK DETECTION PUMP SOLENOID CONTROL
4 K107 18OR LEAK DETECTION PUMP SWITCH SENSE
LEFT COURTESY LAMP - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 M1 20PK/WT FUSED B(+)
2 M2 20YL COURTESY LAMPS DRIVER
LEFT DOME LAMP - WHITE 2 WAY
CAV CIRCUIT FUNCTION
1 M1 20PK/WT FUSED B(+)
2 M2 20YL COURTESY LAMPS DRIVER
LEFT FOG LAMP (EXCEPT EXPORT) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 Z1 18BK GROUND
2 L39 16LB FOG LAMP RELAY NO. 1 OUTPUT
8W - 80 - 32 8W-80 CONNECTOR PIN-OUTS TJ
LEFT FRONT PARK/ TURN SIGNAL LAMP (EXCEPT EXPORT) - BLACK 3 WAY
CAV CIRCUIT FUNCTION
1 L61 18GY LEFT TURN SIGNAL
2 L7 18BK/YL FUSED PARK LAMP RELAY OUTPUT
3 Z1 18BK GROUND
LEFT FRONT POSITION LAMP (EXPORT) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 L7 18BK/YL FUSED PARK LAMP RELAY OUTPUT
2 Z1 20BK GROUND
LEFT FRONT SPEAKER - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 X53 18DG LEFT FRONT SPEAKER (+)
2 X55 18BR/RD LEFT FRONT SPEAKER (-)
LEFT FRONT TURN SIGNAL LAMP (EXPORT) - BLACK 3 WAY
CAV CIRCUIT FUNCTION
1 L61 18GY LEFT TURN SIGNAL
2 - -
3 Z1 18BK GROUND
LEFT FRONT WHEEL SPEED SENSOR - 2 WAY
CAV CIRCUIT FUNCTION
1 B8 18RD/DB LEFT FRONT WHEEL SPEED SENSOR (-)
2 B9 18RD LEFT FRONT WHEEL SPEED SENSOR (+)
TJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 33
LEFT HEADLAMP - BLACK 3 WAY
CAV CIRCUIT FUNCTION
1 L3 14RD/OR DIMMER SWITCH HIGH BEAM OUTPUT
1 L3 14RD/OR DIMMER SWITCH HIGH BEAM OUTPUT
2 L4 14VT/WT DIMMER SWITCH LOW BEAM OUTPUT
2 L4 14VT/WT DIMMER SWITCH LOW BEAM OUTPUT
3 Z1 20BK GROUND
LEFT HEADLAMP LEVELING MOTOR (EXPORT) - BLACK 3 WAY
CAV CIRCUIT FUNCTION
1 L22 20LG/DG FUSED HEADLAMP SWITCH OUTPUT
2 L13 20BR/YL HEADLAMP ADJ UST SIGNAL
3 Z1 20BK GROUND
LEFT LICENSE LAMP (EXPORT) - GRAY 2 WAY
CAV CIRCUIT FUNCTION
1 L7 18BK/YL FUSED PARK LAMP RELAY OUTPUT
2 Z1 20BK GROUND
LEFT REAR LAMP ASSEMBLY - 4 WAY
CAV CIRCUIT FUNCTION
1 L1 20VT/BK (EXCEPT EXPORT) BACK-UP LAMP FEED
1 L63 18DG/RD (EXPORT) LEFT TURN/STOP SIGNAL
2 L63 18DG/RD (EXCEPT EXPORT) LEFT TURN/STOP SIGNAL
2 L1 20VT/BK (EXPORT) BACK-UP LAMP FEED
3 L7 18BK/YL (EXCEPT EXPORT) FUSED PARK LAMP RELAY OUTPUT
3 L50 18WT/TN (EXPORT) BRAKE LAMP SWITCH OUTPUT
4 L7 18BK/YL (EXPORT) FUSED PARK LAMP RELAY OUTPUT
8W - 80 - 34 8W-80 CONNECTOR PIN-OUTS TJ
LEFT REAR SPEAKER - BLACK 3 WAY
CAV CIRCUIT FUNCTION
1 X57 20BR/LB LEFT REAR SPEAKER (-)
2 - -
3 X51 18BR/YL LEFT REAR SPEAKER (+)
LEFT REAR WHEEL SPEED SENSOR - 2 WAY
CAV CIRCUIT FUNCTION
1 B3 18LG/DB LEFT REAR WHEEL SPEED SENSOR (-)
2 B4 18LG LEFT REAR WHEEL SPEED SENSOR (+)
LEFT SIDE MARKER LAMP (EXCEPT EXPORT) - GRAY 2 WAY
CAV CIRCUIT FUNCTION
1 L7 18BK/YL FUSED PARK LAMP RELAY OUTPUT
2 L61 18GY LEFT TURN SIGNAL
LEFT SIDE REPEATER LAMP (EXPORT) - GRAY 2 WAY
CAV CIRCUIT FUNCTION
1 L61 18GY LEFT TURN SIGNAL
2 Z1 18BK GROUND
MANIFOLD ABSOLUTE PRESSURE SENSOR (2.4L) - BLACK 3 WAY
CAV CIRCUIT FUNCTION
1 K1 18DG/RD MAP SIGNAL
2 K4 18BK/LB SENSOR GROUND 1
3 K7 18OR 5 VOLT SUPPLY
TJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 35
MANIFOLD ABSOLUTE PRESSURE SENSOR (4.0L) - 3 WAY
CAV CIRCUIT FUNCTION
1 K1 18DG/RD MAP SIGNAL
2 K4 20BK/LB SENSOR GROUND 1
3 K7 20OR 5V SUPPLY
MULTI-FUNCTION SWITCH C1 - GRAY 20 WAY
CAV CIRCUIT FUNCTION
1 L50 18WT/TN (EXCEPT EXPORT) BRAKE LAMP SWITCH OUTPUT
2 L61 18GY LEFT TURN SIGNAL
3 L5 20BK/GY FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
4 L63 18DG/RD LEFT TURN/STOP SIGNAL
5 L62 18BR/RD RIGHT TURN/STOP SIGNAL
6 L60 18TN RIGHT TURN SIGNAL
7 Z1 18BK (EXCEPT EXPORT) GROUND
7 Z1 20BK (EXPORT) GROUND
8 E19 20RD PANEL LAMPS DRIVER
9 L7 18BK/YL HEADLAMP SWITCH OUTPUT
10 - -
11 L9 18BK/WT HAZARD FLASHER FEED
12 L38 18BR/WT (EXPORT) REAR FOG LAMP FEED
13 F39 16PK/LG FUSED B(+)
14 F61 16WT/OR (EXCEPT EXPORT) FUSED FOG LAMP RELAY OUTPUT
15 - -
16 L4 14VT/WT DIMMER SWITCH LOW BEAM OUTPUT
17 L3 14RD/OR DIMMER SWITCH HIGH BEAM OUTPUT
18 F3 14LB/OR FUSED B(+)
19 F3 14LB/OR FUSED B(+)
20 F33 18PK/RD FUSED B(+)
MULTI-FUNCTION SWITCH C2 - BLACK 7 WAY
CAV CIRCUIT FUNCTION
1 V5 16DG/YL WIPER PARK SWITCH SENSE
2 Z1 20BK (EXCEPT EXPORT) GROUND
2 Z1 18BK (EXPORT) GROUND
3 V10 16BR WASHER PUMP CONTROL SWITCH OUTPUT
4 V6 16PK/BK FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
5 V4 16RD/YL WIPER SWITCH HIGH SPEED OUTPUT
6 V3 16BR/WT LOW SPEED WIPER SWITCH OUTPUT
7 - -
8W - 80 - 36 8W-80 CONNECTOR PIN-OUTS TJ
OUTPUT SPEED SENSOR - 2 WAY
CAV CIRCUIT FUNCTION
1 T14 18LG/WT OUTPUT SPEED SENSOR SIGNAL
2 T13 18DB/BK SPEED SENSOR GROUND
OVERDRIVE OFF SWITCH - 4 WAY
CAV CIRCUIT FUNCTION
1 Z1 20BK GROUND
2 T6 18OR/WT OVERDRIVE OFF SWITCH SENSE
3 T56 18DG/LB OVERDRIVE OFF SWITCH INDICATOR
4 E2 20OR PANEL LAMPS FEED
OXYGEN SENSOR 1/1 UPSTREAM - 4 WAY
CAV CIRCUIT FUNCTION
1 F142 18OR/DG FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT
2 K99 18BR/OR OXYGEN SENSOR 1/1 HEATER CONTROL
3 K4 20BK/LB SENSOR GROUND 1
4 K41 18BK/DG OXYGEN SENSOR 1/1 SIGNAL
OXYGEN SENSOR 1/2 DOWNSTREAM - BLACK 4 WAY
CAV CIRCUIT FUNCTION
1 F142 18OR/DG (EXCEPT EXPORT/J A-
PAN LOW EMISSION VEHICLE)
FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT
1 A242 18VT/OR (EXPORT/J APAN LOW
EMISSIONS VEHICLE)
OXYGEN SENSOR DOWNSTREAM HEATER RELAY
OUTPUT
2 K299 18BR/WT (EXCEPT EXPORT/J A-
PAN LOW EMISSION VEHICLE)
OXYGEN SENSOR 1/2 HEATER CONTROL
2 Z1 18BK (EXPORT/J APAN LOW EMIS-
SIONS VEHICLE)
GROUND
3 K4 20BK/LB SENSOR GROUND 1
4 K141 18TN/WT OXYGEN SENSOR 1/2 SIGNAL
TJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 37
OXYGEN SENSOR 2/1 UPSTREAM (EXCEPT EXPORT/J APAN LOW EMISSION VEHICLE) - 4 WAY
CAV CIRCUIT FUNCTION
1 F142 18OR/DG FUSED AUTO SHUT DOWN RELAY OUTPUT
2 K299 18BR/WT O2 SENSOR 2/1 HEATER CONTROL
3 K4 20BK/LB SENSOR GROUND 1
4 K241 18LG/RD OXYGEN SENSOR 2/1 SIGNAL
OXYGEN SENSOR 2/2 DOWNSTREAM (EXCEPT EXPORT/J APAN LOW EMISSION VEHICLE) - 4 WAY
CAV CIRCUIT FUNCTION
1 A242 18VT/OR OXYGEN SENSOR DOWNSTREAM HEATER RELAY
OUTPUT
2 Z1 18BK GROUND
3 K4 20BK/LB SENSOR GROUND 1
4 K341 18TN/WT OXYGEN SENSOR 2/2 SIGNAL
PASSENGER AIRBAG ON-OFF SWITCH (LHD) - 6 WAY
CAV CIRCUIT FUNCTION
1 F14 18LG/YL FUSED IGNITION SWITCH OUTPUT (RUN)
2 R166 18LG/BR PASSENGER AIRBAG INDICATOR DRIVER
3 R65 18LG/OR PASSENGER AIRBAG MUX SWITCH SENSE
4 - -
5 - -
6 R66 18YL/LG PASSENGER AIRBAG MUX SWITCH RETURN
PASSENGER AIRBAG SQUIB 1 - YELLOW 2 WAY
CAV CIRCUIT FUNCTION
A R44 18DG/YL PASSENGER SQUIB 1 LINE 2
B R42 18BK/YL PASSENGER SQUIB 1 LINE 1
8W - 80 - 38 8W-80 CONNECTOR PIN-OUTS TJ
PASSENGER DOOR AJ AR SWITCH - BLACK 3 WAY
CAV CIRCUIT FUNCTION
1 M23 20YL/BK DOOR AJ AR SWITCH OUTPUT
2 - -
3 G76 20TN/YL PASSENGER DOOR AJ AR SWITCH SENSE
POWER OUTLET - 3 WAY
CAV CIRCUIT FUNCTION
1 F70 16PK/BK FUSED B(+)
2 - -
3 Z1 16BK GROUND
POWER STEERING PRESSURE SWITCH (2.4L) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 K10 18DB/OR POWER STEERING PRESSURE SWITCH SENSE
2 Z1 20BK GROUND
TJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 39
POWERTRAIN CONTROL MODULE C1 - BLACK 32 WAY
CAV CIRCUIT FUNCTION
1 K18 18RD/YL (4.0L) IGNITION COIL NO. 3 DRIVER
2 F15 18DB/WT FUSED IGNITION SWITCH OUTPUT (RUN-START)
3 - -
4 K4 18BK/LB SENSOR GROUND 1
5 - -
6 T41 18BK/WT PARK/NEUTRAL POSITION SWITCH SENSE
7 K19 18BK/GY IGNITION COIL NO. 1 DRIVER
8 K24 18GY/BK CRANKSHAFT POSITION SENSOR SIGNAL
9 - -
10 K60 18YL/BK IDLE AIR CONTROL NO. 2 DRIVER
11 K40 18BR/WT IDLE AIR CONTROL NO. 3 DRIVER
12 K10 18DB/OR (2.4L) POWER STEERING PRESSURE SWITCH SENSE
13 T141 18YL/RD FUSED IGNITION SWITCH OUTPUT (START)
14 K77 18BK/WT (OFF-ROAD PACKAGE) TRANSFER CASE POSITION SENSOR INPUT
15 K21 18BK/RD INTAKE AIR TEMPERATURE SENSOR SIGNAL
16 K2 18TN/BK ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
17 K7 18OR 5V SUPPLY
18 K44 18TN/YL CMP SIGNAL
19 K39 18GY/RD IDLE AIR CONTROL NO. 1 DRIVER
20 K59 18VT/BK IDLE AIR CONTROL NO. 4 DRIVER
21 - -
22 A14 14RD/WT FUSED B(+)
23 K22 18OR/DB THROTTLE POSITION SENSOR SIGNAL
24 K41 18BK/DG OXYGEN SENSOR 1/1 SIGNAL
25 K141 18TN/WT OXYGEN SENSOR 1/2 SIGNAL
26 K241 18LG/RD (4.0L EXCEPT EXPORT/
4.0L J APAN LOW EMISSION VEHICLE)
OXYGEN SENSOR 2/1 SIGNAL
27 K1 18DG/RD MAP SIGNAL
28 - -
29 K341 18TN/WT (4.0L EXCEPT EXPORT/
4.0L J APAN LOW EMISSION VEHICLE)
OXYGEN SENSOR 2/2 SIGNAL
30 - -
31 Z12 14BK/TN GROUND
32 Z12 14BK/TN GROUND
8W - 80 - 40 8W-80 CONNECTOR PIN-OUTS TJ
POWERTRAIN CONTROL MODULE C2 - WHITE 32 WAY
CAV CIRCUIT FUNCTION
1 - -
2 - -
3 - -
4 K11 18WT/DB FUEL INJ ECTOR NO. 1 DRIVER
5 K13 18YL/WT FUEL INJ ECTOR NO. 3 DRIVER
6 K38 18GY (4.0L) FUEL INJ ECTOR NO. 5 DRIVER
7 - -
8 - -
9 K17 18DB/TN IGNITION COIL NO. 2 DRIVER
10 K20 18DG GENERATOR FIELD
11 - -
12 K58 18BR/DB (4.0L) FUEL INJ ECTOR NO. 6 DRIVER
13 - -
14 - -
15 K12 18TN FUEL INJ ECTOR NO. 2 DRIVER
16 K14 18LB/BR FUEL INJ ECTOR NO. 4 DRIVER
17 - -
18 - -
19 C18 18DB (2.4L) A/C PRESSURE SIGNAL
20 - -
21 - -
22 - -
23 G60 18GY/YL ENGINE OIL PRESSURE SIGNAL
24 - -
25 - -
26 - -
27 G7 18WT/OR VEHICLE SPEED SENSOR SIGNAL
28 - -
29 - -
30 - -
31 K6 18VT/WT 5V SUPPLY
32 - -
TJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 41
POWERTRAIN CONTROL MODULE C3 - GRAY 32 WAY
CAV CIRCUIT FUNCTION
1 C13 18DB/OR (A/C) A/C COMPRESSOR CLUTCH RELAY CONTROL
2 C24 18DB/PK (2.4L) LOW SPEED RADIATOR FAN RELAY CONTROL
3 K51 18DB/YL AUTOMATIC SHUT DOWN RELAY CONTROL
4 V36 18TN/RD (SPEED CONTROL) SPEED CONTROL VACUUM SOLENOID CONTROL
5 V35 18LG/RD (SPEED CONTROL) SPEED CONTROL VENT SOLENOID CONTROL
6 - -
7 - -
8 K99 18BR/OR OXYGEN SENSOR 1/1 HEATER CONTROL
9 K512 18RD/YL (4.0L) OXYGEN SENSOR DOWNSTREAM HEATER RELAY
CONTROL
10 K106 18WT/DG LEAK DETECTION PUMP SOLENOID CONTROL
11 V32 18YL/RD (SPEED CONTROL) SPEED CONTROL ON/OFF SWITCH SENSE
12 A142 14DG/PK AUTOMATIC SHUT DOWN RELAY OUTPUT
13 T10 18YL/DG (A/T) TORQUE MANAGEMENT REQUEST SENSE
14 K107 18OR LEAK DETECTION PUMP SWITCH SENSE
15 K118 18PK/YL BATTERY TEMPERATURE SENSOR SIGNAL
16 K299 18BR/WT OXYGEN SENSOR HEATER CONTROL
17 - -
18 - -
19 K31 18BR FUEL PUMP RELAY CONTROL
20 K52 18PK/BK EVAP/PURGE SOLENOID CONTROL
21 C27 18DB (2.4L) HIGH SPEED RADIATOR FAN RELAY CONTROL
22 C21 18DB/OR (A/C) A/C SWITCH SENSE
23 C90 18LG (A/C) A/C SELECT INPUT
24 K29 18WT/PK BRAKE LAMP SWITCH SENSE
25 K125 18WT/DB GENERATOR SOURCE
26 K226 18DB/LG (4.0L) FUEL LEVEL SENSOR SIGNAL
27 D21 18PK SCI TRANSMIT
28 - -
29 D32 18LG/WT SCI RECEIVE
30 D25 18VT/YL PCI BUS
31 - -
32 V37 18RD/LB (SPEED CONTROL) SPEED CONTROL SWITCH SIGNAL
RADIATOR FAN MOTOR (2.4L) - 2 WAY
CAV CIRCUIT FUNCTION
1 C25 12DG RADIATOR FAN RELAY OUTPUT
2 Z213 12BK GROUND
3 C23 12DB FUSED HIGH SPEED RADIATOR RELAY OUTPUT
8W - 80 - 42 8W-80 CONNECTOR PIN-OUTS TJ
RADIATOR FAN MOTOR CIRCUIT BREAKER (2.4L) - 2 WAY
CAV CIRCUIT FUNCTION
A Z213 12BK GROUND
B Z213 12BK GROUND
RADIO - GRAY 22 WAY
CAV CIRCUIT FUNCTION
1 F60 16RD/WT FUSED B(+)
2 X12 20PK FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
3 E2 20OR PANEL LAMPS DRIVER
4 - -
5 - -
6 - -
7 X54 18VT RIGHT FRONT SPEAKER (+)
8 X56 18DB RIGHT FRONT SPEAKER (-)
9 X55 18BR/RD LEFT FRONT SPEAKER (-)
10 X53 18DG LEFT FRONT SPEAKER (+)
11 Z9 16BK GROUND
12 F60 16RD/WT FUSED B(+)
13 X16 20LG RADIO 12V OUTPUT
14 D25 20VT/YL PCI BUS
15 - -
16 - -
17 - -
18 X51 18BR/YL LEFT REAR SPEAKER (+)
19 X57 18BR/LB LEFT REAR SPEAKER (-)
20 X58 18DB/PK RIGHT REAR SPEAKER (-)
21 X52 18DB/WT RIGHT REAR SPEAKER (+)
22 Z9 16BK GROUND
REAR FOG LAMP (EXPORT) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 L38 18BR/WT REAR FOG LAMP FEED
2 Z1 20BK GROUND
TJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 43
REAR LOCKER INDICATOR SWITCH (OFF-ROAD PACKAGE) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 Z1 16BK GROUND
2 G301 16VT/LB REAR LOCKER INDICATOR SWITCH SENSE
REAR LOCKER PUMP (OFF-ROAD PACKAGE) - LT GRAY 3 WAY
CAV CIRCUIT FUNCTION
1 Z1 18BK GROUND
2 - -
3 A850 18RD/WT REAR LOCKER RELAY OUTPUT
REAR WASHER PUMP (HARD TOP) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 V20 18VT/OR REAR WASHER MOTOR CONTROL
2 Z1 18BK GROUND
REAR WINDOW DEFOGGER SWITCH (HARD TOP) - 4 WAY
CAV CIRCUIT FUNCTION
1 Z1 20BK GROUND
2 C80 20DB/WT REAR WINDOW DEFOGGER SWITCH SENSE
3 F81 20DB/RD FUSED REAR WINDOW DEFOGGER RELAY OUTPUT
4 E2 20OR FUSED PANEL LAMPS DIMMER SWITCH SIGNAL
8W - 80 - 44 8W-80 CONNECTOR PIN-OUTS TJ
REAR WIPER MOTOR (HARD TOP) - BLACK 3 WAY
CAV CIRCUIT FUNCTION
1 V23 18BR/PK FUSED IGNITION SWITCH OUTPUT (RUN)
2 Z1 16BK GROUND
3 V13 18BK/LG REAR WIPER MOTOR CONTROL
REAR WIPER/WASHER SWITCH (HARD TOP) - WHITE 6 WAY
CAV CIRCUIT FUNCTION
1 Z1 18BK GROUND
2 V20 18VT/OR REAR WASHER MOTOR CONTROL
3 E2 20OR FUSED PANEL LAMPS DIMMER SWITCH SIGNAL
4 V13 18BR/LG REAR WIPER MOTOR CONTROL
5 V23 18BR/PK FUSED IGNITION SWITCH OUTPUT (RUN)
6 - -
RIGHT COURTESY LAMP - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 M1 20PK/WT FUSED B(+)
2 M2 20YL COURTESY LAMPS DRIVER
RIGHT DOME LAMP - WHITE 2 WAY
CAV CIRCUIT FUNCTION
1 M1 20PK/WT FUSED B(+)
2 M2 20YL COURTESY LAMPS DRIVER
RIGHT FOG LAMP (EXCEPT EXPORT) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 Z1 18BK GROUND
2 L39 16LB FOG LAMP RELAY NO. 1 OUTPUT
TJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 45
RIGHT FRONT PARK/ TURN SIGNAL LAMP (EXCEPT EXPORT) - BLACK 3 WAY
CAV CIRCUIT FUNCTION
1 L60 18TN RIGHT TURN SIGNAL
2 L7 18BK/YL FUSED PARK LAMP RELAY OUTPUT
3 Z1 18BK GROUND
RIGHT FRONT POSITION LAMP (EXPORT) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 L7 18BK/YL FUSED PARK LAMP RELAY OUTPUT
2 Z1 20BK GROUND
RIGHT FRONT SPEAKER - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 X54 18VT RIGHT FRONT SPEAKER (+)
2 X56 18DB RIGHT FRONT SPEAKER (-)
RIGHT FRONT TURN SIGNAL LAMP (EXPORT) - BLACK 3 WAY
CAV CIRCUIT FUNCTION
1 L60 18TN RIGHT TURN SIGNAL
2 - -
3 Z1 18BK GROUND
RIGHT FRONT WHEEL SPEED SENSOR - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 B6 18WT/DB RIGHT FRONT WHEEL SPEED SENSOR (-)
2 B7 18WT RIGHT FRONT WHEEL SPEED SENSOR (+)
8W - 80 - 46 8W-80 CONNECTOR PIN-OUTS TJ
RIGHT HEADLAMP - BLACK 3 WAY
CAV CIRCUIT FUNCTION
1 L3 14RD/OR DIMMER SWITCH HIGH BEAM OUTPUT
2 L4 14VT/WT DIMMER SWITCH LOW BEAM OUTPUT
3 Z1 18BK GROUND
RIGHT HEADLAMP LEVELING MOTOR (EXPORT) - BLACK 3 WAY
CAV CIRCUIT FUNCTION
1 L22 20LG/DG FUSED HEADLAMP SWITCH OUTPUT
2 L13 20BR/YL HEADLAMP ADJ UST SIGNAL
3 Z1 20BK GROUND
RIGHT LICENSE LAMP (EXPORT) - GRAY 2 WAY
CAV CIRCUIT FUNCTION
1 L7 18BK/YL FUSED PARK LAMP RELAY OUTPUT
2 Z1 20BK GROUND
RIGHT REAR LAMP ASSEMBLY - BLACK 4 WAY
CAV CIRCUIT FUNCTION
1 L1 20VT/BK (EXCEPT EXPORT) BACK-UP LAMP FEED
1 L62 18BR/RD (EXPORT) RIGHT TURN/STOP SIGNAL
2 L62 18BR/RD (EXCEPT EXPORT) RIGHT TURN/STOP SIGNAL
2 L1 20VT/BK (EXPORT) BACK-UP LAMP FEED
3 L7 18BK/YL (EXCEPT EXPORT) FUSED PARK LAMP RELAY OUTPUT
3 L50 18WT/TN (EXPORT) BRAKE LAMP SWITCH OUTPUT
4 L63 18DG/RD (EXCEPT EXPORT) LEFT TURN/STOP SIGNAL
4 L7 18BK/YL (EXPORT) FUSED PARK LAMP RELAY OUTPUT
TJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 47
RIGHT REAR SPEAKER - BLACK 3 WAY
CAV CIRCUIT FUNCTION
1 X58 20DB/PK RIGHT REAR SPEAKER (-)
2 - -
3 X52 20DB/WT RIGHT REAR SPEAKER (+)
RIGHT REAR WHEEL SPEED SENSOR - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 B1 18YL/DB RIGHT REAR WHEEL SPEED SENSOR (-)
2 B2 18YL RIGHT REAR WHEEL SPEED SENSOR (+)
RIGHT SIDE MARKER LAMP (EXCEPT EXPORT) - GRAY 2 WAY
CAV CIRCUIT FUNCTION
1 L7 18BK/YL FUSED PARK LAMP RELAY OUTPUT
2 L60 18TN RIGHT TURN SIGNAL
RIGHT SIDE REPEATER LAMP (EXPORT) - GRAY 2 WAY
CAV CIRCUIT FUNCTION
1 L60 18TN RIGHT TURN SIGNAL
2 Z1 18BK GROUND
SEAT BELT SWITCH (EXCEPT LHD EXPORT) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 G10 20LG/RD SEAT BELT SWITCH SENSE
2 Z1 20BK GROUND
8W - 80 - 48 8W-80 CONNECTOR PIN-OUTS TJ
SENTRY KEY IMMOBILIZER MODULE - BLACK 6 WAY
CAV CIRCUIT FUNCTION
1 - -
2 D25 20VT/YL PCI BUS
3 - -
4 F15 20DB FUSED IGNITION SWITCH OUTPUT (RUN-START)
5 Z1 20BK GROUND
6 F33 20PK/RD FUSED B(+)
SPEED CONTROL SERVO - BLACK 4 WAY
CAV CIRCUIT FUNCTION
1 V36 18TN/RD SPEED CONTROL VACUUM SOLENOID CONTROL
2 V35 18LG/RD SPEED CONTROL VENT SOLENOID CONTROL
3 V30 20DB/RD SPEED CONTROL BRAKE LAMP SWITCH OUTPUT
4 Z1 18BK GROUND
SUBWOOFER - 12 WAY
CAV CIRCUIT FUNCTION
1 X54 18VT RIGHT FRONT SPEAKER (+)
2 X56 18DB RIGHT FRONT SPEAKER (-)
3 X53 18DG LEFT FRONT SPEAKER (+)
4 X55 18BR/RD LEFT FRONT SPEAKER (-)
5 X16 20LG RADIO 12V OUTPUT
6 X13 16BK/RD FUSED IGNITION SWITCH OUTPUT
7 X52 18GY/DB RIGHT REAR SPEAKER (+)
8 X58 18DB/PK RIGHT REAR SPEAKER (-)
9 X51 18BR/YL LEFT REAR SPEAKER (+)
10 X57 18BR/LB LEFT REAR SPEAKER (-)
11 - -
12 Z9 16BK/WT GROUND
THROTTLE POSITION SENSOR (2.4L) - WHITE/BLUE 3 WAY
CAV CIRCUIT FUNCTION
1 K7 18OR 5 VOLT SUPPLY
2 K4 18BK/LB SENSOR GROUND 1
3 K22 18OR/DB THROTTLE POSITION SENSOR NO. 1 SIGNAL
TJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 49
THROTTLE POSITION SENSOR (4.0L) - 3 WAY
CAV CIRCUIT FUNCTION
1 K7 20OR 5-VOLT SUPPLY
2 K4 20BK/LB SENSOR GROUND 1
3 K22 18OR/DB THROTTLE POSITION SENSOR NO. 1 SIGNAL
TORQUE CONVERTER CLUTCH SOLENOID - BLACK 2 WAY
CAV CIRCUIT FUNCTION
A F12 20RD/LG FUSED IGNITION SWITCH OUTPUT (RUN-START)
B T23 18OR/LG TRANSMISSION LOW/OVERDRIVE SOLENOID
TRANSFER CASE SWITCH (EXCEPT OFF-ROAD PACKAGE) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
A G107 20BK/RD 4WD INDICATOR
B Z1 18BK GROUND
TRANSFER CASE SWITCH (OFF-ROAD PACKAGE) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 K77 18BR/WT TRANSFER CASE POSITION SENSOR INPUT
2 K4 18BK/LB SENSOR GROUND 1
8W - 80 - 50 8W-80 CONNECTOR PIN-OUTS TJ
TRANSMISSION CONTROL MODULE - 60 WAY
CAV CIRCUIT FUNCTION
1 T1 18LG/BK TRS T1 SENSE
2 - -
3 T3 18VT TRS T3 SENSE
4 - -
5 - -
6 K24 18GY/BK CRANKSHAFT POSITION SENSOR SIGNAL
7 D21 18PK SCI TRANSMIT
8 T141 18YL/RD FUSED IGNITION SWITCH OUTPUT (START)
9 T9 18OR/BK OVERDRIVE PRESSURE SWITCH SENSE
10 T10 18YL/DG TORQUE MANAGEMENT REQUEST SENSE
11 F15 18DB/WT FUSED IGNITION SWITCH OUTPUT (RUN-START)
12 K22 18OR/DB THROTTLE POSITION SENSOR SIGNAL
13 T13 18DB/BK SPEED SENSOR GROUND
14 T14 18LG/WT OUTPUT SPEED SENSOR SIGNAL
15 K30 18PK TRANSMISSION CONTROL RELAY CONTROL
16 T16 16RD TRANSMISSION CONTROL RELAY OUTPUT
17 T16 16RD TRANSMISSION CONTROL RELAY OUTPUT
18 T56 18DG/LB OVERDRIVE OFF SWITCH INDICATOR
19 T19 16WT 2-4 SOLENOID CONTROL
20 T20 16LB LOW/REVERSE SOLENOID CONTROL
21 - -
22 - -
23 - -
24 - -
25 - -
26 - -
27 - -
28 - -
29 - -
30 - -
31 - -
32 - -
33 - -
34 - -
35 - -
36 - -
37 - -
38 - -
39 - -
40 - -
TJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 51
TRANSMISSION CONTROL MODULE - 60 WAY
CAV CIRCUIT FUNCTION
41 T411 18WT/PK TRS T41 SENSE
42 T42 16VT/WT TRS T42 SENSE
43 D25 18VT/YL PCI BUS
44 - -
45 - -
46 D20 18LG SCI RECEIVE
47 T47 18YL/BK 2-4 PRESSURE SWITCH SENSE
48 - -
49 T6 18OR/WT OVERDRIVE OFF SWITCH SENSE
50 T50 18DG LOW/REVERSE PRESSURE SWITCH SENSE
51 K4 18BK/LB SENSOR GROUND 1
52 T52 18RD/BK INPUT SPEED SENSOR SIGNAL
53 Z112 16BK GROUND
54 T54 18VT TRANSMISSION TEMPERATURE SENSOR SIGNAL
55 - -
56 A30 16RD/WT FUSED B(+)
57 Z113 16BK/YL GROUND
58 - -
59 T59 16PK UNDERDRIVE SOLENOID CONTROL
60 T60 16BR OVERDRIVE SOLENOID CONTROL
TRANSMISSION RANGE INDICATOR ILLUMINATION (PRNDL) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 E2 20OR FUSED PANEL LAMPS DIMMER SWITCH SIGNAL
2 Z1 20BK GROUND
TRANSMISSION RANGE SENSOR - 10 WAY
CAV CIRCUIT FUNCTION
1 F20 20VT/WT FUSED IGNITION SWITCH OUTPUT (RUN)
2 - -
3 T13 18DB/BK SPEED SENSOR GROUND
4 T54 18VT TRANSMISSION TEMPERATURE SENSOR SIGNAL
5 T41 20BK/WT PARK/NEUTRAL POSITION SWITCH SENSE (T41)
6 L1 20VT/BK BACK-UP LAMP FEED
7 T1 18LG/BK TRS T1 SENSE
8 T3 18VT TRS T3 SENSE
9 T42 16VT/WT TRS T42 SENSE
10 T411 18WT/PK TRS T41 SENSE
8W - 80 - 52 8W-80 CONNECTOR PIN-OUTS TJ
TRANSMISSION SOLENOID/PRESSURE SWITCH ASSEMBLY - 10 WAY
CAV CIRCUIT FUNCTION
1 T60 16BR OVERDRIVE SOLENOID CONTROL
2 T59 16PK UNDERDRIVE SOLENOID CONTROL
3 T16 16RD TRANSMISSION CONTROL RELAY OUTPUT
4 T19 16WT 2-4 SOLENOID CONTROL
5 T47 18YL/BK 2-4 PRESSURE SWITCH SENSE
6 T9 18OR/BK OVERDRIVE PRESSURE SWITCH SENSE
7 T20 16LB LOW/REVERSE SOLENOID CONTROL
8 - -
9 - -
10 T50 18DG LOW/REVERSE PRESSURE SWITCH SENSE
UNDERHOOD LAMP - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 Z1 18BK GROUND
2 M1 20PK/WT FUSED B(+)
VEHICLE SPEED SENSOR - BLACK 3 WAY
CAV CIRCUIT FUNCTION
1 K6 18VT/WT 5V SUPPLY
2 K4 20BK/LB SENSOR GROUND 1
3 G7 18WT/OR VEHICLE SPEED SENSOR SIGNAL
TJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 53
8W-91 CONNECTOR/GROUND/SPLICE LOCATION
TABLE OF CONTENTS
page
CONNECTOR/GROUND/SPLICE LOCATION
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
CONNECTOR/GROUND/SPLICE
LOCATION
DESCRIPTION
Thi s secti on provi des i l l ustrati ons i denti fyi ng con-
nector, ground, and spl i ce l ocati ons i n the vehi cl e.
Connector, ground, and spl i ce i ndexes are provi ded.
Use the wi ri ng di agrams i n each secti on for connec-
tor, ground, and spl i ce i denti fi cati on. Refer to the
i ndex for the proper fi gure number. For i tems that
are not shown i n thi s secti on N/S i s pl aced i n the
Fi g. col umn.
CONNECTORS
Connector Name/Number Color Location Fig.
A/C Compressor Clutch BK At A/C Compressor Clutch 4, 5
A/C Heater Control - C1 Center of Instrument Panel 24, 27
A/C Heater Control - C2 Center of Instrument Panel 24, 27
A/C Heater Control - C3 Center of Instrument Panel 24, 27
A/C High Pressure Switch BK Left Side of Engine 4
A/C Low Pressure Switch GN Near Powertrain Control Module 5, 10, 16
A/C Pressure Transducer
(2.4L)
BK Near Compressor 5, 10
Airbag Control Module YL Front of Floor Pan Tunnel 18
Ambient Temperature Sensor GY Left Front Fender Side Shield 1
Axle Lock Switch(Off Road) Near Cigar Lighter 24
Back-up Lamp Switch (M/T) BK Right Side of Transmission 32, 33, 34
Battery Temperature Sensor BK Under Battery Tray 7, 8
Blend Door Actuator On HVAC Harness N/S
Blower Motor On HVAC Harness N/S
Blower Motor Relay BK On HVAC Harness N/S
Blower Motor Resistor Block On HVAC Harness N/S
Brake Lamp Switch GY Top of Brake Pedal Bracket 20
Brake Transmission Shift
Interlock Solenoid
WT Near Steering Column N/S
Brake Warning Indicator Switch BK On Brake Master Cylinder 7
C103 BK Rear of Engine Compartment 7, 8, 15, 16
C104 (LHD) GY Rear of Engine Compartment 7, 15, 16
C104 (RHD) GY Rear of Engine Compartment 8, 16
C107 (LHD) YL Left Kick Panel 19, 20, 35
C107 (RHD) YL Right Kick Panel, see LHD Similar 21
TJ 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 1
Connector Name/Number Color Location Fig.
C109 (A/T) LT-GY Rear of Engine Compartment 7, 8, 15
C110 BK Left Fender Side Shield 1, 7
C115 (Off Road) BK Top of Locker Pump Bracket 29
C116 (Off Road) LT-GY Top of Locker Pump Bracket 29
C120 (2.4L) BK Right side of Radiator Fan Shroud 5, 10
C154 BK Top Right Side of Transmission 32
C170 (LHD) NAT Left Kick Panel 20, 22
C170 (RHD) NAT Right Kick Panel 22, 25
C180 BK Below Evap/Purge Solenoid N/S
C181 BK Left Rear of Engine Head 3
C182 BK Left Rear of Engine Head 3
C202 (LHD) GY Left Kick Panel 20, 22, 35
C202 (RHD) GY Right Kick Panel 21, 22,25
C203 (LHD) GN Left Kick Panel 24
C203 (RHD) GN Right Kick Panel 27
C205 LT GN Left Kick Panel 23, 25
C324 (Speaker Pod) WT/BK Right Side of Sport Bar N/S
C325 (Speaker Pod) WT/BK Left Side of Sport Bar 35, 36
C326 (Hard Top) BK Left Rear Quarter Panel 35, 36
C329 (Export) BK Left Rear of Rear Bumper 39
Camshaft Position Sensor
(4.0L)
BK Right Side of Engine 6
Camshaft Position Sensor
(2.4L)
BK Right Front Corner of Engine Head, behind
Air Cleaner
N/S
Capacitor At Right Rear of Engine 14
Center High Mounted Stop
Lamp
BK Near Right Rear Lamp Assembly 39, 40
Cigar Lighter/Power Outlet RD Rear of Cigar Lighter 24, 26
Circuit Breaker GY Near Day Time Running Lamp Module 17, 19
Clockspring - C1 NAT Rear of Clockspring 28
Clockspring - C2 YL Rear of Clockspring 28
Clutch Pedal Position Switch
(M/T)
BK Top of Clutch Pedal Bracket 19, 20
Compass/Temperature Mirror BK At Top Center of Windshield N/S
Controller Anti-Lock Brake BK Rear Left Side of Dash Panel 7
Crankshaft Position Sensor
(4.0L)
BK At Rear of Intake Manifold 6, 12, 33
Crankshaft Position Sensor
(2.4L)
BK Left Bellhousing N/S
Data Link Connector BK Bottom Driver Side of Instrument Panel 20, 25
Daytime Running Lamp
Module (Except Export)
BK Left Side of Engine Compartment N/S
Driver Airbag Squib YL Under Horn Pad N/S
Driver Door Ajar Switch NAT At ЉAЉ Pillar 20, 21
8W - 91 - 2 8W-91 CONNECTOR/GROUND/SPLICE LOCATION TJ
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Connector Name/Number Color Location Fig.
Engine Coolant Temperature
Sensor
BK On Thermostat Housing 4, 15
Engine Oil Pressure Switch
(4.0L)
BK Right Side of Engine Block 12
Engine Oil Pressure Switch
(2.4L)
BK Below A/C Compressor N/S
Engine Starter Solenoid At Starter Motor 3
Evap/Purge Solenoid BK Left Fender Side Shield 7, 9
Front Locker Indicator Switch
(Off Road)
BK Top of Front Differential 30
Front Locker Pump (Off Road) BK Top of Locker Pump Bracket 29
Front Washer Pump BK Under Washer Fluid Reservoir 1
Front Wiper Motor BK At Motor 11
Fuel Injector NO.1 (4.0L) BK At Injector 4
Fuel Injector NO.2(4.0L) BK At Injector 4
Fuel Injector NO.3(4.0L) BK At Injector 4
Fuel Injector NO.4(4.0L) BK At Injector 4
Fuel Injector NO.5(4.0L) BK At Injector 4
Fuel Injector NO.6(4.0L) BK At Injector 4
Fuel Pump Module BK Above Fuel Tank 37
G Switch BK Near T/O for Controller Anti-Lock Brake 18
Generator BK Rear of Generator 3, 6
Ground Strap Attached to Center of Hood 7
Headlamp Leveling Switch
(Export)
WT At Switch 22, 25
Horn BK Left Front Fender Side Shield 1
Idle Air Control Motor BK Side of Throttle Body 3, 4
Ignition Coil Capacitor BK Right Rear of Engine Head 6, 14
Ignition Coil Pack (2.4L) GY Right Side of Engine 3
Ignition Coil Pack (4.0L) BK Right Rear of Engine 6, 12
Ignition Switch On Steering Column 28
Input Speed Sensor BK Left Center of Trans 13
Instrument Cluster - C1 Rear of Cluster 22, 25
Instrument Cluster - C2 Rear of Cluster 22, 25
Intake Air Temperature Sensor GY Rear of Intake Manifold 4
Leak Detection Pump BK Right Rear Quarter, Forward of Tail Lamp
Assembly
38
Left Courtesy Lamp BK Left Side of Instrument Panel 22, 25
Left Dome Lamp WT In Left Speaker Pod N/S
Left Fog Lamp (Except Export) BK At Lamp, See Right N/S
Left Front Park/Turn Signal
Lamp (Except Export)
BK At Lamp, See Right N/S
Left Front Position Lamp
(Export)
BK At Lamp 1
TJ 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 3
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Connector Name/Number Color Location Fig.
Left Front Speaker BK At Speaker 22, 25
Left Front Turn Signal Lamp
(Export)
BK At Lamp, See Right N/S
Left Front Wheel Speed
Sensor
BK Left Side of Engine Compartment Near
Hydraulic Control Unit
7
Left Headlamp BK Rear of Lamp 1
Left Headlamp Leveling Motor
(Export)
BK Near Headlamp at Motor 1
Left License Lamp (Export) GY At Lamp 39, 40
Left Rear Lamp Assembly BK At Lamp 39, 40
Left Rear Speaker BK In Left Speaker/lamp Pod N/S
Left Rear Wheel Speed Sensor BK Near Vehicle Speed Sensor T/O 37
Left Side Marker Lamp GY At Lamp, See Right N/S
Left Side Repeater Lamp
(Export)
GY At Lamp, See Right N/S
Manifold Absolute Pressure
Sensor
BK Side of Throttle Body 3, 4
Multi-Function Switch C1 GY Steering Column 28
Multi-Function Switch C2 BK Steering Column 28
Output Speed Sensor BK Rear Left Side of Trans 13
Overdrive Off Switch Center of Instrument Panel 24, 26
Oxygen Sensor 1/1 Upstream On Front Exhaust Pipe 4, 14
Oxygen Sensor 1/2
Downstream
BK Rear of Catalytic Converter 4, 13, 34
Oxygen Sensor 2/1 Upstream
(4.0L California/European III)
Near Idle Air Control Motor T/O 4, 13
Oxygen Sensor 2/2
Downstream (4.0L California/
European III)
GY T/O near Ignition Coil Pack T/O 6, 12, 13
Park Brake Switch Left of Seat Belt Switch 18
Passenger Airbag YL Rear of Airbag 17, 19
Passenger Airbag On/Off
Switch
Lower Center of Instrument Panel 24
Passenger Door Ajar Switch BK Near Top Hinge of Passenger Door 17, 19
Power Distribution Center BK Engine Compartment Right or Left Fenter 7, 8
Power Outlet Center of Instrument Panel 24, 26
Power Steering Pressure
Switch (2.4L)
BK Near Power Steering Pump 3
Powertrain Control Module -
C1 (LHD)
BK Right Rear of Engine Compartment 14, 16
Powertrain Control Module -
C1 (RHD)
BK Left Rear of Engine Compartment N/S
Powertrain Control Module -
C2 (LHD)
WT Right Rear of Engine Compartment 14, 16
Powertrain Control Module -
C2 (RHD)
WT Left Rear of Engine Compartment N/S
8W - 91 - 4 8W-91 CONNECTOR/GROUND/SPLICE LOCATION TJ
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Connector Name/Number Color Location Fig.
Powertrain Control Module -
C3 (LHD)
GY Right Rear of Engine Compartment 7, 14
Powertrain Control Module -
C3 (RHD)
GY Left Rear of Engine Compartment 8
Radiator Fan Motor Circuit
Breaker (2.4L)
BK On Right Radiator Fan Shroud 5
Radiator Fan Motor (2.4L) BK On Right Radiator Fan Shroud 5
Radiator Fan Relay (2.4L) BK On exterior of PDC, Engine side 10
Radio GY Rear of Radio 24, 27
Rear Fog Lamp (Export) BK At Lamp 39, 40
Rear Locker Indicator Switch
(Off Road)
BK Top of Rear Differential 31
Rear Locker Pump (Off Road) LT-GY Top of Locker Pump Bracket 29
Rear Washer Pump (Hard Top) BK Under Washer Fluid Reservoir 1, 9
Rear Window Defogger At Rear Window 35, 36
Rear Window Defogger Switch
(Hard Top)
GY Behind Rear Window Defogger Switch 24, 26
Rear Wiper Motor (Hard Top) BK At Rear Wiper Motor 35, 36
Rear Wiper/Washer Switch
(Hard Top)
WT Behind Rear Wiper/Washer Switch 24, 26
Right Courtesy Lamp BK Right Side of Instrument Panel 23, 25
Right Dome Lamp WT In Right Speaker Pod
Right Fog Lamp (Except
Export)
BK At Lamp 2
Right Front Park/Turn Signal
Lamp (Except Export)
BK At Lamp 2
Right Front Position Lamp
(Export
BK At Lamp 2
Right Front Speaker BK At Speaker 23, 25
Right Front Turn Signal Lamp
(Export)
BK At Lamp 2
Right Front Wheel Speed
Sensor
BK Rear of Engine N/S
Right Headlamp BK Rear of Lamp 2
Right Headlamp Leveling
Motor (Export)
BK Near Headlamp at Motor 2
Right License Lamp GY At Lamp 39, 40
Right Rear Lamp Assembly BK At Lamp 39, 40
Right Rear Speaker BK In Right Speaker/lamp Pod N/S
Right Rear Wheel Speed
Sensor
BK Near Vehicle Speed Sensor T/O 37
Right Side Marker Lamp
(Except Export)
GY At Lamp 2
Right Side Repeater Lamp GY At Lamp 2
Seat Belt Switch BK Near Park Brake Switch 18, 36
TJ 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 5
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Connector Name/Number Color Location Fig.
Sentry Key Immobilizer Module BK At Immobilizer 28
Speed Control Servo BK Left Side Engine Compartment 7, 9
Subwoofer LT-GY Floor Pan 18
Throttle Position Sensor WT Side of Throttle Body 4, 15
Transfer Case Position Switch BK Left Side of Transfer Case 29
Transmission Control Module BK On Left Fender Shield 9
Transmission Range Indicator
Illumination (PRNDL)
BK Between Seats 18
Transmission Range Sensor GN Left Center of Transmission 13
Transmission Solensid/
Pressure Switch Assembly
NAT Right Center of Transmission 12
Underhood Lamp BK Under Hood 7, 8, 15
Vehicle Speed Sensor BK Left Rear of Transfer Case 29
GROUNDS
Connector Name/
Number
Location Fig.
G100 Rear Center of Engine Compartment 7, 8
G101 Rear Center of Engine Compartment 7
G102 Left Radiator Closure Panel 1
G103 Right Radiator Closure Panel 2
G104 Near Generator N/S
G105 Right Rear of Engine Block (4.0L) Near Left Engine Mount
(2.4L)
36, 12
G106 Right Rear of Engine Block N/S
G107 Right Rear of Engine Block N/S
G110 (2.4L) Near Left Engine Mount 3, 12
G111 Near Right Rear of Engine 6
G190 Near Right Headlamp 10
G191 Near Right Headlamp 10
G200 (LHD) Left Rear of Instrument Panel 20
G200 (RHD) Right Rear of Instrument Panel 25
G201 (LHD) Left Rear of Instrument Panel 20
G201 (RHD) Right Rear of Instrument Panel 25
G202 (LHD) Right Rear of Instrument Panel 23
G202 (RHD) Left Rear of Instrument Panel 25
G203 (LHD) Right Rear of Instrument Panel 23
G203 (RHD) Left Rear of Instrument Panel 25
G204 (RHD) Center of Instrument Panel 25
G300 (LHD) Left Kick Panel 20
G300 (RHD) Right Kick Panel 21
G301 (LHD) At Base of Center Stack 18
G301 (RHD) Left Kick Panel 19
8W - 91 - 6 8W-91 CONNECTOR/GROUND/SPLICE LOCATION TJ
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Connector Name/
Number
Location Fig.
G302 (LHD) Left Kick Panel 20
G302 (RHD) Right Kick Panel 21
G303 (LHD) Near Steering Column Mounting Bracket N/S
G303 (RHD) Near Right Kick Panel N/S
SPLICES
Splice Number Location Fig.
S101 Near T/O for Power Distribution Center 7, 8
S102 Near T/O for G100 or Daytime Running Lamp Module 7, 8
S103 Near T/O for G101 7, 8
S105 Near T/O for Daytime Running Lamp Module N/S
S106 Near T/O for G100 7, 8
S108 Near T/O for Power Distribution Center 7, 8
S111 Near T/O for Battery Temperature Sensor or Power
Distribution Center
7, 8
S113 Near T/O for G100 7, 8
S115 At Left Fender Shield Harness Tie Down 1
S116 (Except-Export) Near T/O for Front Washer Pump 1
S117 Near T/O for Horn 1
S118 Near Left Headlamp T/O 1
S121 Near T/O for Powertrain Control Module - C2 16
S122 Near Grommet for Left Front Turn Signal Lamp, See Right N/S
S123 (4.0L) Near T/O for G105 12
S123 (2.4L) Near T/O for Ignition Coil Pack N/S
S124 (4.0L) Near T/O for 2/1 Oxygen Sensor 4
S124 (2.4L) Near T/O for Ignition Coil Pack N/S
S125 (Export) Near Grommet for Right Front Turn Signal Lamp 2
S126 Near T/O for C104 16
S127 Near T/O for Idle Air Control Motor(4.0L) 4
S128 (4.0L) Between Fuel Injector NO. 2 and Fuel Injector NO. 3 4
S128 (2.4L) Near T/O for C103 on Engine Harness N/S
S129 Near T/O for C104 16
S130 (4.0L) Near T/O for C104 16
S130 (2.4L) Near T/O for C103 on Engine Harness N/S
S132 (4.0L) Trans Harness 6, 12
S132 (2.4L) Near T/O for Engine Starter Solenoid N/S
S133 (4.0L) Trans Harness 6, 12
S133 (2.4L) Near T/O for Input Speed Sensor, See 4.0L N/S
S134 (4.0L) Near T/O for C154 16
S134 (2.4L) Between Engine Starter Solenoid and C182 N/S
S135 (4.0L) Near T/O for Oxygen Sensor 1/2 Downstream N/S
TJ 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 7
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Splice Number Location Fig.
S135 (2.4L) Between Engine Starter Solenoid and C182 N/S
S136 In Battery harness near PDC 16
S137 Near T/O for Throttle Position Sensor 4
S138 Middle of Radiator Closure Panel 2
S140 Near T/O for C104 N/S
S141 Near T/O for Left Front Turn Signal Lamp, See Right N/S
S142 Near T/O for Right Front Turn Signal Lamp 2
S143 Near T/O for Left Front Park/Turn Signal Lamp, See Right N/S
S144 Near T/O for Right Front Park/Turn Signal Lamp 2
S145 (Export) Near T/O for Left Front Turn Signal Lamp N/S
S147 Between T/O’s for Underhood Lamp and C103, C104 7, 8
S150 Right Headlamp T/O 2
S151 Left Headlamp T/O N/S
S152 Near Left Headlamp T/O N/S
S153 Near T/O for Camshaft Position Sensor 6
S155 (Day Time
Running Lamps)
Near T/O for Day Time Running Lamp Module 7
S156 Near T/O for ABS Pump Motor 7
S157 (2.4L) Between Engine Starter Solenoid and C181 N/S
S157 (4.0L) Near T/O For PCM 16
S158 (2.4L) Near T/O For Power Steering Pressure Switch N/S
S159 (2.4L) Near T/O For Power Steering Pressure Switch N/S
S160 (2.4L) In T/O for Transmission Control Module N/S
S161 (2.4L) Near T/O for Ignition Coil Pack N/S
S162 (2.4L) Near T/O for Oxygen jSensor 1/1 Upstream N/S
S162 (4.0L) Near T/O For A/C Low Pressure Switch 16
S163 Between G101 and Right Front Wheel Speed Sensor 16
S164 Near T/O For Rer Locker Indicator Switch Inline C116 29
S170 6Љ(150 mm) From G100 T/O toward Brake Booster N/S
S171 8Љ(200 mm) From Batt Temp Sensor T/O toward G101 N/S
S172 Between G100 and C103 N/S
S173 Near G100 N/S
S176 In Fuel InjectorHarness N/S
S177 n Fuel InjectorHarness N/S
S178 Near T/O for C103 on Engine Harness N/S
S202 (LHD) Center of Instrument Panel 20
S202 (RHD) Center Rear of Instrument Panel 25
S204 Center Rear of Instrument Panel 24, 25
S206 Center Rear of Instrument Panel 24, 25
S207 Near Cigar Lighter T/O 24
S208 Near Blower Motor N/S
S209 Near T/O for C202, C203, and C204 20, 25, 26
8W - 91 - 8 8W-91 CONNECTOR/GROUND/SPLICE LOCATION TJ
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Splice Number Location Fig.
S210 Near T/O for A/C Heater Control C3 24, 27
S211 Near T/O for C202 20, 25
S212 Near T/O to Right Courtesy Lamp 20, 25
S213 Center Rear of Instrument Panel 23, 25
S214 Center Rear of Instrument Panel 23, 25
S215 Center Rear of Instrument Panel 23, 25
S216 Left Side of Instrument Panel 20
S217 Left Side of Instrument Panel 20
S302(LHD) In T/O to Steering Column 17
S302(RHD) Between S315 and S331, near T/O to ACM 19
S304 (LHD) Center Rear of Dash Panel, Near Front Wiper Motor T/O 17
S304 (RHD) Near T/O for C202 and C107 20
S309 Front of Left Door Opening 35
S310 Left Rear Quarter Panel, Near Body Grommet 19, 35
S311 Near Left Rear Lamp Assembly Connector 35, 36, 40
S315 Above Steering Column 17, 19
S316 In T/O for Rear Fog Lamp 39,40
S317 Near T/O for Left License Lamp 39, 40
S320 (LHD) Near T/O for C107 19 35
S320 (RHD) Near T/O for Fuse Block 19
S331 (LHD) Near T/O to Steering Column 17
S331 (RHD) Near T/O for Fuse Block 19
S335 (Except-Export) Near Left Rear Lamp Assembly Connector 35
S350 Near Fuse Block 19, 35
S351 Near T/O to Sport Bar 19, 35
S352 Forward of S351 19, 35
S353 Near T/O to Body Harness 17, 40
S354(Export) At Top of Right Kick Panel 19, 20, 35
S355 (LHD) Near T/O to Steering Column 17
S355 (RHD) Near T/O to Steering Column 20
S356 10Љ(254 mm) Forward from T/O to Rear Washer 19, 35
S357 20Љ(508 mm) Forward from T/O to Rear Washer 19, 35
S358 30Љ(762 mm) Forward from T/O to Rear Washer 19, 35
S359 Near Fuse Block 35
S360 Near T/O for Rear Window Defogger Feed 35, 36
S361 Near T/O for Rear Window Defogger Feed 35, 36
TJ 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 9
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
F
i
g
.
1
L
E
F
T
H
E
A
D
L
A
M
P
8W - 91 - 10 8W-91 CONNECTOR/GROUND/SPLICE LOCATION TJ
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
F
i
g
.
2
R
I
G
H
T
H
E
A
D
L
A
M
P
TJ 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 11
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
F
i
g
.
3
2
.
4
L
I
T
E
R
E
N
G
I
N
E
L
E
F
T
S
I
D
E
8W - 91 - 12 8W-91 CONNECTOR/GROUND/SPLICE LOCATION TJ
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
F
i
g
.
4
4
.
0
L
I
T
E
R
E
N
G
I
N
E
L
E
F
T
S
I
D
E
TJ 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 13
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
F
i
g
.
5
2
.
4
L
A
/
C
R
I
G
H
T
S
I
D
E
8W - 91 - 14 8W-91 CONNECTOR/GROUND/SPLICE LOCATION TJ
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
F
i
g
.
6
4
.
0
L
I
T
E
R
E
N
G
I
N
E
R
I
G
H
T
S
I
D
E
TJ 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 15
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
F
i
g
.
7
E
N
G
I
N
E
C
O
M
P
A
R
T
M
E
N
T
R
E
A
R
L
H
D
8W - 91 - 16 8W-91 CONNECTOR/GROUND/SPLICE LOCATION TJ
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
F
i
g
.
8
E
N
G
I
N
E
C
O
M
P
A
R
T
M
E
N
T
R
E
A
R
R
H
D
TJ 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 17
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
F
i
g
.
9
L
E
F
T
F
E
N
D
E
R
S
H
I
E
L
D
8W - 91 - 18 8W-91 CONNECTOR/GROUND/SPLICE LOCATION TJ
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Fig. 10 2.4 LITER RIGHT FENDER SHIELD
Fig. 11 FRONT WIPER MOTOR
TJ 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 19
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
F
i
g
.
1
2
4
.
0
L
I
T
E
R
E
N
G
I
N
E
A
N
D
T
R
A
N
S
8W - 91 - 20 8W-91 CONNECTOR/GROUND/SPLICE LOCATION TJ
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
F
i
g
.
1
3
4
.
0
L
I
T
E
R
E
N
G
I
N
E
A
N
D
T
R
A
N
S
L
E
F
T
TJ 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 21
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Fig. 14 2.4 LITER ENGINE PCM
Fig. 15 2.4 LITER REAR ENGINE
8W - 91 - 22 8W-91 CONNECTOR/GROUND/SPLICE LOCATION TJ
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Fig. 16 4.0 LITER ENGINE REAR
TJ 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 23
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
F
i
g
.
1
7
D
A
S
H
P
A
N
E
L
L
H
D
8W - 91 - 24 8W-91 CONNECTOR/GROUND/SPLICE LOCATION TJ
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
F
i
g
.
1
8
B
O
D
Y
H
A
R
N
E
S
S
TJ 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 25
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
F
i
g
.
1
9
D
A
S
H
P
A
N
E
L
R
H
D
8W - 91 - 26 8W-91 CONNECTOR/GROUND/SPLICE LOCATION TJ
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Fig. 20 LEFT COWL PANEL LHD
Fig. 21 RIGHT COWL PANEL RHD
TJ 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 27
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
F
i
g
.
2
2
L
E
F
T
S
I
D
E
I
N
S
T
R
U
M
E
N
T
P
A
N
E
L
L
H
D
8W - 91 - 28 8W-91 CONNECTOR/GROUND/SPLICE LOCATION TJ
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
F
i
g
.
2
3
R
I
G
H
T
S
I
D
E
I
N
S
T
R
U
M
E
N
T
P
A
N
E
L
L
H
D
TJ 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 29
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
F
i
g
.
2
4
C
E
N
T
E
R
I
N
S
T
R
U
M
E
N
T
P
A
N
E
L
L
H
D
8W - 91 - 30 8W-91 CONNECTOR/GROUND/SPLICE LOCATION TJ
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
F
i
g
.
2
5
I
N
S
T
R
U
M
E
N
T
P
A
N
E
L
R
H
D
TJ 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 31
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
F
i
g
.
2
6
C
E
N
T
E
R
I
N
S
T
R
U
M
E
N
T
P
A
N
E
L
R
H
D
8W - 91 - 32 8W-91 CONNECTOR/GROUND/SPLICE LOCATION TJ
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
F
i
g
.
2
7
R
I
G
H
T
A
N
D
C
E
N
T
E
R
I
N
S
T
R
U
M
E
N
T
P
A
N
E
L
R
H
D
TJ 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 33
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Fig. 28 STEERING COLUMN CONNECTIONS
8W - 91 - 34 8W-91 CONNECTOR/GROUND/SPLICE LOCATION TJ
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
F
i
g
.
2
9
T
R
A
N
S
F
E
R
C
A
S
E
TJ 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 35
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Fig. 30 FRONT LOCKER INDICATOR SWITCH
Fig. 31 REAR LOCKER INDICATOR SWITCH
8W - 91 - 36 8W-91 CONNECTOR/GROUND/SPLICE LOCATION TJ
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Fig. 32 MANUAL TRANSMISSION BUX
Fig. 33 MANUAL TRANSMISSION
TJ 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 37
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Fig. 34 MANUAL TRANS 2.4L
8W - 91 - 38 8W-91 CONNECTOR/GROUND/SPLICE LOCATION TJ
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
F
i
g
.
3
5
B
O
D
Y
C
O
N
N
E
C
T
O
R
S
L
H
D
TJ 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 39
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
F
i
g
.
3
6
B
O
D
Y
C
O
N
N
E
C
T
O
R
S
R
H
D
8W - 91 - 40 8W-91 CONNECTOR/GROUND/SPLICE LOCATION TJ
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Fig. 37 FUEL PUMP
Fig. 38 LEAK DETECTION PUMP
TJ 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 41
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Fig. 39 REAR LAMPS LHD
Fig. 40 REAR LAMPS RHD
8W - 91 - 42 8W-91 CONNECTOR/GROUND/SPLICE LOCATION TJ
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
8W-97 POWER DISTRIBUTION
TABLE OF CONTENTS
page page
POWER DISTRIBUTION
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SPECIAL TOOLS
POWER DISTRIBUTION SYSTEMS . . . . . . . . . 2
CIGAR LIGHTER OUTLET
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 2
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DIAGNOSIS AND TESTING - CIGAR LIGHTER
OUTLET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
FUSE BLOCK
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 3
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 4
IOD FUSE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 5
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 5
MICRO-RELAY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 6
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
DIAGNOSIS AND TESTING - MICRO-RELAY . . . 6
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 6
POWER DISTRIBUTION CENTER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DISASSEMBLY
POWER DISTRIBUTION CENTER
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 8
ASSEMBLY
POWER DISTRIBUTION CENTER
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11
POWER DISTRIBUTION CENTER SUPPORT
BRACKET
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12
POWER OUTLET
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 12
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
DIAGNOSIS AND TESTING - POWER OUTLET . 12
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 13
RELAY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 13
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
DIAGNOSIS AND TESTING - RELAY . . . . . . . . . 14
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14
POWER DISTRIBUTION
DESCRIPTION
Thi s group covers the vari ous standard and
opti onal power di stri buti on components used on thi s
model . The power di stri buti on system for thi s vehi cl e
consi sts of the fol l owi ng components:
• Power Di stri buti on Center (PDC)
• Fusebl ock
• Ci gar Li ghter Outl et
• Power Outl et
The power di stri buti on system al so i ncorporates
vari ous types of ci rcui t control and protecti on fea-
tures, i ncl udi ng:
• Bl ade-type fuses
• Cartri dge fuses
• Rel ays
Fol l owi ng are general descri pti ons of the major
components i n the power di stri buti on system. See the
owner’s manual i n the vehi cl e gl ove box for more
i nformati on on the features and use of al l of the
power di stri buti on system components. Refer to the
i ndex i n thi s servi ce manual for the l ocati on of com-
pl ete ci rcui t di agrams for the vari ous power di stri bu-
ti on system components.
OPERATION
The power di stri buti on system for thi s vehi cl e i s
desi gned to provi de safe, rel i abl e, and central i zed di s-
tri buti on poi nts for the el ectri cal current requi red to
operate al l of the many standard and opti onal facto-
ry-i nstal l ed el ectri cal and el ectroni c powertrai n,
chassi s, safety, securi ty, comfort and conveni ence sys-
tems. At the same ti me, the power di stri buti on sys-
tem was desi gned to provi de ready access to these
el ectri cal di stri buti on poi nts for the vehi cl e techni -
ci an to use when conducti ng di agnosi s and repai r of
faul ty ci rcui ts. The power di stri buti on system can
al so prove useful for the sourci ng of addi ti onal el ec-
TJ 8W-97 POWER DISTRIBUTION 8W - 97 - 1
tri cal ci rcui ts that may be requi red to provi de the
el ectri cal current needed to operate many accessori es
that the vehi cl e owner may choose to have i nstal l ed
i n the aftermarket.
SPECIAL TOOLS
POWER DISTRIBUTION SYSTEMS
CIGAR LIGHTER OUTLET
DESCRIPTION
An i nstrument panel ci gar l i ghter outl et i s stan-
dard factory-i nstal l ed equi pment on some model s.
Model s equi pped wi th the opti onal smoker’s package
wi l l i ncl ude a ci gar l i ghter knob and heati ng el e-
ment. Model s wi thout the smoker’s package are
equi pped wi th a snap fi t pl asti c cap and the outl et i s
treated as an extra accessory power outl et. The out-
l et i s i nstal l ed i n the i nstrument panel accessory
swi tch bezel , whi ch i s l ocated near the bottom of the
i nstrument panel center bezel area, bel ow the heater
and ai r condi ti oner control s.
The ci gar l i ghter outl et i s servi ced onl y as a part of
the accessory swi tch bezel uni t. I f the base i s faul ty
or damaged, the accessory swi tch bezel uni t must be
repl aced. The ci gar l i ghter knob and heati ng el ement
uni t i s avai l abl e for servi ce. Thi s component cannot
be repai red and, i f faul ty or damaged, i t must be
repl aced.
OPERATION
The ci gar l i ghter base or receptacl e shel l i s con-
nected to ground, and an i nsul ated contact i n the
bottom of the shel l i s connected to battery current.
The ci gar l i ghter recei ves battery vol tage from a fuse
(f13) i n the Power Di stri buti on Center (PDC) through
the i gni ti on swi tch, onl y when i n the Accessory or On
posi ti on and through a fuse (f19) i n the fusebl ock.Ј
The ci gar l i ghter knob and heati ng el ement are
encased wi thi n a spri ng-l oaded housi ng, whi ch al so
features a sl i di ng protecti ve heat shi el d. When the
knob and heati ng el ement are i nserted i n the recep-
tacl e shel l , the heati ng el ement resi stor coi l i s
grounded through i ts housi ng to the receptacl e shel l .
I f the ci gar l i ghter knob i s pushed i nward, the heat
shi el d sl i des up toward the knob exposi ng the heat-
i ng el ement, and the heati ng el ement extends from
the housi ng toward the i nsul ated contact i n the bot-
tom of the receptacl e shel l .
Two smal l spri ng-cl i p retai ners are l ocated on
ei ther si de of the i nsul ated contact i nsi de the bottom
of the receptacl e shel l . These cl i ps engage and hol d
the heati ng el ement of the ci gar l i ghter agai nst the
i nsul ated contact l ong enough for the resi stor coi l to
heat up. When the heati ng el ement i s engaged wi th
the contact, battery current can fl ow through the
resi stor coi l to ground, causi ng the resi stor coi l to
heat.
When the resi stor coi l becomes suffi ci entl y heated,
excess heat radi ates from the heati ng el ement caus-
i ng the spri ng-cl i ps to expand. Once the spri ng-cl i ps
expand far enough to rel ease the heati ng el ement,
the spri ng-l oaded housi ng forces the knob and heat-
i ng el ement to pop back outward to thei r rel axed
posi ti on. When the ci gar l i ghter knob and el ement
are pul l ed out of the receptacl e shel l , the protecti ve
heat shi el d sl i des downward on the housi ng so that
the heati ng el ement i s recessed and shi el ded around
i ts ci rcumference for safety.
DIAGNOSIS AND TESTING - CIGAR LIGHTER
OUTLET
For compl ete ci rcui t di agrams, refer to Wiring
Diagrams.
WARNING: REFER TO THE RESTRAINTS SECTION
OF THE SERVICE MANUAL BEFORE ATTEMPTING
ANY STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Remove the ci gar l i ghter knob and el ement
from the ci gar l i ghter receptacl e shel l . Check for con-
ti nui ty between the i nsi de ci rcumference of the ci gar
l i ghter receptacl e shel l and a good ground. there
shoul d be conti nui ty. I f OK, go to Step 2. I f not OK,
go to Step 3.
(2) Turn the i gni ti on swi tch to the On posi ti on.
Check for battery vol tage at the i nsul ated contact
l ocated at the back of the ci gar l i ghter receptacl e
Terminal Pick Kit 6680
8W - 97 - 2 8W-97 POWER DISTRIBUTION TJ
POWER DISTRIBUTION (Continued)
shel l . I f OK, repl ace the faul ty ci gar l i ghter knob and
el ement. I f not OK, go to Step 3.
(3) Turn the i gni ti on swi tch to the Off posi ti on.
Di sconnect and i sol ate the battery negati ve cabl e.
Remove the i nstrument panel accessory swi tch bezel .
Check for conti nui ty between the ground ci rcui t cav-
i ty #3 of the ci gar l i ghter wi re harness connector and
a good ground. There shoul d be conti nui ty. I f OK, go
to Step 4. I f not OK, repai r the open ground ci rcui t to
ground as requi red.
(4) Connect the battery negati ve cabl e. Turn the
i gni ti on swi tch to the Accessory or On posi ti ons.
Check for battery vol tage at cavi ty #1 of the ci gar
l i ghter wi re harness connector. I f OK, repl ace the
faul ty accessory swi tch bezel uni t. I f not OK, check
for bl own fuse i n the fusebl ock (f19) or i n the PDC
(f13). I f fuse i s bl own check for short ci rcui t. Repai r
the ci rcui t as requi red and repl ace bl own fuse.
FUSE BLOCK
DESCRIPTION
An el ectri cal fusebl ock modul e i s mounted on the
dash panel i n the passenger compartment of the
vehi cl e (Fi g. 1). The fusebl ock modul e serves to di s-
tri bute el ectri cal current to many of the accessory
systems i n the vehi cl e. The fusebl ock modul e houses
up to twenty bl ade-type mi ni fuses.
The mol ded pl asti c fusebl ock modul e housi ng has
an i ntegral mounti ng bracket that i s secured wi th
two screws to a bracket wel ded on the dash panel
just above the heater and ai r condi ti oner housi ng.
The gl ove box i s rol l ed down from the i nstrument
panel for servi ce access of the fusebl ock modul e
fuses. An adhesi ve-backed fuse l ayout map (Fi g. 2)i s
l ocated on the outsi de of the gl ove box bi n (Fi g. 3) to
ensure proper fuse i denti fi cati on.
The fusebl ock modul e i s i ntegral to the body wi re
harness. I f any i nternal ci rcui t or the fusebl ock mod-
ul e housi ng i s faul ty or damaged, the enti re fuse-
bl ock modul e and body harness uni t must be
repl aced.
OPERATION
Al l of the ci rcui ts enteri ng and l eavi ng the fuse-
bl ock modul e do so through the body wi re harness.
I nternal connecti on of al l of the fusebl ock modul e ci r-
cui ts i s accompl i shed by an i ntri cate combi nati on of
hard wi ri ng and bus bars. Refer to Wiring Dia-
grams for the l ocati on of compl ete fusebl ock modul e
ci rcui t di agrams.
REMOVAL
The fusebl ock modul e i s servi ced as a uni t wi th the
body wi re harness. I f any i nternal ci rcui t of the fuse-
bl ock modul e or i f the fusebl ock modul e housi ng i s
faul ty or damaged, the enti re fusebl ock modul e and
the body wi re harness uni t must be repl aced.
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
Fig. 1 Fuseblock Module Location
1 - FUSE BLOCK
2 - HEATER CASE
3 - GLOVE BOX OPENING
Fig. 2 Fuseblock Label
TJ 8W-97 POWER DISTRIBUTION 8W - 97 - 3
CIGAR LIGHTER OUTLET (Continued)
(2) Remove the i nstrument panel assembl y from
the dash panel (Refer to 23 - BODY/I NSTRUMENT
PANEL/I NSTRUMENT PANEL ASSEMBLY -
REMOVAL).
(3) Di sconnect each of the body wi re harness con-
nectors. Refer to Connector Locations i n Wi ri ng
for the l ocati on of the body wi re harness connector
l ocati ons.
(4) Remove al l of the fasteners that secure each of
the body wi re harness ground eyel ets to the vehi cl e
body and chassi s components. Refer to Connector
Locations i n Wi ri ng for the l ocati on of the body wi re
harness ground l ocati ons.
(5) Di sengage each of the retai ners that secure the
body wi re harness to the vehi cl e body and chassi s
components. Refer to Connector Locations i n Wi r-
i ng for the l ocati on of the body wi re harness retai ner
l ocati ons.
(6) Remove the two screws that secure the fuse-
bl ock modul e to the bracket on the dash panel (Fi g.
4).
(7) Remove the fusebl ock modul e and the body
wi re harness from the dash panel as a uni t.
INSTALLATION
The fusebl ock modul e i s servi ced as a uni t wi th the
body wi re harness. I f any i nternal ci rcui t of the fuse-
bl ock modul e or i f the fusebl ock modul e housi ng i s
faul ty or damaged, the enti re fusebl ock modul e and
the body wi re harness uni t must be repl aced.
NOTE: If the fuseblock module is being replaced
with a new unit, be certain to transfer each of the
fuses from the faulty fuseblock module to the
proper cavities of the replacement fuseblock mod-
ule. Refer to Fuse/Fuse Block in the index of this
service manual for the location of complete fuse-
block module circuit diagrams and cavity assign-
ments.
(1) Posi ti on the fusebl ock modul e and the body
wi re harness onto the dash panel as a uni t.
(2) I nstal l and ti ghten the two screws that secure
the fusebl ock modul e to the bracket on the dash
panel . Ti ghten the screws to 3.3 N·m (30 i n. l bs.).
(3) Engage each of the retai ners that secure the
body wi re harness to the vehi cl e body and chassi s
components. Refer to Connector Locations i n Wi r-
i ng for the l ocati on of the body wi re harness retai ner
l ocati ons.
(4) I nstal l al l of the fasteners that secure each of
the body wi re harness ground eyel ets to the vehi cl e
body and chassi s components. Refer to Connector
Locations i n Wi ri ng for the l ocati on of the body wi re
harness ground eyel et l ocati ons.
(5) Reconnect each of the body wi re harness con-
nectors. Refer to Connector Locations i n Wi ri ng
for the l ocati on of the body wi re harness connector
l ocati ons.
(6) I nstal l the i nstrument panel assembl y onto the
dash panel (Refer to 23 - BODY/I NSTRUMENT PAN-
EL/I NSTRUMENT PANEL ASSEMBLY - I NSTAL-
LATI ON).
(7) Reconnect the battery negati ve cabl e.
Fig. 3 Fuseblock Label Location
1 - GLOVE BOX DOOR
2 - FUSEBLOCK LABEL
3 - GLOVE BOX BIN
Fig. 4 Fuseblock Module Remove/Install
1 - BODY WIRE HARNESS
2 - BRACKET
3 - FUSEBLOCK MODULE
4 - SCREWS (2)
8W - 97 - 4 8W-97 POWER DISTRIBUTION TJ
FUSE BLOCK (Continued)
IOD FUSE
DESCRIPTION
Al l vehi cl es are equi pped wi th an I gni ti on-Off
Draw (I OD) fuse (Fi g. 5) that i s removed from i ts
cavi ty i n the Power Di stri buti on Center (PDC) when
the vehi cl e i s shi pped from the factory. Deal er per-
sonnel are to remove the I OD fuse from the storage
l ocati on and i nstal l i t i nto PDC fuse cavi ty 15 as part
of the preparati on procedures performed just pri or to
new vehi cl e del i very.
The PDC has a mol ded pl asti c cover that can be
unl atched and opened to provi de servi ce access to al l
of the fuses and rel ays i n the PDC. An i ntegral l atch
and hi nge tabs are mol ded i nto the PDC cover for
easy removal . A fuse l ayout map i s i ntegral to the
undersi de of the PDC cover to ensure proper fuse
and rel ay i denti fi cati on. The I OD fuse i s a 50 ampere
cartri dge-type fuse and, when removed, i t i s stored i n
the empty fuse cavi ty 11 of the PDC.
OPERATION
The term i gni ti on-off draw i denti fi es a normal con-
di ti on where power i s bei ng drai ned from the battery
wi th the i gni ti on swi tch i n the Off posi ti on. The I OD
fuse feeds the memory and sl eep mode functi ons for
many of the el ectroni c modul es i n the vehi cl e as wel l
as vari ous other accessori es that requi re battery cur-
rent when the i gni ti on swi tch i s i n the Off posi ti on,
i ncl udi ng the cl ock. The onl y reason the I OD fuse i s
removed i s to reduce the normal I OD of the vehi cl e
el ectri cal system duri ng new vehi cl e transportati on
and pre-del i very storage to reduce battery depl eti on,
whi l e sti l l al l owi ng vehi cl e operati on so that the
vehi cl e can be l oaded, unl oaded and moved as needed
by both vehi cl e transportati on company and deal er
personnel .
The I OD fuse i s removed from PDC fuse cavi ty #15
when the vehi cl e i s shi pped from the assembl y pl ant.
Deal er personnel must i nstal l the I OD fuse when the
vehi cl e i s bei ng prepared for del i very i n order to
restore ful l el ectri cal system operati on. Once the
vehi cl e i s prepared for del i very, the I OD functi on of
thi s fuse becomes transparent and the fuse that has
been assi gned the I OD desi gnati on becomes onl y
another Fused B(+) ci rcui t fuse. The I OD fuse serves
no useful purpose to the deal er techni ci an i n the ser-
vi ce or di agnosi s of any vehi cl e system or condi ti on,
other than the same purpose as that of any other
standard ci rcui t protecti on devi ce.
The I OD fuse can be used by the vehi cl e owner as
a conveni ent means of reduci ng battery depl eti on
when a vehi cl e i s to be stored for peri ods not to
exceed about thi rty days. However, i t must be
remembered that removi ng the I OD fuse wi l l not
el i mi nate I OD, but onl y reduce thi s normal condi ti on.
I f a vehi cl e wi l l be stored for more than about thi rty
days, the battery negati ve cabl e shoul d be di scon-
nected to el i mi nate normal I OD; and, the battery
shoul d be tested and recharged at regul ar i nterval s
duri ng the vehi cl e storage peri od to prevent the bat-
tery from becomi ng di scharged or damaged.
REMOVAL
The I gni ti on-Off Draw (I OD) fuse i s removed from
Power Di stri buti on Center (PDC) fuse cavi ty #15
when the vehi cl e i s shi pped from the assembl y pl ant.
Deal er personnel must i nstal l the I OD fuse when the
vehi cl e i s bei ng prepared for del i very i n order to
restore ful l el ectri cal system operati on.
(1) Turn the i gni ti on swi tch to the Off posi ti on.
(2) Unl atch and open the cover from the PDC.
(3) Remove the I OD fuse from fuse cavi ty #15 of
the PDC.
(4) Store the removed I OD fuse by i nserti ng the
termi nal bl ades of the fuse i nto the empty fuse cavi ty
#11 of the PDC.
(5) Cl ose and l atch the cover onto the PDC.
INSTALLATION
The I gni ti on-Off Draw (I OD) fuse i s removed from
Power Di stri buti on Center (PDC) fuse cavi ty #15
when the vehi cl e i s shi pped from the assembl y pl ant.
Deal er personnel must i nstal l the I OD fuse when the
Fig. 5 Ignition-Off Draw Fuse
1 - IGNITION-OFF DRAW FUSE
2 - IGNITION-OFF DRAW FUSE STORAGE LOCATION
3 - POWER DISTRIBUTION CENTER
TJ 8W-97 POWER DISTRIBUTION 8W - 97 - 5
vehi cl e i s bei ng prepared for del i very i n order to
restore ful l el ectri cal system operati on.
(1) Turn the i gni ti on swi tch to the Off posi ti on.
(2) Unl atch and open the cover from the PDC.
(3) Remove the stored I OD fuse from fuse cavi ty
#11 of the PDC.
(4) Al i gn the termi nal bl ades of the I OD fuse wi th
the termi nal receptacl es i n fuse cavi ty #15 of the
PDC.
(5) Use a thumb to press the I OD fuse fi rml y down
i nto PDC fuse cavi ty #15.
(6) Cl ose and l atch the cover onto the PDC.
MICRO-RELAY
DESCRIPTION
A mi cro-rel ay i s a conventi onal I nternati onal Stan-
dards Organi zati on (I SO) mi cro rel ay (Fi g. 6). Rel ays
conformi ng to the I SO speci fi cati ons have common
physi cal di mensi ons, current capaci ti es, termi nal pat-
terns, and termi nal functi ons. The rel ay i s contai ned
wi thi n a smal l , rectangul ar, mol ded pl asti c housi ng
and i s connected to al l of the requi red i nputs and
outputs by fi ve i ntegral mal e spade-type termi nal s
that extend from the bottom of the rel ay base.
Rel ays cannot be adjusted or repai red and, i f faul ty
or damaged, the uni t must be repl aced.
OPERATION
A mi cro-rel ay i s an el ectromechani cal swi tch that
uses a l ow current i nput from one source to control a
hi gh current output to another devi ce. The movabl e
common feed contact poi nt i s hel d agai nst the fi xed
normal l y cl osed contact poi nt by spri ng pressure.
When the rel ay coi l i s energi zed, an el ectromagneti c
fi el d i s produced by the coi l wi ndi ngs. Thi s el ectro-
magneti c fi el d draws the movabl e rel ay contact poi nt
away from the fi xed normal l y cl osed contact poi nt,
and hol ds i t agai nst the fi xed normal l y open contact
poi nt. When the rel ay coi l i s de-energi zed, spri ng
pressure returns the movabl e contact poi nt back
agai nst the fi xed normal l y cl osed contact poi nt. A
resi stor i s connected i n paral l el wi th the rel ay coi l i n
the rel ay, and hel ps to di ssi pate vol tage spi kes and
el ectromagneti c i nterference that can be generated as
the el ectromagneti c fi el d of the rel ay coi l col l apses.
DIAGNOSIS AND TESTING - MICRO-RELAY
(1) Remove the rel ay from i ts mounti ng l ocati on.
(2) A rel ay i n the de-energi zed posi ti on shoul d
have conti nui ty between termi nal s 87A and 30, and
no conti nui ty between termi nal s 87 and 30 (Fi g. 6). I f
OK, go to Step 3. I f not OK, repl ace the faul ty rel ay.
(3) Resi stance between termi nal s 85 and 86 (el ec-
tromagnet) shoul d be 67.5 - 82.5 ohms. I f OK, go to
Step 4. I f not OK, repl ace the faul ty rel ay.
(4) Connect a battery to termi nal s 85 and 86.
There shoul d now be conti nui ty between termi nal s
30 and 87, and no conti nui ty between termi nal s 87A
and 30. I f OK, rei nstal l the rel ay and use a DRBI I I ௡
scan tool to perform further testi ng. Refer to the
appropri ate di agnosti c i nformati on.
Refer to the appropri ate wi ri ng i nformati on. The
wi ri ng i nformati on i ncl udes wi ri ng di agrams, proper
wi re and connector repai r procedures, detai l s of wi re
harness routi ng and retenti on, connector pi n-out
i nformati on and l ocati on vi ews for the vari ous wi re
harness connectors, spl i ces and grounds.
REMOVAL
(1) Di sconnect and i sol ate the negati ve battery
cabl e.
(2) Remove the rel ay by graspi ng i t fi rml y and
pul l i ng i t strai ght out from i ts receptacl e. A sl i ght
back and fourth rocki ng moti on may hel p the
removal process.
INSTALLATION
(1) Al i gn the mi cro-rel ay termi nal s wi th the termi -
nal cavi ti es i n the receptacl e.
(2) Push fi rml y and evenl y on the top of the rel ay
unti l the termi nal s are ful l y seated i n the termi nal
cavi ti es i n the receptacl e.
(3) Connect the battery negati ve cabl e.
Fig. 6 ISO Micro Relay
30 - COMMON FEED
85 - COIL GROUND
86 - COIL BATTERY
87 - NORMALLY OPEN
87A - NORMALLY CLOSED
8W - 97 - 6 8W-97 POWER DISTRIBUTION TJ
IOD FUSE (Continued)
POWER DISTRIBUTION
CENTER
DESCRIPTION
Al l of the el ectri cal current di stri buted throughout
thi s vehi cl e i s di rected through the standard equi p-
ment Power Di stri buti on Center (PDC) (Fi g. 7). The
mol ded pl asti c PDC housi ng i s l ocated on the ri ght
si de of the engi ne compartment, forward of the bat-
tery on the top of the ri ght front i nner fender shi el d.
The PDC houses up to fi fteen maxi -type cartri dge
fuses, whi ch repl ace al l i n-l i ne fusi bl e l i nks. The PDC
al so houses up to thi rteen bl ade-type mi ni fuses, and
up to twel ve I nternati onal Standards Organi zati on
(I SO) rel ays (four standard-type and ei ght mi cro-
type).
The PDC housi ng i s secured i n the engi ne compart-
ment at four poi nts. I ntegral mounts on both si des of
the PDC housi ng engage and l atch to stanchi ons that
are i ntegral to the stamped steel PDC bracket. The
PDC bracket i s secured to the top of the ri ght front
i nner fender shi el d wi th three screws, two at the
front of the bracket and one at the rear. The PDC i s
i ntegral to the dash wi re harness, whi ch exi ts from
the bottom of the PDC housi ng. The PDC housi ng
has a mol ded pl asti c cover that i ncl udes two i ntegral
l atches at the rear and pi vot hooks at the front that
snap over a hi nge pi n on the front of the PDC hous-
i ng. The PDC cover i s easi l y opened or removed for
servi ce access and has a conveni ent fuse and rel ay
l ayout map i ntegral to the i nsi de surface of the cover
to ensure proper component i denti fi cati on.
The PDC cover, the PDC housi ng l ower cover, the
PDC rel ay wedges, the PDC rel ay cassettes and the
PDC B(+) termi nal stud modul e are avai l abl e for ser-
vi ce repl acement. The PDC mai n housi ng uni t, the
fuse wedges and the bus bars cannot be repai red and
are onl y servi ced as a uni t wi th the dash wi re har-
ness. I f the PDC mai n housi ng uni t, fuse wedges or
the bus bars are faul ty or damaged, the dash wi re
harness uni t must be repl aced.
OPERATION
Al l of the current from the battery and the gener-
ator output enters the PDC through two cabl es and a
si ngl e two-hol ed eyel et that i s secured wi th nuts to
the two PDC B(+) termi nal studs near the back of
the PDC housi ng. The mol ded pl asti c PDC cover i s
unl atched and opened to access the battery and gen-
erator output connecti on B(+) termi nal studs. I nter-
nal connecti on of al l of the PDC ci rcui ts i s
accompl i shed by an i ntri cate combi nati on of hard
wi ri ng and bus bars. Refer to theWiring secti on of
thi s servi ce manual for wi ri ng di agrams.
REMOVAL
The Power Di stri buti on Center (PDC) mai n hous-
i ng uni t, the PDC fuse wedges and the PDC bus bars
cannot be repai red and are onl y servi ced as a uni t
wi th the dash wi re harness. I f the PDC mai n housi ng
uni t, the fuse wedges or the bus bars are faul ty or
damaged, the enti re PDC and dash wi re harness uni t
must be repl aced.
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Di sconnect each of the dash wi re harness con-
nectors. Refer to Connector Locations i n the Wi r-
i ng secti on of thi s servi ce manual for the l ocati on of
the dash wi re harness connector l ocati ons.
(3) Remove al l of the fasteners that secure each of
the dash wi re harness ground eyel ets to the vehi cl e
body and chassi s components. Refer to Connector
Locations i n the Wi ri ng secti on of thi s servi ce man-
ual for the l ocati on of the ground eyel et l ocati ons.
(4) Di sengage each of the retai ners that secure the
dash wi re harness to the vehi cl e body and chassi s
components. Refer to Connector Locations i n the
Wi ri ng secti on of thi s servi ce manual for the l ocati on
of the dash wi re harness retai ner l ocati ons.
Fig. 7 Power Distribution Center Location
1 - POWER DISTRIBUTION CENTER (PDC)
2 - LATCHES
3 - COVER
4 - RIGHT FRONT FENDER
TJ 8W-97 POWER DISTRIBUTION 8W - 97 - 7
(5) Unl atch and open the PDC cover (Fi g. 8).
(6) Remove the two nuts that secure the eyel et ter-
mi nal of the battery posi ti ve cabl e take out and the
engi ne wi re harness generator output take out to the
PDC B(+) termi nal studs.
(7) Remove the battery posi ti ve cabl e take out and
the engi ne wi re harness generator output take out
eyel et termi nal from the B(+) termi nal studs.
(8) Di sengage the l atches on the PDC housi ng
mounts from the tabs on the PDC bracket stan-
chi ons, and pul l the PDC housi ng upward to di sen-
gage the mounts from the stanchi ons of the bracket.
(9) Remove the PDC and the dash wi re harness
from the engi ne compartment as a uni t.
DISASSEMBLY
POWER DISTRIBUTION CENTER DISASSEMBLY
The Power Di stri buti on Center (PDC) cover, the
PDC housi ng l ower cover, the PDC rel ay wedges, the
PDC rel ay cassettes and the PDC B(+) termi nal stud
modul e are avai l abl e for servi ce repl acement. The
PDC cover can be si mpl y unl atched and removed
from the PDC housi ng wi thout the PDC bei ng
removed or di sassembl ed. Servi ce of the remai ni ng
PDC components requi res that the PDC be removed
from i ts mounti ng and di sassembl ed. Refer to Wiring
Repair i n the i ndex of thi s servi ce manual for the
l ocati on of the proper wi ri ng repai r procedures.
PDC HOUSING LOWER COVER REMOVAL
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Unl atch and remove the cover from the PDC.
(3) Unl atch and remove the B(+) termi nal stud
cover from the PDC.
(4) Remove the two nuts that secure the eyel et ter-
mi nal to the two B(+) termi nal studs of the PDC.
(5) Remove the eyel et termi nal from the PDC B(+)
termi nal studs.
(6) Di sengage the l atches on the PDC mounts from
the tabs on the PDC bracket stanchi ons, and pul l the
PDC housi ng upward to di sengage the mounts from
the stanchi ons of the bracket.
(7) Usi ng a tri m sti ck or another sui tabl e wi de
fl at-bl aded tool , gentl y pry the l atches on each si de
and one end of the PDC housi ng that secure the
housi ng l ower cover to the PDC and remove the
housi ng l ower cover (Fi g. 9).
Fig. 8 Power Distribution Center
1 - POWER DISTRIBUTION CENTER (PDC)
2 - LATCHES
3 - COVER
4 - RIGHT FRONT FENDER
Fig. 9 PDC Housing Lower Cover Remove/Install -
Typical
1 - THROUGH FORMATION
2 - LATCHES (5)
3 - PDC HOUSING LOWER COVER
4 - WIRE HARNESS
8W - 97 - 8 8W-97 POWER DISTRIBUTION TJ
POWER DISTRIBUTION CENTER (Continued)
PDC B(+) TERMINAL MODULE REMOVAL
(1) Remove the PDC housi ng l ower cover.
(2) From the top of the PDC housi ng, use a smal l
screwdri ver or a termi nal pi ck tool (Speci al Tool Ki t
6680) to rel ease the two l atches that secure the B(+)
termi nal modul e i n the PDC (Fi g. 10).
(3) Gentl y and evenl y press the two B(+) termi nal
studs down through the bus bar i n the PDC.
(4) From the bottom of the PDC housi ng, remove
the B(+) termi nal modul e from the PDC (Fi g. 11).
PDC RELAY WEDGE REMOVAL
(1) Remove the PDC housi ng l ower cover.
(2) Remove each of the rel ays from the PDC rel ay
wedge to be removed.
(3) From the bottom of the PDC housi ng, use a
smal l screwdri ver or a termi nal pi ck tool (Speci al
Tool Ki t 6680) to rel ease the two l atches (yel l ow) that
secure the rel ay wedge to the PDC rel ay cassette.
(4) From the top of the PDC housi ng, remove the
rel ay wedge from the PDC rel ay cassette (Fi g. 12).
PDC RELAY CASSETTE REMOVAL
(1) Remove the rel ay wedge from the PDC rel ay
cassette to be removed.
NOTE: It may be necessary to remove relay cas-
settes that are not being serviced from the PDC
housing in order to obtain sufficient clearance to
service the faulty relay cassette. The same service
procedure is repeated as necessary to remove each
of the interfering relay wedges and relay cassettes
from the PDC housing.
Fig. 10 PDC B(+) Terminal Module Latches
1 - FROM SPECIAL TOOL KIT 6680
2 - PDC HOUSING
3 - LATCHES
4 - BUS BAR
5 - B+ TERMINAL STUDS
Fig. 11 PDC B(+) Terminal Module Remove/Install
1 - PDC HOUSING
2 - LATCHES
3 - B+ TERMINAL MODULE
4 - BUS BAR
Fig. 12 PDC Relay Wedge Remove/Install - Typical
1 - RELAY WEDGE
2 - PDC HOUSING
TJ 8W-97 POWER DISTRIBUTION 8W - 97 - 9
POWER DISTRIBUTION CENTER (Continued)
(2) From the top of the PDC housi ng, use a smal l
screwdri ver or a termi nal pi ck tool (Speci al Tool Ki t
6680) to rel ease the two l atches that secure the rel ay
cassette i n the PDC (Fi g. 13).
(3) Gentl y and evenl y press the rel ay cassette
down through the PDC housi ng.
(4) From the bottom of the PDC housi ng, remove
the rel ay cassette from the PDC (Fi g. 14).
CAUTION: Do not remove the wiring and terminals
from the terminal cavities of the faulty PDC relay
cassette at this time. Refer to the Assembly proce-
dure that follows for the proper procedures for
transferring the wiring and terminals to the replace-
ment PDC relay cassette.
ASSEMBLY
POWER DISTRIBUTION CENTER ASSEMBLY
PDC HOUSING LOWER COVER INSTALLATION
(1) Al i gn the PDC housi ng l ower cover to the bot-
tom of the PDC.
(2) Press the PDC housi ng l ower cover gentl y and
evenl y onto the PDC unti l each of the l atches that
secure the cover to the PDC i s ful l y engaged.
(3) Engage the mounts on the PDC housi ng wi th
the stanchi ons of the PDC bracket and push the uni t
downward unti l the mount l atches ful l y engage the
mounti ng tabs on the PDC bracket.
(4) I nstal l the eyel et termi nal over the two PDC
B(+) termi nal studs.
(5) I nstal l and ti ghten the two nuts that secure
the eyel et termi nal to the B(+) termi nal studs.
Ti ghten the nuts to 11.3 N·m (100 i n. l bs.).
(6) I nstal l the B(+) termi nal stud cover onto the
PDC.
(7) I nstal l the cover onto the PDC.
(8) Reconnect the battery negati ve cabl e.
PDC B+ TERMINAL MODULE INSTALLATION
(1) From the bottom of the PDC housi ng, al i gn and
i nsert the B(+) termi nal modul e i nto the PDC.
(2) From the bottom of the PDC housi ng, al i gn and
i nsert the two studs of the PDC B(+) termi nal mod-
ul e through the bus bar i n the PDC.
(3) From the bottom of the PDC housi ng, press the
B(+) termi nal modul e gentl y and evenl y i nto the PDC
unti l both of the l atches are ful l y engaged.
(4) I nstal l the PDC housi ng l ower cover.
PDC RELAY WEDGE INSTALLATION
(1) From the top of the PDC housi ng, al i gn and
i nsert the PDC rel ay wedge l atch arms i nto the cor-
rect cavi ti es i n the rel ay cassette.
(2) Gentl y and evenl y press the PDC rel ay wedge
down i nto the rel ay cassette unti l both of the l atches
are ful l y engaged.
(3) I nstal l each of the removed rel ays i nto the
proper cavi ti es of the PDC rel ay wedge.
(4) I nstal l the PDC housi ng l ower cover.
Fig. 13 PDC Relay Cassette Latches - Typical
1 - LATCHES
2 - FROM SPECIAL TOOL KIT 6680
3 - PDC RELAY CASSETTES
Fig. 14 PDC Relay Cassette Remove/Install - Typical
1 - PDC HOUSING
2 - PDC RELAY CASSETTE
3 - LATCHES
8W - 97 - 10 8W-97 POWER DISTRIBUTION TJ
POWER DISTRIBUTION CENTER (Continued)
PDC RELAY CASSETTE INSTALLATION
(1) Move the faul ty PDC rel ay cassette wi th i ts
wi ri ng away from the bottom of the PDC housi ng far
enough to al l ow the repl acement rel ay cassette to be
i nstal l ed i nto the PDC.
(2) Usi ng the faul ty rel ay cassette as a gui de, be
certai n that the repl acement rel ay cassette i s cor-
rectl y ori ented before i nstal l i ng i t i nto the PDC hous-
i ng.
(3) From the bottom of the PDC housi ng, al i gn and
i nsert the repl acement rel ay cassette i nto the PDC.
Press the rel ay cassette up i nto the PDC unti l both
of the l atches are ful l y engaged.
CAUTION: Proper care must be taken to be certain
that the wiring and terminals from the faulty PDC
relay cassette are installed in the correct terminal
cavities of the replacement relay cassette. To pre-
vent mistakes it is recommended that the wiring
and terminals be removed from the faulty relay cas-
sette one cavity at a time, repaired or spliced as
necessary, then installed securely into the correct
cavity of the replacement relay cassette. If you are
not absolutely certain into which cavity a terminal
should be installed, refer to Power Distribution in
the index of this service manual for the location of
complete PDC wiring diagrams.
(4) Whi l e pul l i ng gentl y on the wi re from the bottom
of the faul ty PDC rel ay cassette, use a termi nal pi ck
tool (Speci al Tool Ki t 6680) from the top of the rel ay
cassette to rel ease the l atch that secures the termi nal i n
the rel ay cassette termi nal cavi ty (Fi g. 15).
(5) From the bottom of the faul ty PDC rel ay cas-
sette, remove the wi re and termi nal from the rel ay
cassette termi nal cavi ty.
(6) Make al l necessary repai rs and spl i ces to the
wi re for the removed termi nal . Refer to Wiring
Repair i n the i ndex of thi s servi ce manual for the
l ocati on of the proper wi ri ng repai r procedures.
(7) From the bottom of the PDC housi ng, al i gn and
i nsert the removed wi re and termi nal i nto the correct
termi nal cavi ty of the repl acement rel ay cassette.
Push the wi re and termi nal up i nto the rel ay cassette
termi nal cavi ty unti l i t i s ful l y engaged by the l atch.
(8) Repeat Step 4, Step 5, Step 6 and Step 7 one wi re
and termi nal at a ti me unti l each of the wi res and ter-
mi nal s have been transferred from the faul ty PDC rel ay
cassette i nto the repl acement rel ay cassette.
(9) I nstal l the PDC rel ay wedge i nto the repl ace-
ment PDC rel ay cassette.
INSTALLATION
The Power Di stri buti on Center (PDC) mai n hous-
i ng uni t, the PDC fuse wedges and the PDC bus bars
cannot be repai red and are onl y servi ced as a uni t
wi th the dash wi re harness. I f the PDC mai n housi ng
uni t, the fuse wedges or the bus bars are faul ty or
damaged, the enti re PDC and dash wi re harness uni t
must be repl aced.
NOTE: If the PDC is being replaced with a new unit, be
certain to transfer each of the fuses and relays that
have not been included with the replacement PDC
from the faulty PDC to the proper cavities of the
replacement unit. Refer to Power Distribution in the
index of this service manual for the location of com-
plete PDC wiring diagrams and cavity assignments.
(1) Posi ti on the PDC and the dash wi re harness
uni t i n the engi ne compartment.
(2) Engage the mounts on the PDC housi ng wi th
the stanchi ons of the PDC bracket and push the uni t
downward unti l the mount l atches engage the
mounti ng tabs on the PDC bracket.
(3) I nstal l the eyel et termi nal of the battery posi -
ti ve cabl e take out and the engi ne wi re harness gen-
erator output take out onto the PDC B(+) termi nal
studs.
(4) I nstal l and ti ghten the two nuts that secure
the eyel et termi nal of the battery posi ti ve cabl e take
out and the engi ne wi re harness generator output
take out to the B(+) termi nal studs. Ti ghten the nuts
to 11.3 N·m (100 i n. l bs.).
(5) Engage the tabs on the l ower edge of the B(+)
termi nal stud cover i n the sl ots on the back of the
PDC housi ng, then engage the l atch on the top of the
cover wi th the l atch receptacl e on the PDC housi ng.
Fig. 15 PDC Relay Cassette Terminal Remove/Install
1 - TERMINAL CAVITIES
2 - PDC RELAY CASSETTE
3 - TERMINAL LATCHES
4 - FROM SPECIAL TOOL KIT 6680
TJ 8W-97 POWER DISTRIBUTION 8W - 97 - 11
POWER DISTRIBUTION CENTER (Continued)
(6) Engage each of the retai ners that secure the dash
wi re harness to the vehi cl e body and chassi s compo-
nents. Refer to Connector Locations i n the i ndex of
thi s servi ce manual for the l ocati on of more i nforma-
ti on on the dash wi re harness retai ner l ocati ons.
(7) I nstal l al l of the fasteners that secure each of the
dash wi re harness ground eyel ets to the vehi cl e body
and chassi s components. Refer to Connector Loca-
tions i n the i ndex of thi s servi ce manual for the l oca-
ti on of more i nformati on on the ground eyel et l ocati ons.
(8) Reconnect each of the dash wi re harness con-
nectors. Refer to Connector Locations i n the i ndex
of thi s servi ce manual for the l ocati on of more i nfor-
mati on on the dash wi re harness connector l ocati ons.
(9) Reconnect the battery negati ve cabl e.
POWER DISTRIBUTION
CENTER SUPPORT BRACKET
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve cabl e.
(2) Remove the Power Di stri buti on Center (PDC)
from the PDC bracket (Refer to 8 - ELECTRI CAL/
POWER DI STRI BUTI ON/POWER DI STRI BUTI ON
CENTER - REMOVAL).
(3) Remove the three screws that secure the PDC
bracket to the ri ght front i nner fender (Fi g. 16).
(4) Remove the PDC bracket from the ri ght front
i nner fender.
INSTALLATION
(1) Posi ti on the PDC bracket onto the ri ght front
i nner fender.
(2) I nstal l and ti ghten the three screws that secure
the PDC mounti ng bracket to the ri ght front i nner
fender. Ti ghten the screws to 3.9 N·m (35 i n. l bs.).
(3) I nstal l the PDC onto the PDC bracket (Refer to
8 - ELECTRI CAL/POWER DI STRI BUTI ON/POWER
DI STRI BUTI ON CENTER - I NSTALLATI ON).
(4) Reconnect the battery negati ve cabl e.
POWER OUTLET
DESCRIPTION
An i nstrument panel power outl et i s standard fac-
tory i nstal l ed equi pment on thi s model . The power
outl et i s i nstal l ed i n the i nstrument panel accessory
swi tch bezel , whi ch i s l ocated near the bottom of the
center bezel area bel ow the heater and ai r condi ti on-
i ng control s. The power outl et base i s secured by a
snap fi t wi thi n the i nstrument panel . A pl asti c pro-
tecti ve cap snaps i nto the power outl et base when the
power outl et i s not bei ng used, and hangs from the
power outl et base mount by an i ntegral bai l strap
whi l e the power outl et i s i n use.
The power outl et receptacl e uni t and the accessory
power outl et protecti ve cap are avai l abl e for servi ce.
The power outl et receptacl e cannot be repai red and,
i f faul ty or damaged, i t must be repl aced.
OPERATION
The power outl et base or receptacl e shel l i s con-
nected to ground, and an i nsul ated contact i n the
bottom of the shel l i s connected to battery current.
The power outl et recei ves battery vol tage from a fuse
i n the Power Di stri buti on Center at al l ti mes.
Whi l e the power outl et i s very si mi l ar to a ci gar
l i ghter base uni t, i t does not i ncl ude the two smal l
spri ng-cl i p retai ners i nsi de the bottom of the recepta-
cl e shel l that are used to secure the ci gar l i ghter
heati ng el ement to the i nsul ated contact.
DIAGNOSIS AND TESTING - POWER OUTLET
For compl ete ci rcui t di agrams, refer to Power
Outlet i n Wi ri ng Di agrams.
(1) Check the fused B(+) fuse i n the Power Di stri -
buti on Center. I f OK, go to Step 2. I f not OK, repai r
the shorted ci rcui t or component as requi red and
repl ace the faul ty fuse.
(2) Check for battery vol tage at the fused B(+) fuse
i n the Power Di stri buti on Center. I f OK, go to Step 3.
I f not OK, repai r the open fused B(+) ci rcui t to the
battery as requi red.
(3) Remove the pl asti c protecti ve cap from the
power outl et receptacl e. Check for conti nui ty between
Fig. 16 PDC Bracket
1 - SCREWS (3)
2 - RIGHT FRONT FENDER
3 - PDC BRACKET
8W - 97 - 12 8W-97 POWER DISTRIBUTION TJ
POWER DISTRIBUTION CENTER (Continued)
the i nsi de ci rcumference of the power outl et recepta-
cl e and a good ground. There shoul d be conti nui ty. I f
OK, go to Step 4. I f not OK, go to Step 5.
(4) Check for battery vol tage at the i nsul ated con-
tact l ocated at the back of the power outl et recepta-
cl e. I f not OK, go to Step 5.
(5) Di sconnect and i sol ate the battery negati ve
cabl e. Remove the power outl et receptacl e from the
i nstrument panel . Di sconnect the wi re harness con-
nector from the power outl et receptacl e. Check for
conti nui ty between the ground ci rcui t cavi ty of the
power outl et wi re harness connector and a good
ground. There shoul d be conti nui ty. I f OK, go to Step
6. I f not OK, repai r the open ground ci rcui t to ground
as requi red.
(6) Connect the battery negati ve cabl e. Check for
battery vol tage at the fused B(+) ci rcui t cavi ty of the
power outl et wi re harness connector. I f OK, repl ace
the faul ty power outl et receptacl e. I f not OK, repai r
the open fused B(+) ci rcui t to the Power Di stri buti on
Center fuse as requi red.
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Pul l the ci gar l i ghter knob and el ement out of
the ci gar l i ghter receptacl e base, or unsnap the pro-
tecti ve cap from the power outl et receptacl e base.
(3) Look i nsi de the ci gar l i ghter or power outl et
receptacl e base and note the posi ti on of the rectangu-
l ar retai ni ng bosses of the mount that secures the
receptacl e base to the i nstrument panel (Fi g. 17).
(4) I nsert a pai r of external snap ri ng pl i ers i nto
the ci gar l i ghter or power outl et receptacl e base and
engage the ti ps of the pl i ers wi th the retai ni ng
bosses of the mount.
(5) Squeeze the pl i ers to di sengage the mount
retai ni ng bosses from the receptacl e base and, usi ng
a gentl e rocki ng moti on, pul l the pl i ers and the
receptacl e base out of the mount.
(6) Pul l the receptacl e base away from the i nstru-
ment panel far enough to access the i nstrument
panel wi re harness connector.
(7) Di sconnect the i nstrument panel wi re harness
connector from the ci gar l i ghter or power outl et
receptacl e base connector receptacl e.
(8) Remove the ci gar l i ghter or power outl et mount
from the i nstrument panel .
INSTALLATION
(1) Reconnect the i nstrument panel wi re harness
connector to the ci gar l i ghter or power outl et recep-
tacl e base connector receptacl e.
(2) I nstal l the ci gar l i ghter or power outl et mount
i nto the i nstrument panel .
(3) Al i gn the spl i nes on the outsi de of the ci gar
l i ghter or power outl et receptacl e base connector
receptacl e wi th the grooves on the i nsi de of the
mount.
(4) Press fi rml y on the ci gar l i ghter or power out-
l et receptacl e base unti l the retai ni ng bosses of the
mount are ful l y engaged i n thei r receptacl es.
(5) I nstal l the ci gar l i ghter knob and el ement i nto
the ci gar l i ghter receptacl e base, or the protecti ve cap
i nto the power outl et receptacl e base.
(6) Reconnect the battery negati ve cabl e.
RELAY
DESCRIPTION
A rel ay i s an el ectromechani cal devi ce that
swi tches fused battery current to a el ectri cal compo-
nent when the i gni ti on swi tch i s turned to the Acces-
sory or Run posi ti ons, or when control l ed by a
el ectroni c modul e. The rel ays are l ocated i n the junc-
ti on bl ock or power di stri buti on center (Fi g. 18).
The rel ay i s a I nternati onal Standards Organi za-
ti on (I SO) rel ay. Rel ays conformi ng to the I SO speci -
fi cati ons have common physi cal di mensi ons, current
capaci ti es, termi nal patterns, and termi nal functi ons.
Fig. 17 Cigar Lighter and Power Outlet Remove/
Install
1 - KNOB AND ELEMENT
2 - RETAINING BOSSES-ENGAGE PLIERS HERE
3 - BASE
4 - PARTIALLY REMOVED
5 - EXTERNAL SNAP-RING PLIERS
6 - MOUNT
7 - BASE
TJ 8W-97 POWER DISTRIBUTION 8W - 97 - 13
POWER OUTLET (Continued)
A rel ay cannot be repai red or adjusted and, i f
faul ty or damaged, i t must be repl aced.
OPERATION
The I SO rel ay consi sts of an el ectromagneti c coi l , a
resi stor and three (two fi xed and one movabl e) el ectri cal
contacts. The movabl e (common feed) rel ay contact i s
hel d agai nst one of the fi xed contacts (normal l y cl osed)
by spri ng pressure. When the el ectromagneti c coi l i s
energi zed, i t draws the movabl e contact away from the
normal l y cl osed fi xed contact, and hol ds i t agai nst the
other (normal l y open) fi xed contact.
When the el ectromagneti c coi l i s de-energi zed,
spri ng pressure returns the movabl e contact to the
normal l y cl osed posi ti on. The resi stor i s connected i n
paral l el wi th the el ectromagneti c coi l i n the rel ay,
and hel ps to di ssi pate vol tage spi kes that are pro-
duced when the coi l i s de-energi zed.
DIAGNOSIS AND TESTING - RELAY
The rel ays are l ocated i n the juncti on bl ock or
power di stri buti on center. For compl ete ci rcui t di a-
grams, refer to Wiring Diagrams.
(1) Remove the rel ay from i ts mounti ng l ocati on.
(2) A rel ay i n the de-energi zed posi ti on shoul d
have conti nui ty between termi nal s 87A and 30, and
no conti nui ty between termi nal s 87 and 30. I f OK, go
to Step 3. I f not OK, repl ace the faul ty rel ay.
(3) Resi stance between termi nal s 85 and 86 (el ec-
tromagnet) shoul d be 60.7 - 80.3 ohms. I f OK, go to
Step 4. I f not OK, repl ace the faul ty rel ay.
(4) Connect a battery to termi nal s 85 and 86.
There shoul d now be conti nui ty between termi nal s
30 and 87, and no conti nui ty between termi nal s 87A
and 30. I f OK, perform the Rel ay Ci rcui t Test that
fol l ows. I f not OK, repl ace the faul ty rel ay.
DIAGNOSIS & TESTING - RELAY CIRCUIT TEST
(1) The rel ay common feed termi nal cavi ty (30) of
the juncti on bl ock or power di stri buti on center i s con-
nected to battery vol tage and shoul d be hot at al l
ti mes. Check for battery vol tage at the fused B(+) ci r-
cui t cavi ty i n the juncti on bl ock receptacl e for the
rel ay. I f OK, go to Step 2. I f not OK, repai r the fused
B(+) ci rcui t to the Power Di stri buti on Center (PDC)
fuse as requi red.
(2) The rel ay normal l y cl osed termi nal (87A) i s
connected to termi nal 30 i n the de-energi zed posi ti on,
but i s not used for thi s appl i cati on. Go to Step 3.
(3) The rel ay normal l y open termi nal (87) i s con-
nected to the common feed termi nal (30) i n the ener-
gi zed posi ti on. Thi s termi nal suppl i es battery vol tage
to the fused B(+) fuse i n the juncti on bl ock that feeds
the accessory when the rel ay i s energi zed by the i gni -
ti on swi tch. There shoul d be conti nui ty between the
juncti on bl ock cavi ty for rel ay termi nal 87 and the
fused B(+) fuse i n the juncti on bl ock at al l ti mes. I f
OK, go to Step 4. I f not OK, repai r the open fused
B(+) ci rcui t to the juncti on bl ock fuse as requi red.
(4) The coi l ground termi nal (85) i s connected to
the el ectromagnet i n the rel ay. I t recei ves battery
feed to energi ze the rel ay when the i gni ti on swi tch i s
i n the Accessory or Run posi ti ons. Turn the i gni ti on
swi tch to the On posi ti on. Check for battery vol tage
at the fused i gni ti on swi tch output (acc/run) ci rcui t
cavi ty for rel ay termi nal 85 i n the juncti on bl ock
receptacl e for the rel ay. I f OK, go to Step 5. I f not
OK, repai r the open fused i gni ti on swi tch output
(acc/run) ci rcui t to the i gni ti on swi tch as requi red.
(5) The coi l battery termi nal (86) i s connected to
the el ectromagnet i n the rel ay. The juncti on bl ock
cavi ty for thi s termi nal shoul d have conti nui ty to
ground at al l ti mes. I f not OK, repai r the open
ground ci rcui t to ground as requi red.
REMOVAL
(1) Di sconnect and i sol ate the negati ve battery
cabl e.
(2) Remove the rel ay by graspi ng i t fi rml y and
pul l i ng i t strai ght out from i ts receptacl e. A sl i ght
back and fourth rocki ng moti on may hel p the
removal process.
INSTALLATION
(1) Posi ti on the rel ay to the proper receptacl e.
(2) Al i gn the rel ay termi nal s wi th the termi nal
cavi ti es i n the receptacl e.
(3) Push fi rml y and evenl y on the top of the rel ay
unti l the termi nal s are ful l y seated i n the termi nal
cavi ti es i n the receptacl e.
(4) Connect the negati ve battery cabl e.
Fig. 18 ISO Relay
30 - COMMON FEED
85 - COIL GROUND
86 - COIL BATTERY
87 - NORMALLY OPEN
87A - NORMALLY CLOSED
8W - 97 - 14 8W-97 POWER DISTRIBUTION TJ
RELAY (Continued)
ENGINE
TABLE OF CONTENTS
page page
ENGINE 2. 4L. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ENGINE 4. 0L. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
ENGINE 2.4L
TABLE OF CONTENTS
page page
ENGINE 2.4L
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - CYLINDER
COMBUSTION PRESSURE LEAKAGE
TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DIAGNOSIS AND TESTING - CYLINDER
COMPRESSION PRESSURE TEST . . . . . . . . . 4
DIAGNOSIS AND TESTING - ENGINE OIL
LEAK INSPECTION . . . . . . . . . . . . . . . . . . . . . 4
DIAGNOSIS AND TESTING - ENGINE . . . . . . . 5
DIAGNOSIS AND TESTING - ENGINE
MECHANICAL . . . . . . . . . . . . . . . . . . . . . . . . . 6
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - PERFORMANCE . . . . . . . . . . . . 8
STANDARD PROCEDURE
STANDARD PROCEDURE - REPAIR OF
DAMAGED OR WORN THREADS . . . . . . . . . 10
STANDARD PROCEDURE - ENGINE CORE
AND OIL GALLERY PLUGS . . . . . . . . . . . . . . 10
STANDARD PROCEDURE - ENGINE
GASKET SURFACE PREPARATION. . . . . . . . 10
STANDARD PROCEDURE - MEASURING
BEARING CLEARANCE USING
PLASTIGAGE . . . . . . . . . . . . . . . . . . . . . . . . 10
STANDARD PROCEDURE - FORM-IN-
PLACE GASKETS AND SEALERS . . . . . . . . . 11
STANDARD PROCEDURE - HYDROSTATIC
LOCKED ENGINE . . . . . . . . . . . . . . . . . . . . . 12
REMOVAL - ENGINE ASSEMBLY . . . . . . . . . . . 12
INSTALLATION - ENGINE ASSEMBLY . . . . . . . . 13
SPECIFICATIONS
SPECIFICATIONS - 2.4L ENGINE . . . . . . . . . 14
SPECIFICATIONS - TORQUE . . . . . . . . . . . . 17
SPECIAL TOOLS
2.4L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . 18
AIR CLEANER ELEMENT - 2.4L
REMOVAL - 2.4L . . . . . . . . . . . . . . . . . . . . . . . . 20
INSTALLATION - 2.4L . . . . . . . . . . . . . . . . . . . . 20
AIR CLEANER HOUSING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 20
CYLINDER HEAD
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 21
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
DIAGNOSIS AND TESTING - CYLINDER HEAD
GASKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
REMOVAL - CYLINDER HEAD . . . . . . . . . . . . . 22
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 22
INSTALLATION - CYLINDER HEAD . . . . . . . . . . 23
CAMSHAFT OIL SEAL(S)
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 24
CAMSHAFT(S)
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 25
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
STANDARD PROCEDURE - CAMSHAFT
END-PLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 26
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 27
CYLINDER HEAD COVER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 27
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 28
INTAKE/EXHAUST VALVES & SEATS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 29
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
TJ ENGINE 9 - 1
VALVE SPRINGS
REMOVAL
REMOVAL - CYLINDER HEAD ON . . . . . . . . . 29
REMOVAL - CYLINDER HEAD OFF . . . . . . . . 29
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 29
INSTALLATION
INSTALLATION - CYLINDER HEAD ON . . . . . 30
INSTALLATION - CYLINDER HEAD OFF . . . . 30
HYDRAULIC LIFTERS
DIAGNOSIS AND TESTING - LASH ADJUSTER
(TAPPET) NOISE DIAGNOSIS . . . . . . . . . . . . 30
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 31
ROCKER ARMS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 31
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 31
ENGINE BLOCK
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 32
STANDARD PROCEDURE
STANDARD PROCEDURE - PISTON TO
CYLINDER BORE FITTING . . . . . . . . . . . . . . 32
STANDARD PROCEDURE - CYLINDER
BORE HONING . . . . . . . . . . . . . . . . . . . . . . . 32
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 33
CONNECTING ROD BEARINGS
STANDARD PROCEDURE
CONNECTING ROD - FITTING . . . . . . . . . . . 34
CRANKSHAFT
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 34
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
STANDARD PROCEDURE - CRANKSHAFT
END PLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 36
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 36
CRANKSHAFT MAIN BEARINGS
STANDARD PROCEDURE - MAIN BEARING -
FITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
CRANKSHAFT OIL SEAL - FRONT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 40
CRANKSHAFT OIL SEAL - REAR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 41
PISTON & CONNECTING ROD
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 42
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 43
PISTON RINGS
STANDARD PROCEDURE
PISTON RING - FITTING . . . . . . . . . . . . . . . . 44
VIBRATION DAMPER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 46
STRUCTURAL COLLAR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 46
ENGINE MOUNTING
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 46
FRONT MOUNT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 46
REAR MOUNT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 47
LUBRICATION
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 49
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
DIAGNOSIS AND TESTING - ENGINE OIL
PRESSURE CHECKING . . . . . . . . . . . . . . . . . 49
OIL
STANDARD PROCEDURE
ENGINE OIL LEVEL CHECK . . . . . . . . . . . . . 49
STANDARD PROCEDURE - ENGINE OIL
AND FILTER CHANGE . . . . . . . . . . . . . . . . . . 49
OIL FILTER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 50
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 50
OIL PAN
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 50
OIL PRESSURE SENSOR/SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 51
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
OIL PUMP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 52
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 52
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 53
INTAKE MANIFOLD
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 54
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
DIAGNOSIS AND TESTING - INTAKE
MANIFOLD LEAKS . . . . . . . . . . . . . . . . . . . . . 54
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 54
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 55
EXHAUST MANIFOLD
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 55
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 56
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 56
TIMING BELT COVER(S)
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 56
9 - 2 ENGINE 2. 4L TJ
TIMING BELT AND SPROCKET(S)
REMOVAL
REMOVAL - TIMING BELT . . . . . . . . . . . . . . . 57
REMOVAL - CRANKSHAFT SPROCKET . . . . 58
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
INSTALLATION
INSTALLATION - CRANKSHAFT SPROCKET . 58
INSTALLATION - TIMING BELT . . . . . . . . . . . 59
TIMING BELT TENSIONER & PULLEY
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 61
BALANCE SHAFTS AND CARRIER ASSEMBLY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 61
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 63
BALANCE SHAFT CARRIER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 65
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 65
BALANCE SHAFT CHAIN
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 66
ENGINE 2.4L
DESCRIPTION
The 2.4 Li ter (148 cu. i n.) i n-l i ne four cyl i nder
engi ne i s a doubl e over head camshaft wi th hydraul i c
l i fters and four val ve per cyl i nder desi gn. The engi ne
i s free-wheel i ng; meani ng i t has provi si ons for pi ston-
to-val ve cl earance. However val ve-to-val ve i nterfer-
ence can occur, i f camshafts are rotated
i ndependentl y.
The cyl i nders are numbered from front of the
engi ne to the rear. The fi ri ng order i s 1–3–4–2.
The engi ne i denti fi cati on number i s l ocated on the
rear of the cyl i nder bl ock (Fi g. 1).
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - CYLINDER
COMBUSTION PRESSURE LEAKAGE TEST
The combusti on pressure l eakage test provi des an
accurate means for determi ni ng engi ne condi ti on.
Combusti on pressure l eakage testi ng wi l l detect:
• Exhaust and i ntake val ve l eaks (i mproper seat-
i ng).
• Leaks between adjacent cyl i nders or i nto water
jacket.
• Any causes for combusti on/compressi on pressure
l oss.
WARNING: DO NOT REMOVE THE PRESSURE CAP
WITH THE SYSTEM HOT AND UNDER PRESSURE
BECAUSE SERIOUS BURNS FROM COOLANT CAN
OCCUR.
Check the cool ant l evel and fi l l as requi red. DO
NOT i nstal l the pressure cap.
Start and operate the engi ne unti l i t attai ns nor-
mal operati ng temperature, then turn the engi ne
OFF.
Cl ean spark pl ug recesses wi th compressed ai r.
Remove the spark pl ugs.
Remove the oi l fi l l er cap.
Remove the ai r cl eaner.
Cal i brate the tester accordi ng to the manufactur-
er’s i nstructi ons. The shop ai r source for testi ng
shoul d mai ntai n 483 kPa (70 psi ) mi ni mum, 1,379
kPa (200 psi ) maxi mum, wi th 552 kPa (80 psi ) rec-
ommended.
Perform the test procedures on each cyl i nder
accordi ng to the tester manufacturer’s i nstructi ons.
Whi l e testi ng, l i sten for pressuri zed ai r escapi ng
through the throttl e body, tai l pi pe and oi l fi l l er cap
openi ng. Check for bubbl es i n the cool ant.
Al l gauge pressure i ndi cati ons shoul d be equal ,
wi th no more than 25% l eakage per cyl i nder.
FOR EXAMPLE: At 552 kPa (80 psi ) i nput pres-
sure, a mi ni mum of 414 kPa (60 psi ) shoul d be mai n-
tai ned i n the cyl i nder.
Fig. 1 ENGINE IDENTIFICATION
1 - ENGINE IDENTIFICATION
TJ ENGINE 2. 4L 9 - 3
DIAGNOSIS AND TESTING - CYLINDER
COMPRESSION PRESSURE TEST
The resul ts of a cyl i nder compressi on pressure test
can be uti l i zed to di agnose several engi ne mal func-
ti ons.
Ensure the battery i s compl etel y charged and the
engi ne starter motor i s i n good operati ng condi ti on.
Otherwi se the i ndi cated compressi on pressures may
not be val i d for di agnosi s purposes.
(1) Check engi ne oi l l evel and add oi l i f necessary.
(2) Dri ve the vehi cl e unti l engi ne reaches normal
operati ng temperature. Sel ect a route free from traf-
fi c and other forms of congesti on, observe al l traffi c
l aws, and accel erate through the gears several ti mes
bri skl y.
(3) Remove al l spark pl ugs from engi ne. As spark
pl ugs are bei ng removed, check el ectrodes for abnor-
mal fi ri ng i ndi cators foul ed, hot, oi l y, etc. Record cyl -
i nder number of spark pl ug for future reference.
(4) Remove the Auto Shutdown (ASD) rel ay from
the PDC.
(5) Be sure throttl e bl ade i s ful l y open duri ng the
compressi on check.
(6) I nsert compressi on gage adaptor Speci al Tool
8116 or the equi val ent, i nto the #1 spark pl ug hol e i n
cyl i nder head. Connect the 0–500 psi (Bl ue) pressure
transducer wi th cabl e adaptors to the DRBI I I ௡.
(7) Crank engi ne unti l maxi mum pressure i s
reached on gage. Record thi s pressure as #1 cyl i nder
pressure.
(8) Repeat the previ ous step for al l remai ni ng cyl -
i nders.
(9) Compressi on shoul d not be l ess than 689 kPa
(100 psi ) and not vary more than 25 percent from cyl -
i nder to cyl i nder.
(10) I f one or more cyl i nders have abnormal l y l ow
compressi on pressures, repeat the compressi on test.
(11) I f the same cyl i nder or cyl i nders repeat an
abnormal l y l ow readi ng on the second compressi on
test, i t coul d i ndi cate the exi stence of a probl em i n
the cyl i nder i n questi on. The recommended com-
pression pressures are to be used only as a
guide to diagnosing engine problems. An engine
should not be disassembled to determine the
cause of low compression unless some malfunc-
tion is present.
DIAGNOSIS AND TESTING - ENGINE OIL LEAK
INSPECTION
Begi n wi th a thorough vi sual i nspecti on of the
engi ne, parti cul arl y at the area of the suspected l eak.
I f an oi l l eak source i s not readi l y i denti fi abl e, the
fol l owi ng steps shoul d be fol l owed:
(1) Do not cl ean or degrease the engi ne at thi s
ti me because some sol vents may cause rubber to
swel l , temporari l y stoppi ng the l eak.
(2) Add an oi l sol ubl e dye (use as recommended by
manufacturer). Start the engi ne and l et i dl e for
approxi matel y 15 mi nutes. Check the oi l di psti ck to
make sure the dye i s thoroughl y mi xed as i ndi cated
wi th a bri ght yel l ow col or under a bl ack l i ght.
(3) Usi ng a bl ack l i ght, i nspect the enti re engi ne
for fl uorescent dye, parti cul arl y at the suspected area
of oi l l eak. I f the oi l l eak i s found and i denti fi ed,
repai r as necessary.
(4) I f dye i s not observed, dri ve the vehi cl e at var-
i ous speeds for approxi matel y 24 km (15 mi l es), and
repeat i nspecti on.
(5) If the oil leak source is not positively
identified at this time, proceed wi th the ai r l eak
detecti on test method as fol l ows:
• Di sconnect the fresh ai r hose (make-up ai r) at
the cyl i nder head cover and pl ug or cap the ni ppl e on
the cover.
• Remove the PCV val ve hose from the cyl i nder
head cover. Cap or pl ug the PCV val ve ni ppl e on the
cover.
• Attach an ai r hose wi th pressure gauge and reg-
ul ator to the di psti ck tube.
CAUTION: Do not subject the engine assembly to
more than 20.6 kpa (3 PSI) of test pressure.
• Gradual l y appl y ai r pressure from 1 psi to 2.5
psi maxi mum whi l e appl yi ng soapy water at the sus-
pected source. Adjust the regul ator to the sui tabl e
test pressure that provi des the best bubbl es whi ch
wi l l pi npoi nt the l eak source. I f the oi l l eak i s
detected and i denti fi ed, repai r per servi ce manual
procedures.
• I f the l eakage occurs at the crankshaft rear oi l
seal area, refer to the secti on, I nspecti on for Rear
Seal Area Leak.
(6) I f no l eaks are detected, turn off the ai r suppl y.
Remove the ai r hose, al l pl ugs, and caps. I nstal l the
PCV val ve and fresh ai r hose (make-up ai r). Proceed
to next step.
(7) Cl ean the oi l off the suspect oi l l eak area usi ng
a sui tabl e sol vent. Dri ve the vehi cl e at vari ous
speeds approxi matel y 24 km (15 mi l es). I nspect the
engi ne for si gns of an oi l l eak by usi ng a bl ack l i ght.
NOTE: If oil leakage is observed at the dipstick tube
to block location; remove the tube, clean and reseal
using Moparா Stud & Bearing Mount (press fit tube
applications only), and for O-ring style tubes,
remove tube and replace the O-ring seal.
INSPECTION FOR REAR SEAL AREA LEAKS
Si nce i t i s someti mes di ffi cul t to determi ne the
source of an oi l l eak i n the rear seal area of the
engi ne, a more i nvol ved i nspecti on i s necessary. The
9 - 4 ENGINE 2. 4L TJ
ENGINE 2.4L (Continued)
fol l owi ng steps shoul d be fol l owed to hel p pi npoi nt
the source of the l eak.
I f the l eakage occurs at the crankshaft rear oi l seal
area:
(1) Di sconnect the battery.
(2) Rai se the vehi cl e.
(3) Remove torque converter or cl utch housi ng
cover and i nspect rear of bl ock for evi dence of oi l .
Use a bl ack l i ght to check for the oi l l eak. I f a l eak i s
present i n thi s area, remove transmi ssi on for further
i nspecti on.
(a) Ci rcul ar spray pattern general l y i ndi cates
seal l eakage or crankshaft damage.
(b) Where l eakage tends to run strai ght down,
possi bl e causes are a porous bl ock, oi l gal l ery cup
pl ug, bedpl ate to cyl i nder bl ock mati ng surfaces
and seal bore. See proper repai r procedures for
these i tems.
(4) I f no l eaks are detected, pressuri ze the crank-
case as previ ousl y descri bed.
CAUTION: Do not exceed 20.6 kPa (3 psi).
(5) I f the l eak i s not detected, very sl owl y turn the
crankshaft and watch for l eakage. I f a l eak i s
detected between the crankshaft and seal whi l e
sl owl y turni ng the crankshaft, i t i s possi bl e the
crankshaft seal surface i s damaged. The seal area on
the crankshaft coul d have mi nor ni cks or scratches
that can be pol i shed out wi th emery cl oth.
CAUTION: Use extreme caution when crankshaft
polishing is necessary to remove minor nicks and
scratches. The crankshaft seal flange is especially
machined to complement the function of the rear oil
seal.
(6) For bubbl es that remai n steady wi th shaft
rotati on, no further i nspecti on can be done unti l di s-
assembl ed.
(7) After the oi l l eak root cause and appropri ate
correcti ve acti on have been i denti fi ed, repl ace compo-
nent(s) as necessary.
DIAGNOSIS AND TESTING - ENGINE
Engi ne di agnosi s i s hel pful i n determi ni ng the
causes of mal functi ons not detected and remedi ed by
routi ne mai ntenance.
These mal functi ons may be cl assi fi ed as ei ther
mechani cal (e.g., a strange noi se), or performance
(e.g., engi ne i dl es rough and stal l s).
Refer to the Engi ne Mechani cal and the Engi ne
Performance di agnosti c charts, for possi bl e causes
and correcti ons of mal functi ons (Refer to 9 - ENGI NE
- DI AGNOSI S AND TESTI NG - MECHANI CAL)
(Refer to 9 - ENGI NE - DI AGNOSI S AND TESTI NG
- PERFORMANCE).
For fuel system di agnosi s, (Refer to 14 - FUEL
SYSTEM/FUEL DELI VERY - DI AGNOSI S AND
TESTI NG).
Addi ti onal tests and di agnosti c procedures may be
necessary for speci fi c engi ne mal functi ons that can-
not be i sol ated wi th the Servi ce Di agnosi s charts.
I nformati on concerni ng addi ti onal tests and di agno-
si s i s provi ded wi thi n the fol l owi ng:
• Cyl i nder Compressi on Pressure Test
• Cyl i nder Combusti on Pressure Leakage Test
• Engi ne Cyl i nder Head Gasket Fai l ure Di agnosi s
• I ntake Mani fol d Leakage Di agnosi s
• Lash Adjuster (Tappet) Noi se Di agnosi s
• Engi ne Oi l Leak I nspecti on
TJ ENGINE 2. 4L 9 - 5
ENGINE 2.4L (Continued)
DIAGNOSIS AND TESTING - ENGINE MECHANICAL
CONDITION POSSIBLE CAUSES CORRECTION
NOISY VALVES 1. High or low oil level in
crankcase.
1. Check and correct engine oil
level.
2. Thin or diluted oil. 2. Change oil to correct viscosity.
3. Thick oil 3. (a) Change engine oil and filter.
(b) Run engine to operating
temperature.
(c) Change engine oil and filter
again.
4. Low oil pressure. 4. Check and correct engine oil
level.
5. Dirt in tappets/lash adjusters. 5. Replace rocker arm/hydraulic
lash adjuster assembly.
6. Worn rocker arms. 6. Inspect oil supply to rocker arms.
7. Worn tappets/lash adjusters. 7. Install new rocker arm/hydraulic
lash adjuster assembly.
8. Worn valve guides. 8. Replace cylinder head assembly.
9. Excessive runout of valve seats
on valve faces.
9. Grind valve seats and valves.
10. Missing adjuster pivot. 10. Replace rocker arm/hydraulic
lash adjuster assembly.
CONNECTING ROD NOISE 1. Insufficient oil supply. 1. Check engine oil level.
2. Low oil pressure. 2. Check engine oil level. Inspect oil
pump relief valve and spring.
3. Thin or diluted oil. 3. Change oil to correct viscosity.
4. Thick oil 4. (a) Change engine oil and filter.
(b) Run engine to operating
temperature.
(c) Change engine oil and filter
again.
5. Excessive bearing clearance. 5. Measure bearings for correct
clearance. Repair as necessary.
6. Connecting rod journal
out-of-round.
6. Replace crankshaft or grind
surface.
7. Misaligned connecting rods. 7. Replace bent connecting rods.
9 - 6 ENGINE 2. 4L TJ
ENGINE 2.4L (Continued)
CONDITION POSSIBLE CAUSES CORRECTION
MAIN BEARING NOISE 1. Insufficient oil supply. 1. Check engine oil level.
2. Low oil pressure. 2. Check engine oil level. Inspect oil
pump relief valve and spring.
3. Thin or diluted oil. 3. Change oil to correct viscosity.
4. Thick oil 4. (a) Change engine oil and filter.
(b) Run engine to operating
temperature.
(c) Change engine oil and filter
again.
5. Excessive bearing clearance. 5. Measure bearings for correct
clearance. Repair as necessary.
6. Excessive end play. 6. Check thrust bearing for wear on
flanges.
7. Crankshaft journal out-of-round
or worn.
7. Replace crankshaft or grind
journals.
8. Loose flywheel or torque
converter.
8. Tighten to correct torque.
OIL PRESSURE DROP 1. Low oil level. 1. Check engine oil level.
2. Faulty oil pressure sending unit. 2. Install new sending unit.
3. Low oil pressure. 3. Check sending unit and main
bearing oil clearance.
4. Clogged oil filter. 4. Install new oil filter.
5. Worn parts in oil pump. 5. Replace worn parts or pump.
6. Thin or diluted oil. 6. Change oil to correct viscosity.
7. Oil pump relief valve stuck. 7. Replace oil pump.
8. Oil pump suction tube loose. 8. Remove oil pan and install new
tube or clean, if necessary.
9. Oil pump cover warped or
cracked.
9. Install new oil pump.
10. Excessive bearing clearance. 10. Measure bearings for correct
clearance.
OIL AKS 1. Misaligned or deteriorated
gaskets.
1. Replace gasket(s).
2. Loose fastener, broken or porous
metal part.
2. Tighten, repair or replace the
part.
3. Misaligned or deteriorated cup or
threaded plug.
3. Replace as necessary.
TJ ENGINE 2. 4L 9 - 7
ENGINE 2.4L (Continued)
CONDITION POSSIBLE CAUSES CORRECTION
OIL CONSUMPTION OR SPARK
PLUGS FOULED
1. PCV system malfunction. 1. Check system and repair as
necessary. (Refer to 25 -
EMISSIONS CONTROL/
EVAPORATIVE EMISSIONS/PCV
VALVE - DIAGNOSIS AND
TESTING)
2. Worn, scuffed or broken rings. 2. Hone cylinder bores. Install new
rings.
3. Carbon in oil ring slots. 3. Install new rings.
4. Rings fitted too tightly in grooves. 4. Remove rings and check
grooves. If groove is not proper
width, replace piston.
5. Worn valve guide(s). 5. Replace cylinder head assembly.
6. Valve stem seal(s) worn or
damaged.
6. Replace seal(s).
DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - PERFORMANCE
CONDITION POSSIBLE CAUSE CORRECTION
ENGINE WILL NOT START 1. Weak battery. 1. Test battery. Charge or replace
as necessary. (Refer to 8 -
ELECTRICAL/BATTERY SYSTEM -
DIAGNOSIS AND TESTING)
2. Corroded or loose battery
connections.
2. Clean and tighten battery
connections. Apply a coat of light
mineral grease to terminals.
3. Faulty starter. 3. Test starting system. (Refer to 8 -
ELECTRICAL/STARTING -
DIAGNOSIS AND TESTING)
4. Faulty coil(s) or control unit. 4. Test and replace as needed.
(Refer to Appropriate Diagnostic
Information)
5. Incorrect spark plug gap. 5. Set gap. (Refer to 8 -
ELECTRICAL/IGNITION CONTROL
- SPECIFICATIONS)
6. Contamination in fuel system. 6. Clean system and replace fuel
filter.
7. Faulty fuel pump. 7. Test fuel pump and replace as
needed. (Refer to Appropriate
Diagnostic Information)
8. Incorrect engine timing. 8. Check for a skipped timing
belt/chain.
9 - 8 ENGINE 2. 4L TJ
ENGINE 2.4L (Continued)
CONDITION POSSIBLE CAUSE CORRECTION
ENGINE STALLS OR IDLES
ROUGH
1. Idle speed too low. 1. Test minimum air flow. (Refer to
Appropriate Diagnostic Information)
2. Incorrect fuel mixture. 2. (Refer to Appropriate Diagnostic
Information)
3. Intake manifold leakage. 3. Inspect intake manifold, manifold
gasket, and vacuum hoses.
4. Faulty ignition coil(s). 4. Test and replace as necessary.
(Refer to Appropriate Diagnostic
Information)
ENGINE LOSS OF POWER 1. Dirty or incorrectly gapped plugs. 1. Clean plugs and set gap.
2. Contamination in fuel system. 2. Clean system and replace fuel
filter.
3. Faulty fuel pump. 3. Test and replace as necessary.
(Refer to Appropriate Diagnostic
Information)
4. Incorrect valve timing. 4. Correct valve timing.
5. Leaking cylinder head gasket. 5. Replace cylinder head gasket.
6. Low compression. 6. Test compression of each
cylinder.
7. Burned, warped, or pitted valves. 7. Replace valves.
8. Plugged or restricted exhaust
system.
8. Perform exhaust restriction test.
(Refer to 11 - EXHAUST SYSTEM -
DIAGNOSIS AND TESTING) Install
new parts, as necessary.
9. Faulty ignition coil(s). 9. Test and replace as necessary.
(Refer to Appropriate Diagnostic
Information)
ENGINE MISSES ON
ACCELERATION
1. Dirty or incorrectly gapped spark
plugs.
1. Clean spark plugs and set gap.
2. Contamination in Fuel System. 2. Clean fuel system and replace
fuel filter.
3. Burned, warped, or pitted valves. 3. Replace valves.
4. Faulty ignition coil(s). 4. Test and replace as necessary.
(Refer to Appropriate Diagnostic
Information)
ENGINE MISSES AT HIGH SPEED 1. Dirty or incorrect spark plug gap. 1. Clean spark plugs and set gap.
2. Faulty ignition coil(s). 2. Test and replace as necessary.
(Refer to Appropriate Diagnostic
Information)
3. Dirty fuel injector(s). Test and replace as necessary.
(Refer to Appropriate Diagnostic
Information)
4. Contamination in fuel system. 4. Clean system and replace fuel
filter.
TJ ENGINE 2. 4L 9 - 9
ENGINE 2.4L (Continued)
STANDARD PROCEDURE
STANDARD PROCEDURE - REPAIR OF
DAMAGED OR WORN THREADS
Damaged or worn threads (excl udi ng spark pl ug
and camshaft beari ng cap attachi ng threads) can be
repai red. Essenti al l y, thi s repai r consi sts of dri l l i ng
out worn or damaged threads, tappi ng the hol e wi th
a speci al Hel i -Coi l Tap, (or equi val ent) and i nstal l i ng
an i nsert i nto the tapped hol e. Thi s bri ngs the hol e
back to i ts ori gi nal thread si ze.
CAUTION: Be sure that the tapped holes maintain
the original center line.
Hel i -Coi l tool s and i nserts are readi l y avai l abl e
from automoti ve parts jobbers.
STANDARD PROCEDURE - ENGINE CORE AND
OIL GALLERY PLUGS
Usi ng a bl unt tool such as a dri ft and a hammer,
stri ke the bottom edge of the cup pl ug. Wi th the cup
pl ug rotated, grasp fi rml y wi th pl i ers or other sui t-
abl e tool and remove pl ug (Fi g. 2).
CAUTION: Do not drive cup plug into the casting as
restricted cooling can result and cause serious
engine problems.
Thoroughl y cl ean i nsi de of cup pl ug hol e i n cyl i n-
der bl ock or head. Be sure to remove ol d seal er.
Li ghtl y coat i nsi de of cup pl ug hol e wi th Mopar௡
Stud and Beari ng Mount. Make certai n the new pl ug
i s cl eaned of al l oi l or grease. Usi ng proper dri ve
pl ug, dri ve pl ug i nto hol e so that the sharp edge of
the pl ug i s at l east 0.5 mm (0.020 i n.) i nsi de the
l ead-i n chamfer.
I t i s not necessary to wai t for curi ng of the seal ant.
The cool i ng system can be refi l l ed and the vehi cl e
pl aced i n servi ce i mmedi atel y.
STANDARD PROCEDURE - ENGINE GASKET
SURFACE PREPARATION
To ensure engi ne gasket seal i ng, proper surface
preparati on must be performed, especi al l y wi th the
use of al umi num engi ne components and mul ti -l ayer
steel cyl i nder head gaskets.
Never use the fol l owi ng to cl ean gasket surfaces:
• Metal scraper
• Abrasi ve pad or paper to cl ean cyl i nder bl ock
and head
• Hi gh speed power tool wi th an abrasi ve pad or a
wi re brush (Fi g. 3)
NOTE: Multi-Layer Steel (MLS) head gaskets require
a scratch free sealing surface.
Onl y use the fol l owi ng for cl eani ng gasket surfaces:
• Sol vent or a commerci al l y avai l abl e gasket
remover
• Pl asti c or wood scraper (Fi g. 3)
• Dri l l motor wi th 3M Rol oc™ Bri stl e Di sc (whi te
or yel l ow) (Fi g. 3)
CAUTION: Excessive pressure or high RPM (beyond
the recommended speed), can damage the sealing
surfaces. The mild (white, 120 grit) bristle disc is
recommended. If necessary, the medium (yellow, 80
grit) bristle disc may be used on cast iron surfaces
with care.
STANDARD PROCEDURE - MEASURING
BEARING CLEARANCE USING PLASTIGAGE
Engi ne crankshaft beari ng cl earances can be deter-
mi ned by use of Pl asti gage or equi val ent. The fol l ow-
i ng i s the recommended procedure for the use of
Pl asti gage:
(1) Remove oi l fi l m from surface to be checked.
Pl asti gage i s sol ubl e i n oi l .
(2) Pl ace a pi ece of Pl asti gage across the enti re
wi dth of the beari ng shel l i n the cap approxi matel y
6.35 mm (1/4 i n.) off center and away from the oi l
hol es (Fi g. 4). (I n addi ti on, suspected areas can be
checked by pl aci ng the Pl asti gage i n the suspected
area). Torque the beari ng cap bol ts of the beari ng
bei ng checked to the proper speci fi cati ons.
(3) Remove the beari ng cap and compare the
wi dth of the fl attened Pl asti gage wi th the metri c
scal e provi ded on the package. Locate the band cl os-
Fig. 2 Core Hole Plug Removal
1 - CYLINDER BLOCK
2 - REMOVE PLUG WITH PLIERS
3 - STRIKE HERE WITH HAMMER
4 - DRIFT PUNCH
5 - CUP PLUG
9 - 10 ENGINE 2. 4L TJ
ENGINE 2.4L (Continued)
est to the same wi dth. Thi s band shows the amount
of cl earance i n thousandths of a mi l l i meter. Di ffer-
ences i n readi ngs between the ends i ndi cate the
amount of taper present. Record al l readi ngs taken.
Compare cl earance measurements to specs found i n
engi ne speci fi cati ons (Refer to 9 - ENGI NE - SPECI -
FI CATI ONS). Plastigage generally is accompa-
nied by two scales. One scale is in inches, the
other is a metric scale.
NOTE: Plastigage is available in a variety of clear-
ance ranges. Use the most appropriate range for
the specifications you are checking.
(4) I nstal l the proper crankshaft beari ngs to
achi eve the speci fi ed beari ng cl earances. (Refer to 9 -
ENGI NE/ENGI NE BLOCK/CRANKSHAFT MAI N
BEARI NGS - STANDARD PROCEDURE) (Refer to 9
- ENGI NE/ENGI NE BLOCK/CONNECTI NG ROD
BEARI NGS - STANDARD PROCEDURE)
STANDARD PROCEDURE - FORM-IN-PLACE
GASKETS AND SEALERS
There are numerous pl aces where form-i n-pl ace
gaskets are used on the engi ne. Care must be taken
when appl yi ng form-i n-pl ace gaskets to assure
obtai ni ng the desi red resul ts. Do not use form-in-
place gasket material unless specified. Bead si ze,
conti nui ty, and l ocati on are of great i mportance. Too
thi n a bead can resul t i n l eakage whi l e too much can
resul t i n spi l l -over whi ch can break off and obstruct
fl ui d feed l i nes. A conti nuous bead of the proper
wi dth i s essenti al to obtai n a l eak-free gasket.
There are numerous types of form-i n-pl ace gasket
materi al s that are used i n the engi ne area. Mopar௡
Engi ne RTV GEN I I , Mopar௡ ATF-RTV, and Mopar௡
Gasket Maker gasket materi al s, each have di fferent
properti es and can not be used i n pl ace of the other.
MOPAR௡ ENGINE RTV GEN II i s used to seal
components exposed to engi ne oi l . Thi s materi al i s a
speci al l y desi gned bl ack si l i cone rubber RTV that
retai ns adhesi on and seal i ng properti es when
exposed to engi ne oi l . Moi sture i n the ai r causes the
materi al to cure. Thi s materi al i s avai l abl e i n three
ounce tubes and has a shel f l i fe of one year. After one
year thi s materi al wi l l not properl y cure. Al ways
i nspect the package for the expi rati on date before
use.
MOPAR௡ ATF RTV i s a speci fi cal l y desi gned
bl ack si l i cone rubber RTV that retai ns adhesi on and
seal i ng properti es to seal components exposed to
automati c transmi ssi on fl ui d, engi ne cool ants, and
moi sture. Thi s materi al i s avai l abl e i n three ounce
tubes and has a shel f l i fe of one year. After one year
thi s materi al wi l l not properl y cure. Al ways i nspect
the package for the expi rati on date before use.
MOPAR௡ GASKET MAKER i s an anaerobi c type
gasket materi al . The materi al cures i n the absence of
ai r when squeezed between two metal l i c surfaces. I t
wi l l not cure i f l eft i n the uncovered tube. The
anaerobi c materi al i s for use between two machi ned
surfaces. Do not use on fl exi bl e metal fl anges.
MOPAR௡ BED PLATE SEALANT i s a uni que
(green-i n-col or) anaerobi c type gasket materi al that
i s speci al l y made to seal the area between the bed-
pl ate and cyl i nder bl ock wi thout di sturbi ng the bear-
i ng cl earance or al i gnment of these components. The
materi al cures sl owl y i n the absence of ai r when
torqued between two metal l i c surfaces, and wi l l rap-
i dl y cure when heat i s appl i ed.
Fig. 3 Proper Tool Usage For Surface Preparation
1 - ABRASIVE PAD
2 - 3M ROLOC™ BRISTLE DISC
3 - PLASTIC/WOOD SCRAPER
Fig. 4 Plastigage Placed in Lower Shell - Typical
1 - PLASTIGAGE
TJ ENGINE 2. 4L 9 - 11
ENGINE 2.4L (Continued)
MOPAR௡ GASKET SEALANT i s a sl ow dryi ng,
permanentl y soft seal er. Thi s materi al i s recom-
mended for seal i ng threaded fi tti ngs and gaskets
agai nst l eakage of oi l and cool ant. Can be used on
threaded and machi ned parts under al l tempera-
tures. Thi s materi al i s used on engi nes wi th mul ti -
l ayer steel (MLS) cyl i nder head gaskets. Thi s
materi al al so wi l l prevent corrosi on. Mopar௡ Gasket
Seal ant i s avai l abl e i n a 13 oz. aerosol can or 4oz./16
oz. can w/appl i cator.
SEALER APPLICATION
Mopar௡ Gasket Maker materi al shoul d be appl i ed
spari ngl y 1 mm (0.040 i n.) di ameter or l ess of seal ant
to one gasket surface. Be certai n the materi al sur-
rounds each mounti ng hol e. Excess materi al can eas-
i l y be wi ped off. Components shoul d be torqued i n
pl ace wi thi n 15 mi nutes. The use of a l ocati ng dowel
i s recommended duri ng assembl y to prevent smear-
i ng materi al off the l ocati on.
Mopar௡ Engi ne RTV GEN I I or ATF RTV gasket
materi al shoul d be appl i ed i n a conti nuous bead
approxi matel y 3 mm (0.120 i n.) i n di ameter. Al l
mounti ng hol es must be ci rcl ed. For corner seal i ng, a
3.17 or 6.35 mm (1/8 or 1/4 i n.) drop i s pl aced i n the
center of the gasket contact area. Uncured seal ant
may be removed wi th a shop towel . Components
shoul d be torqued i n pl ace whi l e the seal ant i s sti l l
wet to the touch (wi thi n 10 mi nutes). The usage of a
l ocati ng dowel i s recommended duri ng assembl y to
prevent smeari ng materi al off the l ocati on.
Mopar௡ Gasket Seal ant i n an aerosol can shoul d be
appl i ed usi ng a thi n, even coat sprayed compl etel y
over both surfaces to be joi ned, and both si des of a
gasket. Then proceed wi th assembl y. Materi al i n a
can w/appl i cator can be brushed on evenl y over the
seal i ng surfaces. Materi al i n an aerosol can shoul d be
used on engi nes wi th mul ti -l ayer steel gaskets.
STANDARD PROCEDURE - HYDROSTATIC
LOCKED ENGINE
When an engi ne i s suspected to be hydrostati cal l y
l ocked, regardl ess of what caused the probl em, the
fol l owi ng steps shoul d be used.
CAUTION: DO NOT use starter motor to rotate the
engine, severe damage may occur.
(1) I nspect ai r cl eaner, i nducti on system and
i ntake mani fol d to i nsure system i s dry and cl ear of
forei gn materi al .
(2) Remove negati ve battery cabl e.
(3) Pl ace a shop towel around the spark pl ugs
when removi ng them from the engi ne. Thi s wi l l catch
any fl ui d that may possi bl y be i n the cyl i nder under
pressure.
(4) Wi th al l spark pl ugs removed, rotate engi ne
crankshaft usi ng a breaker bar and socket.
(5) I denti fy the fl ui d i n the cyl i nder(s) (i .e., cool -
ant, fuel , oi l or other).
(6) Make sure al l fl ui d has been removed from the
cyl i nders. I nspect engi ne for damage (i .e., connecti ng
rods, pi stons, val ves, etc.)
(7) Repai r engi ne or components as necessary to
prevent thi s probl em from re-occurri ng.
CAUTION: Squirt approximately one teaspoon of oil
into the cylinders, rotate engine to lubricate the cyl-
inder walls to prevent damage on restart.
(8) I nstal l new spark pl ugs.
(9) Drai n engi ne oi l and remove oi l fi l ter.
(10) I nstal l a new oi l fi l ter.
(11) Fi l l engi ne wi th speci fi ed amount of approved
oi l .
(12) Connect negati ve battery cabl e.
(13) Start engi ne and check for any l eaks.
REMOVAL - ENGINE ASSEMBLY
(1) Di sconnect the battery negati ve cabl e.
(2) Remove hood. Mark hood hi nge l ocati on for
rei nstal l ati on.
(3) Remove ai r cl eaner assembl y.
(4) Remove radi ator core support bracket.
(5) Remove fan shroud wi th el ectri c fan assembl y.
(6) Remove dri ve bel t.
NOTE: It is NOT necessary to discharge the A/C
system to remove the engine.
(7) Remove A/C compressor and secure away from
engi ne wi th l i nes attached.
(8) Remove generator and secure away from engi ne.
NOTE: Do NOT remove the phenolic pulley from the
P/S pump. It is not required for P/S pump removal.
(9) Remove power steeri ng pump wi th l i nes
attached and secure away from engi ne.
(10) Drai n cool i ng system.
(11) Remove cool ant bottl e.
(12) Di sconnect the heater hoses from the engi ne.
(13) Di sconnect heater hoses from heater core and
remove hose assembl y.
(14) Di sconnect throttl e and speed control cabl es.
(15) Remove upper radi ator hose from engi ne.
(16) Remove l ower radi ator hose from engi ne.
(17) Di sconnect the engi ne to body ground straps
at the l eft si de of cowl .
(18) Di sconnect the engi ne wi ri ng harness at the
fol l owi ng poi nts:
• I ntake ai r temperature (I AT) sensor
• Fuel I njectors
• Throttl e Posi ti on (TPS) Swi tch
9 - 12 ENGINE 2. 4L TJ
ENGINE 2.4L (Continued)
• I dl e Ai r Control (I AC) Motor
• Engi ne Oi l Pressure Swi tch
• Engi ne Cool ant Temperature (ECT) Sensor
• Mani fol d Absol ute Pressure MAP) Sensor
• Camshaft Posi ti on (CMP) Sensor
• Coi l Over Pl ugs
• Crankshaft Posi ti on Sensor
(19) Remove coi l over pl ugs.
(20) Rel ease fuel rai l pressure.
(21) Remove fuel rai l and secure away from engi ne.
(22) Remove the PCV hose.
(23) Remove the breather hoses.
(24) Remove the vacuum hose for the power brake
booster.
(25) Di sconnect knock sensors.
(26) Secure the l eft and ri ght engi ne wi ri ng har-
nesses away from engi ne.
(27) Rai se vehi cl e.
(28) Di sconnect oxygen sensor wi ri ng.
(29) Di sconnect crankshaft posi ti on sensor.
(30) Di sconnect the engi ne bl ock heater power
cabl e, i f equi pped.
(31) Di sconnect the front propshaft at the front
di fferenti al and secure out of way.
(32) Remove the starter.
(33) Remove the ground straps from the engi ne
(34) Di sconnect the exhaust pi pes at the mani fol d.
(35) Remove the structural cover, i f equi pped.
(36) Remove torque convertor bol ts, and mark
l ocati on for reassembl y.
(37) Remove transmi ssi on bel l housi ng to engi ne
bol ts.
(38) Loosen l eft and ri ght engi ne mount thru bol ts.
NOTE: It is not necessary to completely remove
engine mount thru bolts, for engine removal.
(39) Lower the vehi cl e.
(40) Support the transmi ssi on wi th a sui tabl e jack.
(41) Connect a sui tabl e engi ne hoi st to the engi ne.
CAUTION: The 2.4L engine with manual transmis-
sions, can be removed without removing the man-
ual transmission. Use caution when attempting this
procedure as the clearance is tight.
(42) Remove engi ne from vehi cl e.
INSTALLATION - ENGINE ASSEMBLY
(1) Posi ti on the engi ne i n the vehi cl e.
CAUTION: Use caution when installing 2.4L engine
into vehicle equipped with manual transmission, as
clearance is tight.
(2) I nstal l both l eft and ri ght si de engi ne mounts
i nto the frame mounts.
(3) Rai se the vehi cl e.
(4) I nstal l the transmi ssi on bel l housi ng to engi ne
mounti ng bol ts. Ti ghten the bol ts to 41 N·m (30 ft.
l bs.).
(5) Ti ghten the engi ne mount thru bol ts.
(6) I nstal l the torque convertor bol ts.
(7) Connect the ground straps on the l eft and ri ght
si de of the engi ne.
(8) I nstal l the starter.
(9) Connect the crankshaft posi ti on sensor.
(10) I nstal l the engi ne bl ock heater power cabl e, i f
equi pped.
CAUTION: The structural cover requires a specific
torque sequence. Failure to follow this sequence
may cause severe damage to the cover.
(11) I nstal l the structural cover.
(12) I nstal l the exhaust pi pe.
(13) Connect the oxygen sensors.
(14) Lower vehi cl e.
(15) Connect the knock sensors.
(16) Connect the engi ne to body ground straps.
(17) I nstal l the power brake booster vacuum hose.
(18) I nstal l the breather hoses.
(19) I nstal l the PCV hose.
(20) I nstal l the fuel rai l .
(21) I nstal l the coi l over pl ugs.
(22) Reconnect the engi ne wi ri ng harness at the
fol l owi ng poi nts:
• I ntake ai r temperature (I AT) sensor
• Fuel I njectors
• Throttl e Posi ti on (TPS) Swi tch
• I dl e Ai r Control (I AC) Motor
• Engi ne Oi l Pressure Swi tch
• Engi ne Cool ant Temperature (ECT) Sensor
• Mani fol d Absol ute Pressure MAP) Sensor
• Camshaft Posi ti on (CMP) Sensor
• Coi l Over Pl ugs
• Crankshaft Posi ti on Sensor
(23) Connect l ower radi ator hose.
(24) Connect upper radi ator hose.
(25) Connect throttl e and speed control cabl es.
(26) I nstal l the heater hose assembl y.
(27) I nstal l cool ant recovery bottl e.
(28) I nstal l the power steeri ng pump.
(29) I nstal l the generator.
(30) I nstal l the A/C compressor.
(31) I nstal l the dri ve bel t.
(32) I nstal l the fan shroud wi th the el ectri c fan
assembl y.
(33) I nstal l the radi ator core support bracket.
(34) I nstal l the ai r cl eaner assembl y.
(35) Refi l l the engi ne cool i ng system.
(36) I nstal l the hood.
(37) Check and fi l l engi ne oi l .
(38) Connect the battery negati ve cabl e.
(39) Start the engi ne and check for l eaks.
TJ ENGINE 2. 4L 9 - 13
ENGINE 2.4L (Continued)
SPECIFICATIONS
SPECIFICATIONS - 2. 4L ENGINE
GENERAL SPECIFICATIONS
DESCRIPTION SPECIFICATION
Type In-Line OHV, DOHC
Number of
Cylinders
4
Firing Order 1-3-4-2
Compression
Ratio
9.5:1
Max. Variation
Between
Cylinders
25%
Metric Standard
Displacement 2.4 Liters 148 cu. in.
Bore 87.5 mm 3.445 in.
Stroke 101.0 mm 3.976 in.
Compression
Pressure
1172-1551 kPa 170-225 psi
CYLINDER BLOCK
DESCRIPTION SPECIFICATIONS
Metric Standard
Cylinder Bore
Diameter
87.4924 -
87.5076 mm
3.4446 - 3.4452
in.
Out-of-Round
(Max.)
0.051 mm 0.002 in.
Taper (Max.) 0.051 mm 0.002 in.
PISTONS
DESCRIPTION SPECIFICATION
Metric Standard
Piston Diameter 87.463 - 87.481
mm
3.4434 -3.4441
in.
Clearance @ 14
mm (0.551 in.)
from bottom of
skirt
0.024 - 0.057
mm
0.0009 - 0.0022
in.
Weight 331 - 339
grams
11.67- 11.95 oz.
Land Clearance
(Diametrical)
0.614 - 0.664
mm
0.024 - 0.026 in.
Piston Length 66.25 mm 2.608 in.
Piston Ring
Groove Depth
No. 1
4.640 - 4.784
mm
0.182 - 0.188 in.
Piston Ring
Groove Depth
No. 2
4.575 - 4.719
mm
(0.180 - 0.185
in.)
Piston Ring
Groove Depth
No. 3
4.097 - 4.236
mm
0.161 - 0.166 in.
PISTON PINS
DESCRIPTION SPECIFICATION
Metric Standard
Clearance in
Piston
0.005 - 0.018
mm
0.0002 - 0.0008
in.
Clearance in
Connecting Rod
Interference
Diameter 21.998 - 22.003
mm
0.8660 - 0.8662
in.
End Play None
Length 72.75 - 73.25
mm
2.864 - 2.883 in.
PISTON RINGS
DESCRIPTION SPECIFICATION
Metric Standard
Ring Gap
Top Compression
Ring
0.25 - 0.51
mm
0.0098 - 0.020
in.
Wear Limit 0.8 mm 0.031 in.
2nd Compression
Ring
0.23 - 0.48
mm
0.009 - 0.018
in.
Wear Limit 0.8 mm 0.031 in.
Oil Control Steel
Rails
0.25 - 0.64
mm
0.0098 - 0.025
in.
Wear Limit 1.00 mm 0.039 in.
Compression
Rings
0.030 - 0.080
mm
0.0011 - 0.0031
in.
Wear Limit 0.10 mm 0.004 in.
Ring Side
Clearance - Oil
Ring Pack
0.012 - 0.178
mm
0.0004 -
0.0070 in.
Ring Width -
Compression
Rings
1.47 - 1.50
mm
0.057 - 0.059
in.
Ring Width - Oil
Ring Pack
2.72 - 2.88
mm
0.107 - 0.1133
in.
9 - 14 ENGINE 2. 4L TJ
ENGINE 2.4L (Continued)
CONNECTING ROD
DESCRIPTION SPECIFICATION
Metric Standard
Bearing
Clearance
0.025 - 0.071
mm
0.0009 - 0.0027
in.
Wear Limit 0.075 mm 0.003 in.
Bore Diameter -
Piston Pin
20.96 - 20.98
mm
0.8252 - 0.8260
in.
Bore Diameter -
Crankshaft End
53.007 - 52.993
mm
2.0868 - 2.0863
in.
Side Clearance 0.13 - 0.38 mm 0.005 - 0.015 in.
Wear Limit 0.40 mm 0.016 in.
Weight - Total
(Less Bearing)
565.8 grams 19.96 oz.
CRANKSHAFT
DESCRIPTION SPECIFICATION
Metric Standard
Connecting Rod
Journal
Diameter
49.984 - 50.000
mm
1.968 - 1.9685
in.
Main Bearing
Journal
Diameter
59.992 - 60.008
mm
2.362 - 2.3625
in.
Journal
Out-of-Round
(Max.)
0.0035 mm 0.0003 in.
Journal Taper
(Max.)
0.007 mm 0.0001 in.
End Play 0.09 - 0.24 mm 0.0035 - 0.0094
in.
Wear Limit 0.38 mm 0.015 in.
Main Bearing
Diametrical
Clearance
0.018 - 0.062
mm
0.0007 - 0.0024
in.
HYDRAULIC LASH ADJ USTER
DESCRIPTION SPECIFICATION
Metric Standard
Body Diameter 15.901 - 15.913
mm
0.626 - 0.6264
in.
Plunger Travel
Minimum (Dry)
3.0 mm 0.118 in.
CYLINDER HEAD CAMSHAFT BEARING BORE
DIAMETER
DSECRIPTION SPECIFICATION
Metric Standard
Journals No.1 -
6
26.020 - 26.041
mm
1.024 - 1.025 in.
CAMSHAFT
DESCRIPTION SPECIFICATION
Metric Standard
Journal
Diameter No. 1
- 6
25.951 - 25.970
mm
1.021 - 1.022 in.
Bearing
Clearance -
Diametrical
0.069 - 0.071
mm
0.0027 - 0.003
in.
End Play 0.05 - 0.17 mm 0.0019 - 0.0066
in.
Lift (Zero Lash)
Intake 8.25 mm 0.324 in.
Exhaust 6.60 mm 0.259 in.
Intake Valve
Timing*
Closes (ABDC) 51°
Opens (BTDC) 1°
Duration 232°
Exhaust Valve
Timing*
Closes (ATDC) 7°
Opens (BBDC) 47°
Duration 234°
Valve Overlap 8°
*
All reading in degrees. Timing points @4°from top of
ramp.
CYLINDER HEAD
DESCRIPTION SPECIFICATION
Metric Standard
Material Cast Aluminum
Gasket
Thickness
(Compressed)
0.71 mm 0.028 in.
TJ ENGINE 2. 4L 9 - 15
ENGINE 2.4L (Continued)
VALVE SEAT
DESCRIPTION SPECIFICATION
Metric Standard
Angle 44.5 - 45°
Seat Diameter -
Intake
34.37 - 34.63
mm
1.353 - 1.363 in.
Seat Diameter -
Exhaust
27.06 - 27.32
mm
1.065 - 1.075 in.
Runout (Max.) 0.05 mm 0.002 in.
Valve Seat
Width - Intake
and Exhaust
0.9 - 1.3 mm 0.035 - 0.051 in.
Service Limit -
Intake
2.0 mm 0.079 in.
Service Limit -
Exhaust
2.5 mm 0.098 in.
VALVE GUIDE
DESCRIPTION SPECIFICATION
Metric Standard
Diameter I.D. 5.975 - 6.000
mm
0.235 - 0.236 in.
Guide Bore
Diameter
11.0 - 11.02
mm
0.4330 - 0.4338
in.
Guide Height
(spring seat to
guide tip)
13.25 - 13.75
mm
0.521 - 0.541 in.
VALVES
DESCRIPTION SPECIFICATION
Metric Standard
Face Angle -
Intake and
Exhaust
44.5 - 45°
Head Diameter
- Intake
34.67 - 34.93
mm
1.364 - 1.375 in.
Head Diameter
- Exhaust
28.32 - 28.52
mm
1.114 - 1.122 in.
Valve Length
(Overall)
Intake 112.76 - 113.32
mm
4.439 - 4.461 in.
Exhaust 110.89 - 111.69
mm
4.365 - 4.397 in.
Valve Stem
Diameter
Intake 5.934 - 5.952
mm
0.2337 - 0.2344
in.
Exhaust 5.906 - 5.924
mm
0.2326 - 0.2333
in.
VALVE MARGIN
DESCRIPTION SPECIFICATION
Metric Standard
Intake 1.2 - 1.7 mm 0.047 - 0.066 in.
Service Limit 0.95 mm .0037 in.
Exhaust 0.985 - 1.315
mm
0.038 - 0.051 in.
Service Limit 1.05 mm .039 in.
VALVE STEM TIP
DESCRIPTION SPECIFICATION
Metric Standard
Intake 48.04 mm 1.891 in.
Exhaust 47.99 mm 1.889 in.
VALVE STEM TO GUIDE CLEARANCE
DESCRIPTION SPECIFICATION
Metric Standard
Intake 0.048 - 0.066
mm
0.0018 - 0.0025
in.
Max. Allowable 0.076 mm 0.003 in.
Service Limit 0.25 mm 0.010 in.
Exhaust 0.0736 - 0.094
mm
0.0029 - 0.0037
in.
Max. Allowable 0.101 mm 0.004 in.
Service Limit 0.25 mm 0.010 in.
9 - 16 ENGINE 2. 4L TJ
ENGINE 2.4L (Continued)
VALVE SPRINGS
DESCRIPTION SPECIFICATION
Metric Standard
Free Length
(Approx.)
48.4 mm 1.905 in.
Nominal Force
(Valve Closed)
338 N @ 38.0
mm
75.98 lbs. @
1.496 in.
Nominal Force
(Valve Open)
607 N @ 29.75
mm
136 lbs. @
1.172 in.
Installed Height 38.00 mm 1.496 in.
Number of Coils 7.82
Wire Diameter 3.86 mm 1.496 in
OIL PUMP
DESCRIPTION SPECIFICATION
Metric Standard
Clearance Over
Rotors (Max.)
0.10 mm 0.004 in.
Cover
Out-of-Flat
(Max.)
0.025 mm 0.001 in.
Inner Rotor
Thickness (Min.)
9.40 mm 0.370 in.
Outer Rotor
Thickness (Min.)
9.40 mm 0.370 in.
Outer Rotor
Clearance
(Max.)
0.039 mm 0.015 in.
Outer Rotor
Diameter (Min.)
79.95 mm 3.148 in.
Tip Clearance
Between Rotors
(Max.)
0.20 mm 0.008 in.
OIL PRESSURE
DESCRIPTION SPECIFICATION
Metric Standard
At Curb Idle
Speed*
25 kPa 4 psi
At 3000 rpm 170 - 550 kPa 25 - 80 psi
CAUTION:
*If pressure is ZERO at curb idle, DO NOT run engine
at 3000 rpm.
SPECIFICATIONS - TORQUE
DESCRIPTION N·m Ft.
Lbs.
In.
Lbs.
Bolts, Balance Shaft
Carrier to Block
54 40 -
Fastener - Double Ended,
Balance Shaft Gear
Cover
12 - 105
Bolt, Balance Shaft
Sprocket
28 - 250
Bolts, Balance Shaft
Chain Tensioner
12 - 105
Bolts, Balance Shaft
Carrier Cover
12 - 105
Bolt, Camshaft Sprocket 115 85 -
Bolts, Connecting Rod
Cap
27 +
1
⁄4
turn
20
+
1
⁄4
turn
-
Bolts, Crankshaft Main
Bearing Cap/Bedplate
M8 Bolts 28 - 250
M11 Bolts 75 55 -
Crankshaft Damper 136 100 -
Bolts, Cylinder Head (Refer to 9 - ENGINE/
CYLINDER HEAD -
INSTALLATION)
Bolts, Cylinder Head
Cover
12 - 105
Flex Plate to Crankshaft 95 70 -
Flywheel Mounting Bolts 81 60 -
Bolts, Engine Mount
Bracket Right
61 45 -
Bolts, Engine Mounting (Refer to 9 ENGINE/
ENGINE MOUNTING)
Bolts, Exhaust Manifold to
Cylinder Head
23 - 200
Bolts, Exhaust Manifold
Heat Shield
12 - 105
Bolts, Intake Manifold -
Lower
28 - 250
Oil Filter 20 15 -
Bolts, Oil Pan 12 - 105
Plug, Oil Pan Drain 27 20 -
Bolts, Oil Pump to Block 28 - 250
Bolts, Oil Pump Cover
Plate
12 - 105
TJ ENGINE 2. 4L 9 - 17
ENGINE 2.4L (Continued)
DESCRIPTION N·m Ft.
Lbs.
In.
Lbs.
Bolt, Oil Pump Pick-up
Tube
28 20 -
Cap - Oil Pump Relief
Valve
41 30 -
Spark Plugs 28 20.6 -
Bolts, Timing Belt Covers
- Front Covers to Rear
Covers
12 - 105
- Rear Cover 12 - 105
Bolts, Timing Belt
Tensioner Assembly
61 45 -
SPECIAL TOOLS
2. 4L ENGINE
Puller 1026
Crankshaft Damper Removal Insert 6827-A
Camshaft Sprocket Holder 6847
Camshaft Seal Remover C-4679-A
Camshaft Seal Installer MD-998306
Crankshaft Damper Installer 6792
Valve Spring Compressor 8215
Adaptor 8436
9 - 18 ENGINE 2. 4L TJ
ENGINE 2.4L (Continued)
Valve Spring Compressor MD998772A
Valve Spring Compressor Adapter 6779
Cylinder Bore Gage C-119
Crankshaft Sprocket Remover 6793
Crankshaft Sprocket Remover Insert C-4685-C2
Crankshaft Seal Remover 6771
Oil Pressure Gauge C-3292
Rear Crankshaft Seal Guide and Installer 6926-1 and
6926-2
Balance Shaft Sprocket Installer 6052
Front Crankshaft Oil Seal Installer 6780
TJ ENGINE 2. 4L 9 - 19
ENGINE 2.4L (Continued)
AIR CLEANER ELEMENT - 2.4L
REMOVAL - 2. 4L
Housi ng removal i s not necessary for el ement (fi l -
ter) repl acement.
(1) Di sconnect ai r i ntake duct at front of el ement
cover.
(2) Pry up spri ng cl i ps (Fi g. 5) from housi ng cover
(spri ng cl i ps retai n cover to housi ng).
(3) Rel ease housi ng cover from l ocati ng tabs
l ocated on housi ng, and remove cover.
(4) Remove ai r cl eaner el ement (fi l ter) from hous-
i ng.
(5) Cl ean i nsi de of housi ng before repl aci ng el e-
ment.
INSTALLATION - 2. 4L
(1) I nstal l el ement i nto housi ng.
(2) Posi ti on housi ng cover i nto housi ng l ocati ng
tabs.
(3) Pry up spri ng cl i ps and l ock cover to housi ng.
(4) Connect ai r i ntake duct.
I f any ai r fi l ter, ai r resonator, ai r i ntake tubes or
ai r fi l ter housi ng cl amps had been l oosened or
removed, ti ghten them to 5 N·m (40 i n. l bs.) torque.
AIR CLEANER HOUSING
REMOVAL
(1)
(2) Di sconnect ai r i ntake duct at front of el ement
cover.
(3) Pry up spri ng cl i ps from housi ng cover (spri ng
cl i ps retai n cover to housi ng).
(4) Rel ease housi ng cover from l ocati ng tabs
l ocated on housi ng, and remove cover. (Fi g. 6)
(5) Remove ai r cl eaner el ement (fi l ter) from hous-
i ng.
(6) Remove vent hose.
(7) Remove the housi ng mounti ng nut.
(8) Remove the ai r cl eaner housi ng.
INSTALLATION
(1) I nstal l the ai r cl eaner housi ng mounti ng
bracket.
(2) I nstal l the ai r cl eaner housi ng and mounti ng
nut. Ti ghten nut to 4.5 N·m ( 40 i n. l bs.).
(3) I nstal l vent hose.
(4) I nstal l ai r cl eaner el ement i nto the housi ng.
(5) Posi ti on the housi ng cover i nto the l ocati ng
tabs on the housi ng and i nstal l the cover.
(6) Pry up the spri ng cl i ps and l ock the cover i n
pl ace.
(7) I nstal l the ai r i ntake duct. (Fi g. 6)
(8) I nstal l the ai r outl et duct.
Combustion Leak Tester C-3685-A
Cylinder Compression Pressure Adaptor 8116
Fig. 5 AIR CLEANER ELEMENT - 2.4L
1 - COVER
2 - HOUSING
3 - CLAMP
4 - SPRING CLIPS
5 - HOUSING MOUNTING NUT
9 - 20 ENGINE 2. 4L TJ
ENGINE 2.4L (Continued)
CYLINDER HEAD
DESCRIPTION
The cross fl ow desi gned, al umi num cyl i nder head
contai ns dual over-head camshafts wi th four val ves
per cyl i nder (Fi g. 7). The val ves are arrange i n two
i n-l i ne banks. The i ntake val ves face toward the l eft
si de of the vehi cl e. The exhaust val ves face the ri ght
si de. The cyl i nder head i ncorporates powdered metal
val ve gui des and seats. The cyl i nder head i s seal ed to
the bl ock usi ng a mul ti -l ayer steel head gasket and
retai ni ng bol ts.
I ntegral oi l gal l eri es provi di ng l ubri cati on passages
to the hydraul i c l ash adjusters, camshafts, and val ve
mechani sms.
OPERATION
The cyl i nder head cl oses the combusti on chamber,
al l owi ng the pi stons to compress the fuel /ai r mi xture
for i gni ti on. The val ves are actuated by the l obe pro-
fi l es on the camshaft to open and cl ose at speci fi ed
durati on to ei ther al l ow cl ean ai r i n the combusti on
chamber or the exhaust gases out; dependi ng on the
stroke of the engi ne.
DIAGNOSIS AND TESTING - CYLINDER HEAD
GASKET
A cyl i nder head gasket l eak can be l ocated between
adjacent cyl i nders or between a cyl i nder and the
adjacent water jacket.
Possi bl e i ndi cati ons of the cyl i nder head gasket
l eaki ng between adjacent cyl i nders are:
• Loss of engi ne power
• Engi ne mi sfi ri ng
• Poor fuel economy
Possi bl e i ndi cati ons of the cyl i nder head gasket
l eaki ng between a cyl i nder and an adjacent water
jacket are:
• Engi ne overheati ng
• Loss of cool ant
• Excessi ve steam (whi te smoke) emi tti ng from
exhaust
• Cool ant foami ng
CYLINDER-TO-CYLINDER LEAKAGE TEST
To determi ne i f an engi ne cyl i nder head gasket i s
l eaki ng between adjacent cyl i nders, fol l ow the proce-
dures i n Cyl i nder Compressi on Pressure Test (Refer
to 9 - ENGI NE - DI AGNOSI S AND TESTI NG). An
engi ne cyl i nder head gasket l eaki ng between adja-
Fig. 6 AIR CLEANER ELEMENT - 2.4L
1 - COVER
2 - HOUSING
3 - CLAMP
4 - SPRING CLIPS
5 - HOUSING MOUNTING NUT
Fig. 7 Cylinder Head and Camshafts
1 - CAMSHAFT BEARING CAPS
2 - PLUG
3 - CAMSHAFT
4 - CYLINDER HEAD
5 - CAMSHAFT OIL SEAL
TJ ENGINE 2. 4L 9 - 21
AIR CLEANER HOUSING (Continued)
cent cyl i nders wi l l resul t i n approxi matel y a 50 - 70%
reducti on i n compressi on pressure.
CYLINDER-TO-WATER JACKET LEAKAGE TEST
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING WITH COOLANT PRES-
SURE CAP REMOVED.
VISUAL TEST METHOD
Wi th the engi ne cool , remove the cool ant pressure
cap. Start the engi ne and al l ow i t to warm up unti l
thermostat opens.
I f a l arge combusti on/compressi on pressure l eak
exi sts, bubbl es wi l l be vi si bl e i n the cool ant.
COOLING SYSTEM TESTER METHOD
WARNING: WITH COOLING SYSTEM TESTER IN
PLACE, PRESSURE WILL BUILD UP FAST. EXCES-
SIVE PRESSURE BUILT UP, BY CONTINUOUS
ENGINE OPERATION, MUST BE RELEASED TO A
SAFE PRESSURE POINT. NEVER PERMIT PRES-
SURE TO EXCEED 138 kPa (20 psi).
I nstal l Cool i ng System Tester 7700 or equi val ent to
pressure cap neck. Start the engi ne and observe the
tester’s pressure gauge. I f gauge pul sates wi th every
power stroke of a cyl i nder a combusti on pressure
l eak i s evi dent.
CHEMICAL TEST METHOD
Combusti on l eaks i nto the cool i ng system can al so
be checked by usi ng Bl oc-Chek Ki t C-3685-A or
equi val ent. Perform test fol l owi ng the procedures
suppl i ed wi th the tool ki t.
REMOVAL - CYLINDER HEAD
(1) Perform fuel system pressure rel ease procedure
before attempting any repairs. (Refer to 14 -
FUEL SYSTEM/FUEL DELI VERY - SPECI FI CA-
TI ONS)
(2) Di sconnect battery negati ve cabl e.
(3) Drai n cool i ng system. (Refer to 7 - COOLI NG -
STANDARD PROCEDURE)
(4) Remove ai r fi l ter housi ng and i nl et tube.
(5) Remove i ntake mani fol d.
(6) Remove heater tube support bracket from cyl -
i nder head.
(7) Di sconnect radi ator upper and heater suppl y
hoses from water outl et connecti ons.
(8) Remove accessory dri ve bel ts. (Refer to 7 -
COOLI NG/ACCESSORY DRI VE/DRI VE BELTS -
REMOVAL)
(9) Rai se vehi cl e and remove exhaust pi pe from
mani fol d.
(10) Remove power steeri ng pump and set asi de.
Do not di sconnect l i nes.
(11) Remove accessory dri ve bracket
(12) Remove i gni ti on coi l and wi res from engi ne.
(13) Di sconnect cam sensor and fuel i njector wi r-
i ng connectors.
(14) Remove ti mi ng bel t and camshaft sprockets.
(Refer to 9 - ENGI NE/VALVE TI MI NG/TI MI NG
BELT/CHAI N AND SPROCKETS - REMOVAL)
(15) Remove ti mi ng bel t i dl er pul l ey and rear ti m-
i ng bel t cover. (Refer to 9 - ENGI NE/VALVE TI M-
I NG/TI MI NG BELT / CHAI N COVER(S) -
REMOVAL)
(16) Remove cyl i nder head cover. (Refer to 9 -
ENGI NE/CYLI NDER HEAD/CYLI NDER HEAD
COVER(S) - REMOVAL)
(17) Remove camshafts (Refer to 9 - ENGI NE/
CYLI NDER HEAD/CAMSHAFT(S) - REMOVAL).
NOTE: Identify rocker arm position to ensure cor-
rect re-installation in original position, if reused.
(18) Remove rocker arms. (Refer to 9 - ENGI NE/
CYLI NDER HEAD/ROCKER ARMS - REMOVAL).
(19) Remove cyl i nder head bol ts i n REVERSE
sequence of ti ghteni ng.
(20) Remove cyl i nder head from engi ne bl ock.
(21) I nspect and cl ean cyl i nder head. (Refer to 9 -
ENGI NE/CYLI NDER HEAD - I NSPECTI ON) (Refer
to 9 - ENGI NE/CYLI NDER HEAD - CLEANI NG)
CLEANING
To ensure engi ne gasket seal i ng, proper surface
preparati on must be performed, especi al l y wi th the
use of al umi num engi ne components and mul ti -l ayer
steel cyl i nder head gaskets.
NOTE: Multi-Layer Steel (MLS) head gaskets require
a scratch free sealing surface.
Remove al l gasket materi al from cyl i nder head and
bl ock (Refer to 9 - ENGI NE - STANDARD PROCE-
DURE). Be careful not to gouge or scratch the al umi -
num head seal i ng surface.
Cl ean al l engi ne oi l passages.
INSPECTION
(1) Cyl i nder head must be fl at wi thi n 0.1 mm
(0.004 i n.) (Fi g. 8).
(2) I nspect camshaft beari ng journal s for scori ng.
(3) Remove carbon and varni sh deposi ts from
i nsi de of val ve gui des wi th a rel i abl e gui de cl eaner.
(4) Usi ng a smal l hol e gauge and a mi crometer,
measure val ve gui des i n 3 pl aces top, mi ddl e and bot-
tom (Fi g. 9). (Refer to 9 - ENGI NE - SPECI FI CA-
TI ONS) Repl ace gui des i f they are not wi thi n
speci fi cati on.
9 - 22 ENGINE 2. 4L TJ
CYLINDER HEAD (Continued)
(5) Check val ve gui de hei ght (Fi g. 10).
INSTALLATION - CYLINDER HEAD
NOTE: The Cylinder head bolts should be examined
BEFORE reuse. If the threads are necked down, the
bolts must be replaced (Fig. 11).
Necki ng can be checked by hol di ng a scal e or
strai ght edge agai nst the threads. I f al l the threads
do not contact the scal e, the bol t shoul d be repl aced.
(1) Before i nstal l i ng the bol ts, the threads shoul d
be coated wi th engi ne oi l .
(2) Posi ti on cyl i nder head gasket on engi ne bl ock
(Fi g. 12).
(3) I nstal l cyl i nder head on engi ne bl ock.
(4) Ti ghten the cyl i nder head bol ts i n the sequence
shown i n (Fi g. 13). Usi ng the 4 step torque turn
method, ti ghten accordi ng to the fol l owi ng val ues:
• Fi rst Al l to 34 N·m (25 ft. l bs.)
• Second Al l to 68 N·m (50 ft. l bs.)
• Thi rd Al l to 68 N·m (50 ft. l bs.)
CAUTION: Do not use a torque wrench for the fol-
lowing step.
Fig. 8 Checking Cylinder Head Flatness
1 - FEELER GAUGE
2 - STRAIGHT EDGE
Fig. 9 Checking Wear on Valve Guide - Typical
1 - TOP
2 - MIDDLE
3 - BOTTOM
4 - CUT AWAY VIEW OF VALVE GUIDE MEASUREMENT
LOCATIONS
Fig. 10 Valve Guide Height
1 - VALVE GUIDE
2 - 13.25 - 13.75 MM (.521 - .541 IN.)
3 - SPRING SEAT
Fig. 11 Checking Bolts for Stretching (Necking)
1 - STRETCHED BOLT
2 - THREADS ARE NOT STRAIGHT ON LINE
3 - THREADS ARE STRAIGHT ON LINE
4 - UNSTRETCHED BOLT
Fig. 12 Cylinder Head Gasket Positioning
1 - PART NUMBER FACES UP
2 - NO. 1 CYLINDER
TJ ENGINE 2. 4L 9 - 23
CYLINDER HEAD (Continued)
• Fourth Turn an addi ti onal 1/4 Turn,
(5) I nstal l rocker arms. (Refer to 9 - ENGI NE/
CYLI NDER HEAD/ROCKER ARMS - I NSTALLA-
TI ON)
(6) I nstal l camshafts. (Refer to 9 - ENGI NE/CYL-
I NDER HEAD/CAMSHAFT(S) - I NSTALLATI ON).
(7) I nstal l cyl i nder head cover. (Refer to 9 -
ENGI NE/CYLI NDER HEAD/CYLI NDER HEAD
COVER(S) - I NSTALLATI ON)
(8) I nstal l ti mi ng bel t rear cover and ti mi ng bel t
i dl er pul l ey. (Refer to 9 - ENGI NE/VALVE TI MI NG/
TI MI NG BELT / CHAI N COVER(S) - I NSTALLA-
TI ON)
(9) I nstal l ti mi ng bel t and camshaft sprockets.
(Refer to 9 - ENGI NE/VALVE TI MI NG/TI MI NG
BELT/CHAI N AND SPROCKETS - I NSTALLATI ON)
(10) Connect cam sensor and fuel i njectors wi ri ng
connectors.
(11) I nstal l i gni ti on coi l and wi res. Connect i gni -
ti on coi l wi ri ng connector.
(12) I nstal l accessary dri ve bracket.
(13) I nstal l power steeri ng pump to cyl i nder head.
(14) Rai se vehi cl e and i nstal l the exhaust pi pe to
the mani fol d.
(15) I nstal l accessory dri ve bel ts. (Refer to 7 -
COOLI NG/ACCESSORY DRI VE/DRI VE BELTS -
I NSTALLATI ON)
(16) I nstal l heater tube support bracket to cyl i nder
head.
(17) I nstal l i ntake mani fol d.
(18) Connect al l vacuum l i nes, el ectri cal wi ri ng,
ground straps and fuel l i ne.
(19) Fi l l cool i ng system. (Refer to 7 - COOLI NG -
STANDARD PROCEDURE)
(20) Connect battery negati ve cabl e.
CAMSHAFT OIL SEAL(S)
REMOVAL
(1) Remove ti mi ng bel t. (Refer to 9 - ENGI NE/
VALVE TI MI NG/TI MI NG BELT/CHAI N AND
SPROCKETS - REMOVAL)
(2) Hol d each camshaft sprocket wi th Speci al Tool
6847 whi l e removi ng center bol t (Fi g. 14).
(3) Remove camshaft sprockets.
(4) Remove exhaust camshaft target ri ng.
(5) Remove exhaust camshaft sensor.
CAUTION: Inspect sensor and target ring for exces-
sive wear. Clean sensor face and install new spacer
pad.
(6) Remove rear ti mi ng bel t cover. (Refer to 9 -
ENGI NE/VALVE TI MI NG/TI MI NG BELT / CHAI N
COVER(S) - REMOVAL)
(7) Remove camshaft seal usi ng Speci al Tool
C-4679-A (Fi g. 15).
CAUTION: Do not nick shaft seal surface or seal
bore.
INSTALLATION
NOTE: Clean and inspect sensor and target ring for
excessive wear. Clean sensor face and always
install a new spacer pad.
(1) Shaft seal surface must be free of varni sh, di rt
or ni cks. Pol i sh wi th 400 gri t paper i f necessary.
Fig. 13 Cylinder Head Tightening Sequence
Fig. 14 Camshaft Sprocket - Removal/Installation
1 - SPECIAL TOOL 6847
9 - 24 ENGINE 2. 4L TJ
CYLINDER HEAD (Continued)
(2) I nstal l camshaft seal s i nto cyl i nder head usi ng
Speci al Tool MD-998306 unti l fl ush wi th head (Fi g.
16).
(3) I nstal l ti mi ng bel t rear cover. (Refer to 9 -
ENGI NE/VALVE TI MI NG/TI MI NG BELT / CHAI N
COVER(S) - I NSTALLATI ON)
NOTE: Target ring tab should provide positive
snap-on fit on the camshaft.
(4) I nstal l exhaust camshaft target ri ng wi th the
word FRONT faci ng forward.
(5) I nstal l exhaust camshaft sensor.
(6) I nstal l camshaft sprockets. Hol d each sprocket
wi th Speci al Tool 6847 and ti ghten center bol t to 101
N·m (75 ft. l bs.).
(7) I nstal l ti mi ng bel t and front covers. (Refer to 9
- ENGI NE/VALVE TI MI NG/TI MI NG BELT/CHAI N
AND SPROCKETS - I NSTALLATI ON) (Refer to 9 -
ENGI NE/VALVE TI MI NG/TI MI NG BELT / CHAI N
COVER(S) - I NSTALLATI ON)
CAMSHAFT(S)
DESCRIPTION
Both nodul ar i ron camshafts have si x beari ng jour-
nal surfaces and two cam l obes per cyl i nder (Fi g. 17).
Fl anges at the rear journal s control camshaft end
pl ay. Provi si on for a cam posi ti on sensor i s l ocated on
the exhaust camshaft on the front of the cyl i nder
head. A hydrodynami c oi l seal i s used for oi l control
at the front of the camshaft.
OPERATION
The camshaft i s dri ven by the crankshaft vi a dri ve
sprockets and bel t. The camshaft has preci sel y
machi ned l obes to provi de accurate val ve ti mi ng and
durati on.
STANDARD PROCEDURE - CAMSHAFT
END-PLAY
(1) Oi l camshaft journal s and i nstal l camshaft
WITHOUT cam fol l ower assembl i es. I nstal l rear cam
caps and ti ghten screws to speci fi ed torque.
(2) Usi ng a sui tabl e tool , move camshaft as far
rearward as i t wi l l go.
Fig. 15 Camshaft Oil Seal - Removal With C-4679-A
1 - SPECIAL TOOL C-4679
Fig. 16 Camshaft Seal - Installation
1 - SPECIAL TOOL MD 998306
Fig. 17 Camshafts
1 - CAMSHAFT BEARING CAPS
2 - PLUG
3 - CAMSHAFT
4 - CYLINDER HEAD
5 - CAMSHAFT OIL SEAL
TJ ENGINE 2. 4L 9 - 25
CAMSHAFT OIL SEAL(S) (Continued)
(3) Zero di al i ndi cator (Fi g. 18).
(4) Move camshaft as far forward as i t wi l l go.
(5) Record readi ng on di al i ndi cator. For end pl ay
speci fi cati on, (Refer to 9 - ENGI NE - SPECI FI CA-
TI ONS).
(6) I f end pl ay i s excessi ve, check cyl i nder head
and camshaft for wear; repl ace as necessary.
REMOVAL
(1) Remove cyl i nder head cover. (Refer to 9 -
ENGI NE/CYLI NDER HEAD/CYLI NDER HEAD
COVER(S) - REMOVAL)
(2) Remove camshaft posi ti on sensor and camshaft
target magnet. (Refer to 8 - ELECTRI CAL/I GNI -
TI ON CONTROL/CAMSHAFT POSI TI ON SENSOR -
REMOVAL)
(3) Remove ti mi ng bel t. (Refer to 9 - ENGI NE/
VALVE TI MI NG/TI MI NG BELT/CHAI N AND
SPROCKETS - REMOVAL)
(4) Remove camshaft sprockets and ti mi ng bel t
rear cover. (Refer to 9 - ENGI NE/VALVE TI MI NG/
TI MI NG BELT / CHAI N COVER(S) - REMOVAL)
(5) Beari ng caps are i denti fi ed for l ocati on.
Remove the outsi de beari ng caps fi rst (Fi g. 19).
(6) Loosen the camshaft beari ng cap attachi ng
fasteners i n sequence shown (Fi g. 20) one camshaft
at a ti me.
CAUTION: Camshafts are not interchangeable. The
intake cam number 6 thrust bearing face spacing is
wider.
(7) I denti fy the camshafts before removi ng from
the head. The camshafts are not i nterchangeabl e.
(8) Remove camshafts from cyl i nder head.
NOTE: If removing rocker arms, identify for reinstal-
lation in the original position.
CLEANING
Cl ean camshaft wi th a sui tabl e sol vent.
INSPECTION
(1) I nspect camshaft beari ng journal s for damage
and bi ndi ng (Fi g. 21). I f journal s are bi ndi ng, check
the cyl i nder head for damage. Al so check cyl i nder
head oi l hol es for cl oggi ng.
(2) Check the cam l obe and beari ng surfaces for
abnormal wear and damage. Repl ace camshaft i f
defecti ve.
NOTE: If camshaft is replaced due to lobe wear or
damage, always replace the rocker arms.
(3) Measure the l obe actual wear (unworn area -
wear zone = actual wear) (Fi g. 21) and repl ace cam-
shaft i f out of l i mi t. Standard val ue i s 0.0254 mm
(0.001 i n.), wear limit i s 0.254 mm (0.010 i n.).
Fig. 18 Camshaft End Play - Typical
Fig. 19 Camshaft Bearing Cap Identification
Fig. 20 Camshaft Bearing Cap - Removal
1 - REMOVE OUTSIDE BEARING CAPS FIRST
9 - 26 ENGINE 2. 4L TJ
CAMSHAFT(S) (Continued)
INSTALLATION
CAUTION: Ensure that NONE of the pistons are at
top dead center when installing the camshafts.
(1) Lubri cate al l camshaft beari ng journal s, rocker
arms and camshaft l obes.
(2) I nstal l al l rocker arms i n ori gi nal posi ti ons, i f
reused.
(3) Posi ti on camshafts on cyl i nder head beari ng
journal s. I nstal l ri ght and l eft camshaft beari ng caps
No. 2 – 5 and ri ght No. 6. Ti ghten M6 fasteners to 12
N·m (105 i n. l bs.) i n sequence shown i n (Fi g. 22).
(4) Appl y Mopar௡ Gasket Maker to No. 1 and No.
6 beari ng caps (Fi g. 23). I nstal l beari ng caps and
ti ghten M8 fasteners to 28 N·m (250 i n. l bs.).
NOTE: Bearing end caps must be installed before
seals can be installed.
(5) I nstal l camshaft oi l seal s. (Refer to 9 -
ENGI NE/CYLI NDER HEAD/CAMSHAFT OI L
SEAL(S) - I NSTALLATI ON)
(6) I nstal l camshaft target magnet and camshaft
posi ti on sensor.
(7) I nstal l cyl i nder head cover. (Refer to 9 -
ENGI NE/CYLI NDER HEAD/CYLI NDER HEAD
COVER(S) - I NSTALLATI ON)
(8) I nstal l ti mi ng bel t rear cover and camshaft
sprocket. (Refer to 9 - ENGI NE/VALVE TI MI NG/
TI MI NG BELT / CHAI N COVER(S) - I NSTALLA-
TI ON)
(9) I nstal l ti mi ng bel t. (Refer to 9 - ENGI NE/
VALVE TI MI NG/TI MI NG BELT/CHAI N AND
SPROCKETS - I NSTALLATI ON)
CYLINDER HEAD COVER
REMOVAL
(1) Remove i ntake mani fol d. (Refer to 9 -
ENGI NE/MANI FOLDS/I NTAKE MANI FOLD -
REMOVAL)
(2) Remove i gni ti on coi l and spark pl ug wi res.
(3) Di sconnect PCV and make-up ai r hoses from
cyl i nder head cover.
(4) Remove cyl i nder head cover bol ts.
(5) Remove cyl i nder head cover from cyl i nder
head.
CLEANING
Cl ean cyl i nder head and cover mati ng surfaces
usi ng a sui tabl e sol vent.
INSPECTION
I nspect cover rai l s for fl atness.
Fig. 21 Checking Camshaft(s) for Wear
1 - UNWORN AREA
2 - ACTUAL WEAR
3 - BEARING JOURNAL
4 - LOBE
5 - WEAR ZONE
Fig. 22 Camshaft Bearing Cap Tightening Sequence
Fig. 23 Camshaft Bearing Cap Sealing
1 - 1.5 mm (.060 in.) DIAMETER BEAD OF MOPAR GASKET
MAKER
TJ ENGINE 2. 4L 9 - 27
CAMSHAFT(S) (Continued)
INSTALLATION
NOTE: Replace spark plug well seals and bolt
assemblies when installing a new cylinder head
cover gasket.
(1) I nstal l new cyl i nder head cover gaskets and
spark pl ug wel l seal s (Fi g. 24).
(2) Repl ace cyl i nder head cover bol t assembl i es
(Fi g. 25).
CAUTION: Do not allow oil or solvents to contact
the timing belt as they can deteriorate the rubber
and cause tooth skipping.
(3) Appl y Mopar௡ Engi ne RTV GEN I I at the
camshaft cap corners and at the top edges of the 1/2
round seal (Fi g. 26).
(4) I nstal l cyl i nder head cover assembl y to cyl i n-
der head. I nstal l al l bol ts, ensuri ng the two (2) bol ts
contai ni ng the seal i ng washer are l ocated i n the cen-
ter l ocati ons of cover. Ti ghten bol ts i n sequence
shown i n (Fi g. 27). Usi ng a 3 step torque method as
fol l ows:
(a) Ti ghten al l bol ts to 4.5 N·m (40 i n. l bs.).
(b) Ti ghten al l bol ts to 9.0 N·m (80 i n. l bs.).
(c) Ti ghten al l bol ts to 12 N·m (105 i n. l bs.).
(5) I nstal l i ntake mani fol d.
(6) I nstal l i gni ti on coi l and spark pl ug wi res.
Ti ghten fasteners to 12 N·m (105 i n. l bs.).
(7) I f the PCV val ve was removed, appl y Mopar௡
Thread Seal ant wi th Tefl on to threads and i nstal l
val ve to cyl i nder head cover. Ti ghten PCV val ve to 8
N·m (70 i n. l bs.).
(8) Connect PCV and make-up ai r hoses to cyl i n-
der head cover.
Fig. 24 Spark Plug Well Seals
Fig. 25 Cylinder Head Cover Bolt Assembly
Fig. 26 Sealer Locations - Typical
1 – SEALER LOCATION
9 - 28 ENGINE 2. 4L TJ
CYLINDER HEAD COVER (Continued)
INTAKE/EXHAUST VALVES &
SEATS
DESCRIPTION
The four val ves per cyl i nder are opened by usi ng
rol l er rocker arms whi ch pi vot on hydraul i c l ash
adjusters. The val ves have chrome pl ated val ve
stems. Vi ton rubber val ve stem seal s are i ntegral
wi th the spri ng seats. They have chrome pl ated
stems to prevent scuffi ng. Vi ton rubber val ve stem
seal s are i ntegral wi th the spri ng seats. The val ves,
spri ng retai ners,and l ocks, are the 3 - bead l ock
desi gn
CLEANING
(1) Cl ean al l val ves thoroughl y and di scard
burned, warped and cracked val ves.
VALVE SPRINGS
REMOVAL
REMOVAL - CYLINDER HEAD ON
(1) Remove camshafts.
(2) Rotate crankshaft unti l pi ston i s at TDC on
compressi on.
(3) Wi th ai r hose attached to adapter tool i nstal l ed
i n spark pl ug hol e, appl y 90-120 psi ai r pressure.
(4) Usi ng Speci al Tool MD-998772-A wi th adapter
6779 (Fi g. 28), compress val ve spri ngs and remove
val ve l ocks.
(5) Remove val ve spri ng(s).
(6) Remove val ve stem seal (s) by a usi ng val ve
stem seal tool (Fi g. 30).
REMOVAL - CYLINDER HEAD OFF
(1) Wi th cyl i nder head removed from cyl i nder
bl ock, compress val ve spri ngs usi ng a uni versal val ve
spri ng compressor.
(2) Remove val ve retai ni ng l ocks, val ve spri ng
retai ners, val ve stem seal s and val ve spri ngs.
(3) Before removi ng val ves, remove any burrs
from valve stem lock grooves to prevent dam-
age to the valve guides. I denti fy val ves, l ocks and
retai ners to i nsure i nstal l ati on i n ori gi nal l ocati on.
(4) I nspect the val ves. (Refer to 9 - ENGI NE/CYL-
I NDER HEAD/VALVE SPRI NGS - I NSPECTI ON)
INSPECTION
(1) Whenever val ves have been removed for i nspec-
ti on, recondi ti oni ng or repl acement, val ve spri ngs
shoul d be tested for correct tensi on. Di scard the
spri ngs that do not meet speci fi cati ons. The fol l owi ng
speci fi cati ons appl y to both i ntake and exhaust
val ves spri ngs:
• Val ve Cl osed Nomi nal Tensi on - 76 l bs. @ 38.0
mm (1.50 i n.)
• Val ve Open Nomi nal Tensi on - 136 l bs. @ 29.75
mm (1.17 i n.)
(2) I nspect each val ve spri ng for squareness wi th a
steel square and surface pl ate, test spri ngs from both
ends. I f the spri ng i s more than 1.5 mm (1/16 i nch)
out of square, i nstal l a new spri ng.
Fig. 27 CYLINDER HEAD TIGHTENING SEQUENCE
Fig. 28 Valve Spring - Removal/Installation
1 - VALVE SPRING COMPRESSOR MD 998772A
2 - AIR HOSE
TJ ENGINE 2. 4L 9 - 29
CYLINDER HEAD COVER (Continued)
INSTALLATION
INSTALLATION - CYLINDER HEAD ON
(1) I nstal l val ve seal /val ve spri ng seat assembl y
(Fi g. 29). Push the assembl y down to seat i t onto the
val ve gui de.
(2) I nstal l val ve spri ng and retai ner, use Speci al
Tool MD-998772-A wi th adapter 6779 to compress
val ve spri ngs onl y enough to i nstal l l ocks. Correct
al i gnment of tool i s necessary to avoi d ni cki ng val ve
stems.
(3) Remove ai r hose and i nstal l spark pl ugs.
(4) I nstal l camshafts and cyl i nder head cover .
INSTALLATION - CYLINDER HEAD OFF
(1) Coat val ve stems wi th cl ean engi ne oi l and
i nsert i n cyl i nder head.
(2) I nstal l new val ve stem seal s on al l val ves
usi ng a val ve stem seal tool (Fi g. 30). The val ve stem
seal s shoul d be pushed fi rml y and squarel y over
val ve gui de.
CAUTION: When oversize valves are used, the cor-
responding oversize valve seal must also be used.
Excessive guide wear may result if oversize seals
are not used with oversize valves.
(3) I nstal l val ve spri ngs and retai ners. Compress
val ve spri ngs onl y enough to i nstal l l ocks, taki ng
care not to mi sal i gn the di recti on of compressi on.
Ni cked val ve stems may resul t from mi sal i gnment of
the val ve spri ng compressor.
CAUTION: When depressing the valve spring retain-
ers with valve spring compressor the locks can
become dislocated. Ensure both locks are in the
correct location after removing tool.
(4) Check the val ve spri ng i nstal l ed hei ght B after
refaci ng the val ve and seat (Fi g. 31). Make sure mea-
surements are taken from top of spri ng seat to the
bottom surface of spri ng retai ner. I f hei ght i s greater
than 38.75 mm (1.525 i n.), i nstal l a 0.762 mm (0.030
i n.) spacer under the val ve spri ng seat to bri ng
spri ng hei ght back wi thi n speci fi cati on.
HYDRAULIC LIFTERS
DIAGNOSIS AND TESTING - LASH ADJUSTER
(TAPPET) NOISE DIAGNOSIS
A tappet-l i ke noi se may be produced from several
i tems. Check the fol l owi ng i tems.
(1) Engi ne oi l l evel too hi gh or too l ow. Thi s may
cause aerated oi l to enter the adjusters and cause
them to be spongy.
(2) I nsuffi ci ent runni ng ti me after rebui l di ng cyl i n-
der head. Low speed runni ng up to 1 hour may be
requi red.
Fig. 29 Valve Stem Seal/Valve Spring Seat - Typical
1 - 3-GROOVE -VALVE RETAINING LOCKS
2 - VALVE SPRING
3 - VALVE SEAL AND VALVE SPRING SEAT ASSEMBLY
4 - VALVE SPRING RETAINER
Fig. 30 Valve Stem Oil Seal Tool
1 - VALVE SEAL TOOL
2 - VALVE STEM
Fig. 31 Checking Spring Installed Height and Valve
Tip Height Dimensions
1 - GARTER SPRING
2 - VALVE SPRING SEAT
3 - CYLINDER HEAD SURFACE
9 - 30 ENGINE 2. 4L TJ
VALVE SPRINGS (Continued)
(3) Duri ng thi s ti me, turn engi ne off and l et set for
a few mi nutes before restarti ng. Repeat thi s several
ti mes after engi ne has reached normal operati ng
temperature.
(4) Low oi l pressure.
(5) The oi l restri ctor (i ntegral to the head gasket)
i n the verti cal oi l passage to the cyl i nder head i s
pl ugged wi th debri s.
(6) Ai r i ngested i nto oi l due to broken or cracked
oi l pump pi ck up.
(7) Worn val ve gui des.
(8) Rocker arm ears contacti ng val ve spri ng
retai ner.
(9) Rocker arm l oose, adjuster stuck or at maxi -
mum extensi on and sti l l l eaves l ash i n the system.
(10) Faul ty l ash adjuster.
a. Check l ash adjusters for spongi ness whi l e
i nstal l ed i n cyl i nder head. Depress part of rocker
arm over adjuster. Normal adjusters shoul d feel very
fi rm. Spongy adjusters can be bottomed out easi l y.
b. Remove suspected l ash adjusters, and repl ace as
necessary.
REMOVAL
NOTE: This procedure is for in-vehicle service with
camshafts installed.
(1) Remove cyl i nder head cover. (Refer to 9 -
ENGI NE/CYLI NDER HEAD/CYLI NDER HEAD
COVER(S) - REMOVAL)
(2) Remove the camshafts (Refer to 9 - ENGI NE/
CYLI NDER HEAD/CAMSHAFT(S) - REMOVAL).
(3) Remove rocker arm. (Refer to 9 - ENGI NE/
CYLI NDER HEAD/ROCKER ARMS - REMOVAL)
(4) Remove hydraul i c l i fter (Fi g. 32).
(5) Repeat removal procedure for each hydraul i c
l i fter.
(6) I f reusi ng, mark each hydraul i c l i fter for reas-
sembl y i n ori gi nal posi ti on. Li fters are servi ced as an
assembl y.
INSTALLATION
(1) I nstal l hydraul i c l i fter (Fi g. 32). Ensure the
l i fters are at l east parti al l y ful l of engi ne oi l . Thi s i s
i ndi cated by l i ttl e or no pl unger travel when the
l i fter i s depressed.
(2) I nstal l rocker arm. (Refer to 9 - ENGI NE/CYL-
I NDER HEAD/ROCKER ARMS - I NSTALLATI ON)
(3) Repeat i nstal l ati on procedure for each hydrau-
l i c l i fter.
(4) I nstal l camshafts (Refer to 9 - ENGI NE/CYL-
I NDER HEAD/CAMSHAFT(S) - I NSTALLATI ON).
(5) I nstal l cyl i nder head cover. (Refer to 9 -
ENGI NE/CYLI NDER HEAD/CYLI NDER HEAD
COVER(S) - I NSTALLATI ON)
ROCKER ARMS
REMOVAL
NOTE: This procedure is for in-vehicle service with
camshafts installed.
(1) Remove cyl i nder head cover. (Refer to 9 -
ENGI NE/CYLI NDER HEAD/CYLI NDER HEAD
COVER(S) - REMOVAL)
(2) Remove fuel rai l . (Refer to 14 - FUEL SYS-
TEM/FUEL DELI VERY/FUEL RAI L - REMOVAL)
(3) Remove spark pl ugs.
(4) Rotate engi ne unti l the camshaft l obe, on the
fol l ower bei ng removed, i s posi ti on on i ts base ci rcl e
(heel ). Al so, the pi ston shoul d be a mi ni mum of 6.3
mm (0.25 i n) bel ow TDC posi ti on.
CAUTION: If cam follower assemblies are to be
reused, always mark position for reassembly in
their original positions.
(5) Usi ng Speci al Tool s 8215 and 8436 sl owl y
depress val ve assembl y unti l rocker arm can be
removed (Fi g. 33).
NOTE: It may be necessary to remove additional
brackets or components to allow clearance for tool
handle movement.
(6) Repeat removal procedure for each rocker arm.
INSPECTION
I nspect the rocker arm for wear or damage (Fi g.
34). Repl ace as necessary.
INSTALLATION
(1) Lubri cate rocker arm wi th cl ean engi ne oi l .
Fig. 32 Hydraulic Lash Adjuster
TJ ENGINE 2. 4L 9 - 31
HYDRAULIC LIFTERS (Continued)
(2) Usi ng Speci al Tool s 8215 and 8436 sl owl y
depress val ve assembl y unti l rocker arm can be
i nstal l ed on the hydraul i c l i fter and val ve stem.
(3) Repeat i nstal l ati on procedure for each rocker
arm.
(4) I nstal l spark pl ugs.
(5) I nstal l fuel rai l . (Refer to 14 - FUEL SYSTEM/
FUEL DELI VERY/FUEL RAI L - I NSTALLATI ON)
(6) I nstal l cyl i nder head cover. (Refer to 9 -
ENGI NE/CYLI NDER HEAD/CYLI NDER HEAD
COVER(S) - I NSTALLATI ON)
ENGINE BLOCK
DESCRIPTION
The cast i ron cyl i nder bl ock i s a two-pi ece assem-
bl y, consi sti ng of the cyl i nder bl ock and bedpl ate (Fi g.
35). The bedpl ate i ncorporates the mai n beari ng caps
and bol ts to the cyl i nder bl ock. Thi s desi gn offers a
much stronger l ower end and i ncreased cyl i nder
bl ock ri gi di ty. The rear oi l seal retai ner i s i ntegral
wi th the bl ock. The bedpl ate and bl ock are servi ced
as an assembl y.
STANDARD PROCEDURE
STANDARD PROCEDURE - PISTON TO
CYLINDER BORE FITTING
Pi ston and cyl i nder wal l must be cl ean and dry.
Pi ston di ameter shoul d be measured 90 degrees to
pi ston pi n about 14 mm (9/16 i nch.) from the bottom
of the ski rt as shown i n (Fi g. 37). Cyl i nder bores
shoul d be measured hal fway down the cyl i nder bore
and transverse to the engi ne crankshaft center l i ne
shown i n (Fi g. 36). Refer to for Engi ne Speci fi cati ons
(Refer to 9 - ENGI NE - SPECI FI CATI ONS). Correct
pi ston to bore cl earance must be establ i shed i n order
to assure qui et and economi cal operati on.
NOTE: Pistons and cylinder bores should be mea-
sured at normal room temperature, 21°C (70°F).
STANDARD PROCEDURE - CYLINDER BORE
HONING
(1) Used careful l y, the cyl i nder bore resi zi ng hone,
recommended tool C-823 or equi val ent, equi pped wi th
220 gri t stones, i s the best tool for thi s honi ng proce-
dure. I n addi ti on to degl azi ng, i t wi l l reduce taper and
out-of-round as wel l as removi ng l i ght scuffi ng, scori ng
or scratches. Usual l y a few strokes wi l l cl ean up a bore
and mai ntai n the requi red l i mi ts.
Fig. 33 Rocker Arm - Removal/Installation
1 - SPECIAL TOOL 8215
2 - ROCKER ARM
3 - SPECIAL TOOL 8436
Fig. 34 Rocker Arm - Typical
1 - TIP
2 - LASH ADJUSTER POCKET
3 - ROLLER
Fig. 35 2.4L Cylinder Block and Bedplate - Typical
1 - CYLINDER BLOCK
2 - BEDPLATE
9 - 32 ENGINE 2. 4L TJ
ROCKER ARMS (Continued)
(2) Degl azi ng of the cyl i nder wal l s may be done
usi ng a cyl i nder surfaci ng hone, recommended tool
C-3501 or equi val ent, equi pped wi th 280 gri t stones,
i f the cyl i nder bore i s strai ght and round. 20–60
strokes dependi ng on the bore condi ti on, wi l l be suf-
fi ci ent to provi de a sati sfactory surface. Use a l i ght
honi ng oi l . Do not use engine or transmission oil,
mineral spirits or kerosene. I nspect cyl i nder wal l s
after each 20 strokes.
(3) Honi ng shoul d be done by movi ng the hone up
and down fast enough to get a cross-hatch pattern.
When hone marks intersect at 40-60 degrees, the
cross hatch angl e i s most sati sfactory for proper seat-
i ng of ri ngs (Fi g. 38).
(4) A control l ed hone motor speed between
200–300 RPM i s necessary to obtai n the proper cross-
hatch angl e. The number of up and down strokes per
mi nute can be regul ated to get the desi red 40–60
degree angl e. Faster up and down strokes i ncrease
the cross-hatch angl e.
(5) After honi ng, i t i s necessary that the bl ock be
cl eaned agai n to remove al l traces of abrasi ve.
CAUTION: Ensure all abrasives are removed from
engine parts after honing. It is recommended that a
solution of soap and hot water be used with a
brush and the parts then thoroughly dried. The bore
can be considered clean when it can be wiped
clean with a white cloth and cloth remains clean.
Oil the bores after cleaning to prevent rusting.
CLEANING
Cl ean cyl i nder bl ock thoroughl y usi ng a sui tabl e
cl eani ng sol vent.
INSPECTION
ENGINE BLOCK
(1) Cl ean cyl i nder bl ock thoroughl y and check al l
core hol e pl ugs for evi dence of l eaki ng.
(2) I f new core pl ugs are to be i nstal l ed, (Refer to 9
- ENGI NE - STANDARD PROCEDURE - ENGI NE
CORE AND OI L GALLERY PLUGS).
(3) Exami ne bl ock and cyl i nder bores for cracks or
fractures.
(4) Check bl ock deck surfaces for fl atness. Deck
surface must be wi thi n servi ce l i mi t of 0.1 mm (0.004
i n.).
CYLINDER BORE
NOTE: The cylinder bores should be measured at
normal room temperature, 21°C (70°F).
Fig. 36 Checking Cylinder Bore -Typical
Fig. 37 Piston Measurement - Typical
Fig. 38 Cylinder Bore Cross-Hatch Pattern
1 - CROSS-HATCH PATTERN
2 - 40°–60°
TJ ENGINE 2. 4L 9 - 33
ENGINE BLOCK (Continued)
The cyl i nder wal l s shoul d be checked for out-of-
round and taper wi th Tool C119 or equi val ent (Fi g.
39) (Refer to 9 - ENGI NE - SPECI FI CATI ONS). I f
the cyl i nder wal l s are badl y scuffed or scored, the
cyl i nder bl ock shoul d be repl aced, and new pi stons
and ri ngs fi tted.
Measure the cyl i nder bore at three l evel s i n di rec-
ti ons A and B (Fi g. 39). Top measurement shoul d be
10 mm (3/8 i n.) down and bottom measurement
shoul d be 10 mm (3/8 i n.) up from bottom of bore.
(Refer to 9 - ENGI NE - SPECI FI CATI ONS).
CONNECTING ROD BEARINGS
STANDARD PROCEDURE
CONNECTING ROD - FITTING
(1) For measuri ng connecti ng rod beari ng cl ear-
ance procedure and use of Pl asti gage(Refer to 9 -
ENGI NE - STANDARD PROCEDURE). For beari ng
cl earance refer to Engi ne Speci fi cati ons. (Refer to 9 -
ENGI NE - SPECI FI CATI ONS)
NOTE: The rod bearing bolts should not be reused.
(2) Before i nstal l i ng the NEW bol ts the threads
shoul d be oi l ed wi th cl ean engi ne oi l .
(3) I nstal l each bol t fi nger ti ght then al ternatel y
torque each bol t to assembl e the cap properl y.
(4) Ti ghten the bol ts to 27 N·m PLUS 1/4 turn (20
ft. l bs. PLUS 1/4 turn) Do not use a torque
wrench for last step.
(5) Usi ng a feel er gauge, check connecti ng rod si de
cl earance (Fi g. 40). Refer to cl earance speci fi cati ons
(Refer to 9 - ENGI NE - SPECI FI CATI ONS).
CRANKSHAFT
DESCRIPTION
The crankshaft i s made of nodul ar cast i ron and
i ncl udes fi ve mai n beari ng journal s and four connect-
i ng rod journal s (Fi g. 41). The number three journal
i s the l ocati on for the thrust beari ng. The mai ns and
connecti ng rod journal s have undercut fi l l et radi uses
that are rol l ed for added strength. To opti mi ze bear-
i ng l oadi ng, ei ght counterwei ghts are used.
OPERATION
The crankshaft transfers force generated by com-
busti on wi thi n the cyl i nder to the fl ywheel or fl ex-
pl ate.
STANDARD PROCEDURE - CRANKSHAFT END
PLAY
(1) Usi ng Di al I ndi cator C-3339 and Mounti ng
Post L-4438, attach to front of engi ne, l ocati ng probe
perpendi cul ar on nose of crankshaft (Fi g. 42).
(2) Move crankshaft al l the way to the rear of i ts
travel .
(3) Zero the di al i ndi cator.
(4) Move crankshaft al l the way to the front and
read the di al i ndi cator. Refer to Engi ne Speci fi ca-
ti ons.
Fig. 39 Checking Cylinder Bore Size
Fig. 40 Connecting Rod Side Clearance
9 - 34 ENGINE 2. 4L TJ
ENGINE BLOCK (Continued)
REMOVAL
NOTE: Crankshaft can not be removed when engine
is in vehicle.
(1) Remove engi ne assembl y from vehi cl e. (Refer to
9 - ENGI NE - REMOVAL)
(2) Remove fl ex pl ate and crankshaft rear oi l seal .
(3) Mount engi ne on a repai r stand.
(4) Drai n engi ne oi l and remove oi l fi l ter.
(5) Remove the oi l pan. (Refer to 9 - ENGI NE/LU-
BRI CATI ON/OI L PAN - REMOVAL)
(6) Remove the ti mi ng bel t covers. (Refer to 9 -
ENGI NE/VALVE TI MI NG/TI MI NG BELT / CHAI N
COVER(S) - REMOVAL)
(7) Remove the ti mi ng bel t. (Refer to 9 - ENGI NE/
VALVE TI MI NG/TI MI NG BELT/CHAI N AND
SPROCKETS - REMOVAL)
(8) Remove the oi l pump. (Refer to 9 - ENGI NE/
LUBRI CATI ON/OI L PUMP - REMOVAL)
(9) Remove bal ance shafts and housi ng assembl y.
(Refer to 9 - ENGI NE/VALVE TI MI NG/BALANCE
SHAFT - REMOVAL)
(10) Usi ng a permanent i nk or pai nt marker, i den-
ti fy cyl i nder number on each connecti ng rod cap (Fi g.
43).
CAUTION: DO NOT use a number stamp or a punch
to mark connecting rods. Damage to connecting
rod could occur.
(11) Remove al l connecti ng rod bol ts and caps.
Care shoul d be taken not to damage the fracture rod
and cap surfaces.
NOTE: Do not reuse connecting rod bolts.
(12) Remove al l bedpl ate bol ts from the engi ne
bl ock (Fi g. 44).
(13) Usi ng a mal l et gentl y tap the bedpl ate l oose
from the engi ne bl ock dowel pi ns.
CAUTION: Do not pry up on one side of the bed-
plate. Damage may occur to cylinder block to bed-
plate alignment and thrust bearing.
(14) Bedpl ate shoul d be removed evenl y from the
cyl i nder bl ock dowel pi ns to prevent damage to the
dowel pi ns and thrust beari ng.
(15) Li ft out crankshaft from cyl i nder bl ock. Do
not damage the mai n beari ngs or journal s when
removi ng the crankshaft.
(16) Remove the target ri ng mounti ng screws and
di scard.
(17) Remove the target ri ng from the crankshaft.
Fig. 41 Crankshaft - Typical
1 - MAIN BEARING JOURNALS
2 - COUNTER BALANCE WEIGHTS
Fig. 42 CHECKING CRANKSHAFT END PLAY
Fig. 43 Identify Connecting Rod to Cylinder-Typical
TJ ENGINE 2. 4L 9 - 35
CRANKSHAFT (Continued)
INSPECTION
The crankshaft journal s shoul d be checked for
excessi ve wear, taper and scori ng (Fi g. 45). Li mi ts of
taper or out of round on any crankshaft journal s
shoul d wi thi n speci ti fi cati ons. (Refer to 9 - ENGI NE -
SPECI FI CATI ONS) Journal gri ndi ng shoul d not
exceed 0.305 mm (0.012 i n.) under the standard jour-
nal di ameter. DO NOT gri nd thrust faces of No. 3
mai n beari ng. DO NOT ni ck crank pi n or beari ng fi l -
l ets. After gri ndi ng, remove rough edges from crank-
shaft oi l hol es and cl ean out al l passages.
CAUTION: With the nodular cast iron crankshafts, it
is important that the final paper or cloth polish be
in the same direction as normal rotation in the
engine.
INSTALLATION
(1) I nstal l the mai n beari ng shel l s wi th the l ubri -
cati on groove i n the cyl i nder bl ock (Fi g. 46).
(2) Make certai n oi l hol es i n bl ock l i ne up wi th oi l
hol e i n beari ngs and beari ng tabs seat i n the bl ock
tab sl ots.
CAUTION: Do not get oil on the bedplate mating
surface. It will affect the sealer ability to seal the
bedplate to cylinder block.
NOTE: If the crankshaft is sent out for machine
work, it must be balenced as an assembly with the
target ring installed.
(3) Cl ean crankshaft and target ri ng wi th
MOPAR௡ brake parts cl eaner and dry wi th com-
pressed ai r to ensure that the crankshaft mati ng sur-
face and target ri ng mounti ng hol es are free from oi l
and l ock patch debri s.
NOTE: Always use NEW mounting screws whether
installing original or new target ring.
(4) I nstal l NEW mounti ng screws fi nger ti ght
starti ng wi th the #1 l ocati on. (Fi g. 47) Make sure
engagment occurs wi th the shoul der of the screw and
mounti ng hol e before starti ng al l other screws.
(5) Torque al l mounti ng screws wi th T30 torx bi t
to 13 Nm (110 i n-l bs) fol l owi ng the torque sequence.
CAUTION: Use extreme care when handling crank-
shaft. Tone wheel damage can occur if crankshaft is
mis-handled.
(6) Oi l the beari ngs and journal s. I nstal l crank-
shaft.
CAUTION: Use only the specified anaerobic sealer
on the bedplate or damage may occur to the
engine.
Fig. 44 Bedplate Bolt Tightening Sequence
Fig. 45 Crankshaft Journal Measurements
Fig. 46 Installing Main Bearing Upper Shell
1 - LUBRICATION GROOVES
2 - OIL HOLES
9 - 36 ENGINE 2. 4L TJ
CRANKSHAFT (Continued)
(7) Appl y 1.5 to 2.0 mm (0.059 to 0.078 i n.) bead of
Mopar௡ Bed Pl ate Seal ant to cyl i nder bl ock as shown
i n (Fi g. 48).
(8) I nstal l l ower mai n beari ngs i nto mai n beari ng
cap/bedpl ate. Make certai n the beari ng tabs are
seated i nto the bedpl ate sl ots. I nstal l the mai n bear-
i ng/bedpl ate i nto engi ne bl ock.
(9) Before i nstal l i ng the bol ts the threads shoul d
be oi l ed wi th cl ean engi ne oi l , wi pe off any excess oi l .
(10) I nstal l mai n beari ng bedpl ate to engi ne bl ock
bol ts 11, 17, and 20 fi nger ti ght. Ti ghten these bol ts
down together unti l the bedpl ate contacts the cyl i n-
der bl ock.
(11) To ensure correct thrust beari ng al i gnment,
perform the fol l owi ng steps:
• Step 1: Rotate crankshaft unti l number 4 pi ston
i s at TDC.
• Step 2: Move crankshaft rearward to l i mi ts of
travel .
• Step 3: Then, move crankshaft forward to l i mi ts
of travel .
• Step 4: Wedge an appropri ate tool between the
rear of the cyl i nder bl ock (NOT BED PLATE) and
the rear crankshaft counterwei ght. Thi s wi l l hol d the
crankshaft i n i t’s furthest forward posi ti on.
• Step 5: I nstal l and ti ghten bol ts (1–10) i n
sequence shown i n (Fi g. 49) to 41 N·m (30 ft. l bs.).
• Step 6: Remove wedge tool used to hol d crank-
shaft.
(12) Ti ghten bol ts (1–10) agai n to 41 N·m (30 ft.
l bs.) +1/4 turn i n sequence shown i n (Fi g. 49).
(13) I nstal l mai n beari ng bedpl ate to engi ne bl ock
bol ts (11–20), and torque each bol t to 28 N·m (20 ft.
l bs.) i n sequence shown i n (Fi g. 49).
(14) After the mai n beari ng bedpl ate i s i nstal l ed,
check the crankshaft turni ng torque. The turni ng
torque shoul d not exceed 5.6 N·m (50 i n. l bs.).
(15) I nstal l connecti ng rod beari ngs and caps. Do
Not Reuse Connecting Rod Bolts. Torque connect-
i ng rod bol ts to 27 N·m (20 ft. l bs.) pl us 1/4 turn.
(16) I nstal l bal ance shafts and housi ng assembl y.
(Refer to 9 - ENGI NE/VALVE TI MI NG/BALANCE
SHAFT - I NSTALLATI ON)
(17) I nstal l the oi l pump and pi ckup tube. (Refer
to 9 - ENGI NE/LUBRI CATI ON/OI L PUMP -
I NSTALLATI ON)
(18) I nstal l the ti mi ng bel t rear cover. (Refer to 9 -
ENGI NE/VALVE TI MI NG/TI MI NG BELT / CHAI N
COVER(S) - I NSTALLATI ON)
(19) I nstal l the ti mi ng bel t. (Refer to 9 - ENGI NE/
VALVE TI MI NG/TI MI NG BELT/CHAI N AND
SPROCKETS - I NSTALLATI ON)
(20) I nstal l the ti mi ng bel t front covers. (Refer to 9
- ENGI NE/VALVE TI MI NG/TI MI NG BELT / CHAI N
COVER(S) - I NSTALLATI ON)
(21) I nstal l engi ne support bracket.
Fig. 47 Target Ring Torque Sequence
Fig. 48 Bedplate Sealing
Fig. 49 Bedplate Bolt Torque Sequence
TJ ENGINE 2. 4L 9 - 37
CRANKSHAFT (Continued)
(22) I nstal l the oi l pan. (Refer to 9 - ENGI NE/LU-
BRI CATI ON/OI L PAN - I NSTALLATI ON)
(23) I nstal l the oi l fi l ter.
(24) I nstal l crankshaft rear oi l seal . (Refer to 9 -
ENGI NE/ENGI NE BLOCK/CRANKSHAFT OI L
SEAL - REAR - I NSTALLATI ON)
(25) I nstal l fl ex pl ate. Appl y Mopar௡ Lock & Seal
Adhesi ve to bol t threads and ti ghten to 95 N·m (70
ft. l bs.).
(26) I nstal l the engi ne assembl y. (Refer to 9 -
ENGI NE - I NSTALLATI ON)
CRANKSHAFT MAIN
BEARINGS
STANDARD PROCEDURE - MAIN BEARING -
FITTING
For crankshaft speci fi cati ons (Refer to 9 - ENGI NE
- SPECI FI CATI ONS).
CRANKSHAFT MAIN BEARINGS
The crankshaft i s supported i n fi ve mai n beari ngs.
Al l upper and l ower beari ng shel l s i n the crankcase
have oi l grooves. Crankshaft end pl ay i s control l ed by
a fl anged beari ng on the number three mai n beari ng
journal (Fi g. 50).
Upper and l ower Number 3 beari ng hal ves are
fl anged to carry the crankshaft thrust l oads and are
NOT i nterchangeabl e wi th any other beari ng hal ves
i n the engi ne (Fi g. 50). Al l beari ng cap bol ts removed
duri ng servi ce procedures are to be cl eaned and oi l ed
before i nstal l ati on. Beari ng shel l s are avai l abl e i n
standard and the fol l owi ng undersi zed: 0.025 mm
(0.001 i n.) and 0.250 mm (0.010 i n.). Never i nstal l an
undersi ze beari ng that wi l l reduce cl earance bel ow
speci fi cati ons. Repl ace or machi ne the crankshaft as
necessary to obtai n proper beari ng cl earances.
MAIN BEARING INSTALLATION
(1) I nstal l the mai n beari ng shel l s wi th the l ubri -
cati on groove i n the cyl i nder bl ock (Fi g. 51).
(2) Make certai n oi l hol es i n bl ock l i ne up wi th oi l
hol es i n beari ngs. Beari ng tabs must seat i n the
bl ock tab sl ots.
CAUTION: Do not get oil on the bedplate mating
surface. It will may effect the sealer ability to seal
the bedplate to cylinder block.
(3) Oi l the beari ngs and journal s and i nstal l
crankshaft.
CAUTION: Use only the specified anaerobic sealer
on the bedplate or damage may occur to the
engine. Ensure that both cylinder block and bed-
plate surfaces are clean.
(4) Appl y 1.5 to 2.0 mm (0.059 to 0.078 i n.) bead
of anaerobi c seal er Mopar௡ Bed Pl ate Seal ant to cyl -
i nder bl ock as shown i n (Fi g. 52).
(5) I nstal l l ower mai n beari ngs i nto mai n beari ng
cap/bedpl ate. Make certai n the beari ng tabs are
seated i nto the bedpl ate sl ots.
(6) Posi ti on the mai n beari ng/bedpl ate onto the
engi ne bl ock.
(7) Before i nstal l i ng bol ts, l ubri cate the threads
wi th cl ean engi ne oi l , wi pe off any excess oi l .
Fig. 50 Main Bearing Identification
1 - OIL GROOVE
2 - MAIN BEARINGS
3 - OIL HOLE
Fig. 51 Installing Main Bearing Upper Shell
1 - LUBRICATION GROOVES
2 - OIL HOLES
9 - 38 ENGINE 2. 4L TJ
CRANKSHAFT (Continued)
(8) I nstal l mai n beari ng bedpl ate to engi ne bl ock
bol ts 11, 17 and 20 fi nger ti ght. Ti ghten these bol ts
down together unti l the bedpl ate contacts the cyl i n-
der bl ock.
(9) To ensure correct thrust beari ng al i gnment,
perform the fol l owi ng steps:
• Step 1: Rotate crankshaft unti l number 4 pi ston
i s at TDC.
• Step 2: Move crankshaft rearward to l i mi ts of
travel .
• Step 3: Then, move crankshaft forward to l i mi ts
of travel .
• Step 4: Wedge an appropri ate tool between the
rear of the cyl i nder bl ock (NOT BED PLATE) and
the rear crankshaft counterwei ght. Thi s wi l l hol d the
crankshaft i n i t’s furthest forward posi ti on.
• Step 5: I nstal l and ti ghten bol ts (1–10) i n
sequence shown i n (Fi g. 53) to 41 N·m (30 ft. l bs.).
• Step 6: Remove wedge tool used to hol d crank-
shaft.
(10) Ti ghten bol ts (1–10) agai n to 41 N·m (30 ft.
l bs.) PLUS 1/4 turn i n sequence shown i n (Fi g. 53).
(11) I nstal l mai n beari ng bedpl ate to engi ne bl ock
bol ts (11–20), and torque each bol t to 28 N·m (20 ft.
l bs.) i n sequence shown i n (Fi g. 53).
(12) After the mai n beari ng bedpl ate i s i nstal l ed,
check the crankshaft turni ng torque. The turni ng
torque shoul d not exceed 5.6 N·m (50 i n. l bs.).
CRANKSHAFT OIL SEAL -
FRONT
REMOVAL
(1) Remove the crankshaft vi brati on damper (Fi g.
54). (Refer to 9 - ENGI NE/ENGI NE BLOCK/VI BRA-
TI ON DAMPER - REMOVAL)
(2) Remove ti mi ng bel t. (Refer to 9 - ENGI NE/
VALVE TI MI NG/TI MI NG BELT/CHAI N AND
SPROCKETS - REMOVAL)
(3) Remove crankshaft sprocket usi ng Speci al Tool
6793 and i nsert C-4685-C2 (Fi g. 55).
CAUTION: Do not nick shaft seal surface or seal
bore.
(4) Usi ng Tool 6771 to remove front crankshaft oi l
seal (Fi g. 56). Be careful not to damage the seal sur-
face of cover.
Fig. 52 Bed plate Sealing
Fig. 53 Main Bearing Caps/Bedplate Tightening
Sequence
Fig. 54 Crankshaft Vibration Damper - Removal -
Typical
1 - SPECIAL TOOL 1026 3-JAW PULLER
2 - SPECIAL TOOL 6827–A INSERT
TJ ENGINE 2. 4L 9 - 39
CRANKSHAFT MAIN BEARINGS (Continued)
INSTALLATION
(1) I nstal l new seal by usi ng Speci al Tool 6780
(Fi g. 57).
(2) Pl ace seal i nto openi ng wi th seal spri ng
towards the i nsi de of engi ne. I nstal l seal unti l fl ush
wi th cover.
(3) I nstal l crankshaft sprocket usi ng Speci al Tool
6792 (Fi g. 58).
(4) I nstal l ti mi ng bel t. (Refer to 9 - ENGI NE/
VALVE TI MI NG/TI MI NG BELT/CHAI N AND
SPROCKETS - I NSTALLATI ON)
(5) I nstal l crankshaft vi brati on damper (Fi g. 59).
(Refer to 9 - ENGI NE/ENGI NE BLOCK/VI BRATI ON
DAMPER - I NSTALLATI ON)
Fig. 55 Crankshaft Sprocket - Removal
1 - SPECIAL TOOL 6793
2 - CRANKSHAFT SPROCKET
Fig. 56 Front Crankshaft Oil Seal - Removal
1 - SPECIAL TOOL 6771
2 - REAR TIMING BELT COVER
Fig. 57 Crankshaft Front Oil Seal - Installation
1 - PROTECTOR
2 - SEAL
3 - SPECIAL TOOL 6780
Fig. 58 Crankshaft Sprocket - Installation
1 - SPECIAL TOOL 6792
2 - TIGHTEN NUT TO INSTALL
9 - 40 ENGINE 2. 4L TJ
CRANKSHAFT OIL SEAL - FRONT (Continued)
CRANKSHAFT OIL SEAL -
REAR
REMOVAL
(1) Remove transmi ssi on.
(2) Remove fl ex pl ate.
(3) I nsert a 3/16 fl at bl aded screwdri ver between
the dust l i p and the metal case of the crankshaft
seal . Angl e the screwdri ver (Fi g. 60)through the dust
l i p agai nst metal case of the seal . Pry out seal .
CAUTION: Do not permit the screwdriver blade to
contact crankshaft seal surface. Contact of the
screwdriver blade against crankshaft edge (cham-
fer) is permitted.
INSTALLATION
CAUTION: If burr or scratch is present on the
crankshaft edge (chamfer), cleanup with 400 grit
sand paper to prevent seal damage during installa-
tion of new seal.
(1) Lubri cate the crankshaft fl ange wi th engi ne oi l .
(2) Pl ace Speci al Tool 6926-1 Seal Gui de on crank-
shaft (Fi g. 61).
(3) Posi ti on seal over gui de tool (Fi g. 61). Gui de
tool shoul d remai n on crankshaft duri ng i nstal l ati on
of seal . Ensure that the l i p of the seal i s faci ng
towards the crankcase duri ng i nstal l ati on.
CAUTION: If the seal is driven into the block past
flush, this may cause an oil leak.
(4) Dri ve the seal i nto the bl ock usi ng Speci al Tool
6926-2 and handl e C-4171 (Fi g. 62) unti l the tool bot-
toms out agai nst the bl ock (Fi g. 63).
(5) I nstal l fl ex pl ate. Appl y Mopar௡ Lock & Seal
Adhesi ve to bol t threads and ti ghten bol ts to 95 N·m
(70 ft. l bs.).
(6) I nstal l the transmi ssi on.
Fig. 59 Crankshaft Vibration Damper - Installation -
Typical
1 - M12–1.75 × 150 MM BOLT, WASHER AND THRUST BEARING
FROM SPECIAL TOOL 6792
Fig. 60 Rear Crankshaft Oil Seal - Removal
1 - REAR CRANKSHAFT SEAL
2 - ENGINE BLOCK
3 - ENGINE BLOCK
4 - REAR CRANKSHAFT SEAL METAL CASE
5 - PRY IN THIS DIRECTION
6 - CRANKSHAFT
7 - SCREWDRIVER
8 - REAR CRANKSHAFT SEAL DUST LIP
9 - SCREWDRIVER
TJ ENGINE 2. 4L 9 - 41
CRANKSHAFT OIL SEAL - FRONT (Continued)
PISTON & CONNECTING ROD
DESCRIPTION
The pi stons are made of a cast al umi num al l oy.
The pi stons have pressed-i n pi ns attached to forged
powdered metal connecti ng rods. The pi stons pi n i s
offset 1 mm (0.0394 i n.) towards the thrust si de of
the pi ston. The connecti ng rods are a cracked cap
desi gn and are not repai rabl e. Hex head cap screws
are used to provi de al i gnment and durabi l i ty i n the
assembl y. The pi stons and connecti ng rods are ser-
vi ced as an assembl y.
OPERATION
The pi ston and connecti ng rod i s the l i nk between
the combusti on force to the crankshaft.
REMOVAL
NOTE: Cylinder Head must be removed before Pis-
tons and Rods. Refer to Cylinder Head Removal in
this section.
Fig. 61 Rear Crankshaft Seal and Special Tool
6926-1
1 - SPECIAL TOOL 6926–1 PILOT
2 - SEAL
Fig. 62 Crankshaft Seal and Special Tools 6926-2 &
C-4171
1 - SPECIAL TOOL 6926–1 PILOT
2 - SEAL
3 - SPECIAL TOOL 6926–2 INSTALLER
4 - SPECIAL TOOL C-4171
Fig. 63 Rear Crankshaft Seal - Installation
1 - SPECIAL TOOL 6926–2 INSTALLER
9 - 42 ENGINE 2. 4L TJ
CRANKSHAFT OIL SEAL - REAR (Continued)
(1) Remove top ri dge of cyl i nder bores wi th a rel i -
abl e ri dge reamer before removi ng pi stons from cyl -
i nder bl ock. Be sure to keep tops of pistons
covered during this operation. Mark pi ston wi th
matchi ng cyl i nder number (Fi g. 64).
(2) Remove oi l pan. Scri be the cyl i nder number on
the si de of the rod and cap (Fi g. 65) for i denti fi cati on.
(3) Pi stons have a di recti onal stampi ng i n the
front hal f of the pi ston faci ng towards the front of
engi ne.
(4) Pi stons and connecti ng rods must be removed
from top of cyl i nder bl ock. Rotate crankshaft so that
each connecti ng rod i s centered i n cyl i nder bore.
(5) Remove Bal ance Shaft Assembl y. Refer to Bal -
ance Shaft Removal i n thi s secti on.
(6) Remove connecti ng rod cap bol ts. Push each
pi ston and rod assembl y out of cyl i nder bore.
NOTE: Be careful not to nick crankshaft journals.
(7) After removal , i nstal l beari ng cap on the mat-
i ng rod.
(8) Pi ston and Rods are servi ced as an assembl y.
INSTALLATION
(1) Before i nstal l i ng pi stons and connecti ng rod
assembl i es i nto the bore, be sure that compressi on
ri ng gaps are staggered so that nei ther i s i n l i ne wi th
oi l ri ng rai l gap.
(2) Before i nstal l i ng the ri ng compressor, make
sure the oi l ri ng expander ends are butted and the
rai l gaps l ocated as shown i n (Fi g. 66). As vi ewed
from top.
(3) I mmerse the pi ston head and ri ngs i n cl ean
engi ne oi l , sl i de the ri ng compressor, over the pi ston
(Fi g. 67). Be sure position of rings does not
change during this operation .
(4) The di recti onal stamp on the pi ston shoul d face
toward the front of the engi ne.
(5) Rotate crankshaft so that the connecti ng rod
journal i s on the center of the cyl i nder bore. I nsert
rod and pi ston assembl y i nto cyl i nder bore and gui de
rod over the crankshaft journal .
(6) Tap the pi ston down i n cyl i nder bore, usi ng a
hammer handl e. At the same ti me, gui de connecti ng
rod i nto posi ti on on connecti ng rod journal .
Fig. 64 Piston Markings
1 - DIRECTIONAL ARROW WILL BE IMPRINTED IN THIS AREA
Fig. 65 Identify Connecting Rod to Cylinder
Fig. 66 Piston Ring End Gap Position
1 - GAP OF LOWER SIDE RAIL
2 - NO. 1 RING GAP
3 - GAP OF UPPER SIDE RAIL
4 - NO. 2 RING GAP AND SPACER EXPANDER GAP
Fig. 67 Piston - Installation
TJ ENGINE 2. 4L 9 - 43
PISTON & CONNECTING ROD (Continued)
NOTE: The connecting rod cap bolts should not be
reused.
(7) Before i nstal l i ng the NEW bol ts the threads
shoul d be coated wi th cl ean engi ne oi l .
(8) I nstal l each bol t fi nger ti ght than al ternatel y
torque each bol t to assembl e the cap properl y.
CAUTION: Do not use a torque wrench for second
part of last step.
(9) Ti ghten the bol ts to 54 N·m PLUS 1/4 turn (40
ft. l bs. PLUS 1/4 turn).
(10) Usi ng a feel er gauge, check connecti ng rod
si de cl earance (Fi g. 68).
PISTON RINGS
STANDARD PROCEDURE
PISTON RING - FITTING
(1) Wi pe cyl i nder bore cl ean. I nsert ri ng and push
down wi th pi ston to ensure i t i s square i n bore. The
ri ng gap measurement must be made wi th the ri ng
posi ti oni ng at l east 12 mm (0.50 i nch) from bottom of
cyl i nder bore. Check gap wi th feel er gauge (Fi g. 69).
Refer to Engi ne Speci fi cati ons.
(2) Check pi ston ri ng to groove si de cl earance (Fi g.
70). Refer to Engi ne Speci fi cati ons.
Fig. 68 Checking Connecting Rod Side Clearance
Fig. 69 Piston Ring Gap
1 - FEELER GAUGE
Fig. 70 Piston Ring Side Clearance
1 - FEELER GAUGE
9 - 44 ENGINE 2. 4L TJ
PISTON & CONNECTING ROD (Continued)
PISTON RINGS - INSTALLATION
(1) I nstal l ri ngs wi th manufacturers I .D. mark fac-
i ng up, to the top of the pi ston (Fi g. 71).
CAUTION: Install piston rings in the following
order:
a. Oi l ri ng expander.
b. Upper oi l ri ng si de rai l .
c. Lower oi l ri ng si de rai l .
d. No. 2 I ntermedi ate pi ston ri ng.
e. No. 1 Upper pi ston ri ng.
(2) I nstal l the si de rai l by pl aci ng one end
between the pi ston ri ng groove and the expander.
Hol d end fi rml y and press down the porti on to be
i nstal l ed unti l si de rai l i s i n posi ti on. Do not use a
piston ring expander (Fi g. 72).
(3) I nstal l upper si de rai l fi rst and then the l ower
si de rai l .
(4) I nstal l No. 2 pi ston ri ng and then No. 1 pi ston
ri ng.
(5) Posi ti on pi ston ri ng end gaps as shown i n (Fi g.
73).
(6) Posi ti on oi l ri ng expander gap at l east 45°
from the si de rai l gaps but not on the pi ston pi n cen-
ter or on the thrust di recti on. Staggeri ng ri ng gap i s
i mportant for oi l control .
Fig. 71 Piston Ring Installation
1 - NO. 1 PISTON RING
2 - NO. 2 PISTON RING
3 - SIDE RAIL
4 - OIL RING
5 - SPACER EXPANDER
Fig. 72 Installing Side Rail - Typical
1 - SIDE RAIL END
Fig. 73 Piston
1 - GAP OF LOWER SIDE RAIL
2 - NO. 1 RING GAP
3 - GAP OF UPPER SIDE RAIL
4 - NO. 2 RING GAP AND SPACER EXPANDER GAP
TJ ENGINE 2. 4L 9 - 45
PISTON RINGS (Continued)
VIBRATION DAMPER
REMOVAL
(1) Remove accesory dri ve bel ts. (Refer to 7 -
COOLI NG/ACCESSORY DRI VE/DRI VE BELTS -
REMOVAL)
(2) Remove crankshaft damper bol t.
(3) Remove damper usi ng Speci al Tool 3-Jaw
Pul l er 1026 and I nsert 6827–A (Fi g. 74).
INSTALLATION
(1) I nstal l crankshaft vi brati on damper usi ng M12
1.75 x 150 mm bol t, washer, thrust beari ng and nut
from Speci al Tool 6792 (Fi g. 75).
(2) I nstal l crankshaft vi brati on damper bol t and
ti ghten to 142 N·m (105 ft. l bs.).
(3) I nstal l accessory dri ve bel ts. (Refer to 7 -
COOLI NG/ACCESSORY DRI VE/DRI VE BELTS -
I NSTALLATI ON)
STRUCTURAL COLLAR
REMOVAL
(1) Rai se vehi cl e on hoi st.
(2) Remove structural col l ar attachi ng bol ts.
(3) Remove col l ar.
INSTALLATION
CAUTION: Torque procedure for the structural collar
must be followed or damage could occur to oil pan
and collar.
(1) Perform the fol l owi ng steps for i nstal l i ng struc-
tural col l ar.
• Step 1: Posi ti on col l ar between transmi ssi on and
oi l pan. I nstal l col l ar to transmi ssi on bol ts, hand
start only.
• Step 2: I nstal l col l ar to oi l pan bol ts, hand snug
only.
• Step 3: Ti ghten col l ar to transmi ssi on bol ts.
• Step 4: Ti ghten col l ar to oi l pan bol ts.
(2) Lower vehi cl e.
ENGINE MOUNTING
DESCRIPTION
The engi ne mounti ng system consi st of three
mounts; ri ght and a l eft si de support the powertrai n,
and rear mount to control powertrai n torque. The
mounts are of mol ded rubber materi al .
FRONT MOUNT
REMOVAL
(1) Rai se vehi cl e on hoi st.
(2) Remove the front engi ne mount through bol t
from the i nsul ator.
(3) Remove the engi ne front mount bol ts and
remove the i nsul ator assembl y.
(4) Remove the front mounti ng bracket from
engi ne, i f necessary.
INSTALLATION
(1) I nstal l the i nsul ator mount assembl y (Fi g.
76)and (Fi g. 77).
(2) Ti ghten the mount to engi ne bol ts.
(3) Loosel y i nstal l the front engi ne mount through
bol t to the i nsul ator.
Fig. 74 Crankshaft Vibration Damper - Removal -
Typical
1 - SPECIAL TOOL 1026 3-JAW PULLER
2 - SPECIAL TOOL 6827–A INSERT
Fig. 75 Crankshaft Vibration Damper - Installation -
Typical
1 - M12–1.75 × 150 MM BOLT, WASHER AND THRUST BEARING
FROM SPECIAL TOOL 6792
9 - 46 ENGINE 2. 4L TJ
(4) Lower the engi ne.
(5) Ti ghten the through bol t.
(6) Lower the vehi cl e.
REAR MOUNT
REMOVAL
NOTE: A resilient rubber cushion supports the
transmission at the rear between the transmission
extension housing and the rear support crossmem-
ber or skid plate.
(1) Di sconnect negati ve cabl e from battery.
(2) Rai se the vehi cl e and support the transmi ssi on.
(3) Remove the nuts hol di ng the support cushi on
to the crossmember. Remove the crossmember.
MANUAL TRANSMISSION
a. Remove the support cushi on nuts and remove
the cushi on.
b. Remove the transmi ssi on support bracket bol ts
and remove the bracket from the transmi ssi on.
AUTOMATIC TRANSMISSION
c. Remove the support cushi on bol ts and remove
the cushi on and the support bracket from the trans-
mi ssi on (4WD) or from the adaptor bracket (2WD).
d. On 2WD vehi cl es, remove the bol ts hol di ng the
transmi ssi on support adaptor bracket to the trans-
mi ssi on. Remove the adaptor bracket.
INSTALLATION
MANUAL TRANSMISSION:
(1) I nstal l the support cushi on to the transmi ssi on
(Fi g. 78)or (Fi g. 79). I nstal l the bol ts and ti ghten.
(2) Posi ti on the crossmember i n the vehi cl e. I nstal l
the crossmember to mount through bol t and nut.
(3) I nstal l crossmember-to-si l l bol ts and ti ghten to
41 N·m (30 ft. l bs.) torque.
(4) Remove the transmi ssi on support.
(5) Lower the vehi cl e.
(6) Connect negati ve cabl e to battery.
AUTOMATIC TRANSMISSION:
(1) I nstal l the transmi ssi on mount to transmi ssi on
(Fi g. 80) and (Fi g. 81). I nstal l the bol ts.
(2) Posi ti on the crossmember i n the vehi cl e. I nstal l
the crossmember to mount through bol t and nut.
(3) Remove the transmi ssi on support.
(4) Lower the vehi cl e.
(5) Connect negati ve cabl e to battery.
Fig. 76 LH ENGINE MOUNT
1 - ENGINE MOUNT
2 - ENGINE MOUNT BOLT (3)
3 - ENGINE MOUNT THROUGH BOLT
Fig. 77 RH ENGINE MOUNT
1 - ENGINE MOUNT BOLT (4)
2 - ENGINE MOUNT THROUGH BOLT
3 - ENGINE MOUNT
TJ ENGINE 2. 4L 9 - 47
FRONT MOUNT (Continued)
Fig. 78 TRANSMISSION MOUNT - 2.4L MANUAL
TRANS
1 - TRANSMISSION MOUNT
2 - MOUNTING BOLT
Fig. 79 TRANSMISSION MOUNT - 3.7L MANUAL
TRANS 2WD
1 - NUT
2 - BOLT
3 - TRANS MOUNT
Fig. 80 TRANSMISSION MOUNT - 3.7L 2WD AUTO
TRANS
1 - BOLT
2 - MOUNT
Fig. 81 TRANSMISSION MOUNT - 3.7L 4WD AUTO
TRANS
1 - MOUNT
2 - BOLT
9 - 48 ENGINE 2. 4L TJ
REAR MOUNT (Continued)
LUBRICATION
DESCRIPTION
The l ubri cati on system i s a ful l -fl ow fi l trati on,
pressure feed type. The oi l pump i s mounted i n the
front engi ne cover and dri ven by the crankshaft.
OPERATION
Engi ne oi l drawn up through the pi ckup tube and
i s pressuri zed by the oi l pump and routed through
the ful l -fl ow fi l ter to the mai n oi l gal l ery runni ng the
l ength of the cyl i nder bl ock. A di agonal hol e i n each
bul khead feeds oi l to each mai n beari ng. Dri l l ed pas-
sages wi thi n the crankshaft route oi l from mai n bear-
i ng journal s to connecti ng rod journal s. Bal ance shaft
l ubri cati on i s provi ded through an oi l passage from
the number one mai n beari ng cap through the bal -
ance shaft carri er support l eg. Thi s passage di rectl y
suppl i es oi l to the front beari ngs and i nternal
machi ned passages i n the shafts that routes oi l from
front to the rear shaft beari ng journal s. A verti cal
hol e at the number fi ve bul khead routes pressuri zed
oi l through a restri ctor (i ntegral to the cyl i nder head
gasket) up past a cyl i nder head bol t to an oi l gal l ery
runni ng the l ength of the cyl i nder head. The cam-
shaft journal s are parti al l y sl otted to al l ow a prede-
termi ned amount of pressuri zed oi l to pass i nto the
beari ng cap cavi ti es. Lubri cati on of the camshaft
l obes are provi ded by smal l hol es i n the camshaft
beari ng caps that are di rected towards each l obe. Oi l
returni ng to the pan from pressuri zed components
suppl i es l ubri cati on to the val ve stems. Cyl i nder
bores and wri st pi ns are spl ash l ubri cated from
di rected sl ots on the connecti ng rod thrust col l ars.
DIAGNOSIS AND TESTING - ENGINE OIL
PRESSURE CHECKING
(1) Di sconnect and remove oi l pressure swi tch.
(Refer to 9 - ENGI NE/LUBRI CATI ON/OI L PRES-
SURE SENSOR/SWI TCH - REMOVAL)
(2) I nstal l Speci al Tool s C-3292 Gauge wi th 8406
Adaptor fi tti ng.
(3) Start engi ne and record oi l pressure. Refer to
Speci fi cati ons for correct oi l pressure requi rements.
(Refer to 9 - ENGI NE - SPECI FI CATI ONS)
CAUTION: If oil pressure is 0 at idle, do not perform
the 3000 RPM test
(4) I f oi l pressure i s 0 at i dl e. Shut off engi ne,
check for pressure rel i ef val ve stuck open, a cl ogged
oi l pi ck-up screen or a damaged oi l pi ck-up tube
O-ri ng.
(5) After test i s compl ete, remove test gauge and
fi tti ng.
(6) I nstal l oi l pressure swi tch and connector. (Refer
to 9 - ENGI NE/LUBRI CATI ON/OI L PRESSURE
SENSOR/SWI TCH - I NSTALLATI ON)
OIL
STANDARD PROCEDURE
ENGINE OIL LEVEL CHECK
The best ti me to check engi ne oi l l evel i s after i t
has sat overni ght, or i f the engi ne has been runni ng,
al l ow the engi ne to be shut off for at l east 5 mi nutes
before checki ng oi l l evel .
Checki ng the oi l whi l e the vehi cl e i s on l evel
ground wi l l i mprove the accuracy of the oi l l evel
readi ng. Remove di psti ck and observe oi l l evel . Add
oi l onl y when the l evel i s at or bel ow the ADD mark
(Fi g. 82).
STANDARD PROCEDURE - ENGINE OIL AND
FILTER CHANGE
Change engi ne oi l at mi l eage and ti me i nterval s
descri bed i n the Mai ntenance Schedul e. (Refer to
LUBRI CATI ON & MAI NTENANCE/MAI NTE-
NANCE SCHEDULES - DESCRI PTI ON)
WARNING: NEW OR USED ENGINE OIL CAN BE
IRRITATING TO THE SKIN. AVOID PROLONGED OR
REPEATED SKIN CONTACT WITH ENGINE OIL.
CONTAMINANTS IN USED ENGINE OIL, CAUSED BY
INTERNAL COMBUSTION, CAN BE HAZARDOUS TO
YOUR HEALTH. THOROUGHLY WASH EXPOSED
SKIN WITH SOAP AND WATER. DO NOT WASH
SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR
SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO
NOT POLLUTE, DISPOSE OF USED ENGINE OIL
PROPERLY. CONTACT YOUR DEALER OR GOVERN-
MENT AGENCY FOR LOCATION OF COLLECTION
CENTER IN YOUR AREA.
Run engi ne unti l achi evi ng normal operati ng tem-
perature.
(1) Posi ti on the vehi cl e on a l evel surface and turn
engi ne off.
(2) Hoi st and support vehi cl e on safety stands.
Refer to Hoi sti ng and Jacki ng Recommendati ons.
Fig. 82 Oil Level
1 - ENGINE OIL LEVEL DIPSTICK
TJ ENGINE 2. 4L 9 - 49
(Refer to LUBRI CATI ON & MAI NTENANCE/HOI ST-
I NG - STANDARD PROCEDURE)
(3) Remove oi l fi l l cap.
(4) Pl ace a sui tabl e drai n pan under crankcase
drai n.
(5) Remove drai n pl ug from crankcase and al l ow
oi l to drai n i nto pan. I nspect drai n pl ug threads for
stretchi ng or other damage. Repl ace drai n pl ug and
gasket i f damaged.
(6) Remove oi l fi l ter. (Refer to 9 - ENGI NE/LUBRI -
CATI ON/OI L FI LTER - REMOVAL)
(7) I nstal l and ti ghten drai n pl ug i n crankcase.
(8) I nstal l new oi l fi l ter. (Refer to 9 - ENGI NE/LU-
BRI CATI ON/OI L FI LTER - I NSTALLATI ON)
(9) Lower vehi cl e and fi l l crankcase wi th speci fi ed
type and amount of engi ne oi l . (Refer to LUBRI CA-
TI ON & MAI NTENANCE/FLUI D TYPES -
DESCRI PTI ON)
(10) I nstal l oi l fi l l cap.
(11) Start engi ne and i nspect for l eaks.
(12) Stop engi ne and i nspect oi l l evel .
NOTE: Care should be exercised when disposing
used engine oil after it has been drained from a
vehicle engine. Refer to the WARNING listed above.
OIL FILTER
DESCRIPTION
The engi ne oi l fi l ter i s a hi gh qual i ty ful l -fl ow, di s-
posabl e type. Repl ace the oi l fi l ter wi th a Mopar௡ or
the equi val ent.
REMOVAL
(1) Rai se vehi cl e on hoi st.
(2) Posi ti on an oi l col l ecti ng contai ner under oi l fi l -
ter l ocati on.
CAUTION: When servicing the oil filter avoid
deforming the filter can by installing the remove/in-
stall tool band strap against the can to base lock
seam. The lock seam joining the can to the base is
reinforced by the base plate.
(3) Usi ng a sui tabl e fi l ter wrench, turn oi l fi l ter
countercl ockwi se to remove (Fi g. 83).
INSTALLATION
(1) Cl ean and check fi l ter mounti ng surface. The
surface must be smooth, fl at and free of debri s or
pi eces of gasket.
(2) Lubri cate new oi l fi l ter gasket wi th cl ean
engi ne oi l .
(3) Screw oi l fi l ter on unti l the gasket contacts
base. Ti ghten to 21 N·m (15 ft. l bs.).
OIL PAN
REMOVAL
(1) Remove ai r cl eaner assembl y.
(2) Rai se vehi cl e on hoi st and drai n engi ne oi l .
(3) Loosen the engi ne mount thru bol ts.
(4) Di sconnect exhaust pi pe at mani fol d.
(5) Remove structural col l ar, i f equi pped.
(6) Remove front axl e mounti ng bol ts, and l ower
axl e as far possi bl e, i f equi pped.
(7) Posi ti on Speci al Tool 8534 on fender l i p and
al i gn the sl ots i n the brackets wi th the fender
mounti ng hol es.
(8) Secure brackets to the fender usi ng four M6 X
1.0 X 25 MM fl anged cap screws.
(9) Ti ghten the thumbscrews to secure the sl eeves
to the support tube.
(10) Secure the support tube i n an upri ght posi -
ti on.
(11) Assembl e the fl at washer, thrust beari ng,
hook and T handl e.
(12) Usi ng the M10 X 1.5 X 40 mm capscrew sup-
pl i ed wi th the support fi xture, secure the chai n to
the front cover and the hook.
(13) Support engi ne as needed.
(14) Remove oi l pan attachi ng bol ts.
(15) Remove oi l pan.
(16) Cl ean oi l pan and al l gasket surfaces.
INSTALLATION
(1) I nstal l the oi l pan gasket to the bl ock.
Fig. 83 2.4 OIL FILTER
9 - 50 ENGINE 2. 4L TJ
OIL (Continued)
(2) Appl y a 3MM (1/8 i nch) bead of Mopar௡ Engi ne
RTV at the oi l pump to engi ne bl ock parti ng l i ne
(Fi g. 84).
(3) I nstal l pan and ti ghten the screws to 12 N·m
(105 i n. l bs.).
(4) Lower engi ne, and remove Speci al Tool 8534.
(5) Ti ghten engi ne mount thru bol ts.
(6) Rai se the front axl e i nto posi ti on, and rei nstal l
front axl e mounti ng bol ts. I f equi pped.
(7) Reconnect exhaust pi pe to mani fol d.
(8) I nstal l structural col l ar, i f equi pped.
(9) Lower vehi cl e.
(10) Fi l l engi ne crankcase wi th proper oi l to cor-
rect l evel .
(11) Rei nstal l ai r cl eaner assembl y.
OIL PRESSURE SENSOR/
SWITCH
DESCRIPTION
The 3–wi re, el ectri cal /mechani cal engi ne oi l pres-
sure sensor (sendi ng uni t) i s l ocated i n an engi ne oi l
pressure gal l ery.
OPERATION
The oi l pressure sensor uses three ci rcui ts. They
are:
• A 5 vol t power suppl y from the Powertrai n Con-
trol Modul e (PCM)
• A sensor ground through the PCM’s sensor
return
• A si gnal to the PCM rel ati ng to engi ne oi l pres-
sure
The oi l pressure sensor has a 3 wi re el ectri cal
functi on very much l i ke the Mani fol d Absol ute Pres-
sure (MAP) sensor. Meani ng di fferent pressures
rel ate to di fferent output vol tages.
A 5 vol t suppl y i s sent to the sensor from the PCM
to power up the sensor. The sensor returns a vol tage
si gnal back to the PCM rel ati ng to engi ne oi l pres-
sure. Thi s si gnal i s then transferred (bussed) to the
i nstrument panel on ei ther a CCD or PCI bus ci rcui t
(dependi ng on vehi cl e l i ne) to operate the oi l pressure
gauge and the check gauges l amp. Ground for the
sensor i s provi ded by the PCM through a l ow-noi se
sensor return.
OIL PUMP
REMOVAL
(1) Di sconnect negati ve cabl e from battery.
(2) Remove ti mi ng bel t. (Refer to 9 - ENGI NE/
VALVE TI MI NG/TI MI NG BELT/CHAI N AND
SPROCKETS - REMOVAL)
(3) Remove ti mi ng bel t rear cover. (Refer to 9 -
ENGI NE/VALVE TI MI NG/TI MI NG BELT / CHAI N
COVER(S) - REMOVAL)
(4) Remove oi l pan. (Refer to 9 - ENGI NE/LUBRI -
CATI ON/OI L PAN - REMOVAL)
(5) Remove crankshaft sprocket usi ng Speci al
Tool s 6793 and C-4685-C2 (Fi g. 85).
(6) Remove crankshaft key (Fi g. 86).
(7) Remove oi l pi ck-up tube.
(8) Remove oi l pump (Fi g. 87) and front crankshaft
seal .
Fig. 84 OIL PAN GASKET INSTALLATION
1 - SEALER LOCATION
Fig. 85 Crankshaft Sprocket - Removal
1 - SPECIAL TOOL 6793
2 - SPECIAL TOOL C-4685–C2
3 - CRANKSHAFT SPROCKET
TJ ENGINE 2. 4L 9 - 51
OIL PAN (Continued)
DISASSEMBLY
(1) To remove the rel i ef val ve, proceed as fol l ows:
(a) Remove the threaded pl ug and gasket from
the oi l pump.
(b) Remove spri ng and rel i ef val ve.
(2) Remove oi l pump cover fasteners, and l i ft off
cover.
(3) Remove pump rotors.
(4) Wash al l parts i n a sui tabl e sol vent and
i nspect careful l y for damage or wear.
CLEANING
(1) Cl ean al l parts thoroughl y i n a sui tabl e sol -
vent.
INSPECTION
(1) I nspect the mati ng surface of the oi l pump.
Surface shoul d be smooth. Repl ace pump cover i f
scratched or grooved.
(2) Lay a strai ghtedge across the pump cover sur-
face (Fi g. 88). I f a 0.025 mm (0.001 i n.) feel er gauge
can be i nserted between cover and strai ght edge,
cover shoul d be repl aced.
(3) Measure thi ckness and di ameter of outer rotor.
I f outer rotor thi ckness measures 9.40 mm (0.370 i n.)
or l ess (Fi g. 89), or i f the di ameter i s 79.95 mm
(3.148 i n.) or l ess, repl ace outer rotor.
(4) I f i nner rotor measures 9.40 mm (0.370 i n.) or
l ess repl ace i nner rotor (Fi g. 90).
ASSEMBLY
(1) Assembl e pump, usi ng new parts as requi red.
Install the inner rotor with chamfer facing the
cast iron oil pump cover.
(2) Pri me oi l pump before i nstal l ati on by fi l l i ng
rotor cavi ty wi th engi ne oi l .
(3) I nstal l cover and ti ghten fasteners to 12 N·m
(105 i n. l bs.).
CAUTION: Oil pump pressure relief valve must be
installed correctly or serious engine damage may
occur.
(4) I nstal l rel i ef val ve, spri ng, gasket and cap.
Ti ghten cap to 41 N·m (30 ft. l bs.).
Fig. 86 Crankshaft Key
1 - CRANKSHAFT KEY
Fig. 87 2.4L OIL PUMP
1 - BOLTS
2 - BOLTS
Fig. 88 Checking Oil Pump Cover Flatness
1 - STRAIGHT EDGE
2 - FEELER GAUGE
3 - OIL PUMP COVER
9 - 52 ENGINE 2. 4L TJ
OIL PUMP (Continued)
INSTALLATION
(1) Make sure al l surfaces are cl ean and free of oi l
and di rt.
(2) Appl y Mopar௡ Gasket Maker to oi l pump as
shown i n (Fi g. 91). I nstal l O-ri ng i nto oi l pump body
di scharge passage.
(3) Pri me oi l pump wi th engi ne oi l before i nstal l a-
ti on.
(4) Al i gn oi l pump rotor fl ats wi th fl ats on crank-
shaft. I nstal l the oi l pump to the bl ock.
CAUTION: To align, the front crankshaft seal MUST
be out of pump, or damage may result.
(5) I nstal l new front crankshaft seal usi ng Speci al
Tool 6780 (Fi g. 92).
(6) I nstal l crankshaft key (Fi g. 86).
CAUTION: The crankshaft sprocket is set to a pre-
determined depth from the factory for correct tim-
ing belt tracking. If removed, use of Special Tool
6792 is required to set the sprocket to original
installation depth. An incorrectly installed sprocket
will result in timing belt and engine damage.
(7) I nstal l crankshaft sprocket usi ng Speci al Tool
6792 (Fi g. 93).
(8) I nstal l oi l pump pi ck-up tube.
Fig. 89 Measuring Outer Rotor Thickness
Fig. 90 Measuring Inner Rotor Thickness
Fig. 91 Oil Pump Sealing - Typical
1 - O-RING
2 - SEALER LOCATION
Fig. 92 Front Crankshaft Seal - Installation
1 - PROTECTOR
2 - SEAL
3 - SPECIAL TOOL 6780
TJ ENGINE 2. 4L 9 - 53
OIL PUMP (Continued)
(9) I nstal l oi l pan. (Refer to 9 - ENGI NE/LUBRI -
CATI ON/OI L PAN - I NSTALLATI ON)
(10) I nstal l ti mi ng bel t rear cover. (Refer to 9 -
ENGI NE/VALVE TI MI NG/TI MI NG BELT / CHAI N
COVER(S) - I NSTALLATI ON)
(11) I nstal l ti mi ng bel t. (Refer to 9 - ENGI NE/
VALVE TI MI NG/TI MI NG BELT/CHAI N AND
SPROCKETS - I NSTALLATI ON)
INTAKE MANIFOLD
DESCRIPTION
The i ntake mani fol d i s a one pi ece composi te mod-
ul e that attaches to the cyl i nder head wi th fasteners.
The mani fol d i s a l ong branch desi gn to enhance l ow
and mi d-range torque
OPERATION
The i ntake mani fol d del i vers ai r to the combusti on
chambers. Thi s ai r al l ows the fuel del i vered by the
fuel i njectors to i gni te when the spark pl ug fi re.
DIAGNOSIS AND TESTING - INTAKE
MANIFOLD LEAKS
An i ntake mani fol d ai r l eak i s characteri zed by
l ower than normal mani fol d vacuum. Al so, one or
more cyl i nders may not be functi oni ng.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR THE FAN.
DO NOT WEAR LOOSE CLOTHING.
(1) Start the engi ne.
(2) Spray a smal l stream of water (Spray Bottl e) at
the suspected l eak area.
(3) I f engi ne RPM’S change, the area of the sus-
pected l eak has been found.
(4) Repai r as requi red.
REMOVAL
(1) Di sconnect negati ve cabl e from battery.
(2) Di sconnect connector from i nl et ai r tempera-
ture sensor.
(3) Di sconnect ai r i ntake tube at throttl e body and
remove upper ai r cl eaner housi ng.
(4) Di sconnect connector from throttl e posi ti on
sensor (TPS).
(5) Di sconnect connector from i dl e ai r control (I AC)
motor.
(6) Di sconnect connector from MAP sensor.
(7) Remove vacuum l i nes for purge sol enoi d and
PCV val ve at i ntake mani fol d.
(8) Remove vacuum l i nes for power brake booster,
LDP, EGR transducer, and speed control vacuum res-
ervoi r (i f equi pped) at i ntake mani fol d fi tti ngs.
(9) Di sconnect throttl e, speed control (i f equi pped),
and transaxl e control (i f equi pped) and cabl es from
throttl e l ever and bracket. (Refer to 14 - FUEL SYS-
TEM/FUEL I NJECTI ON/THROTTLE CONTROL
CABLE - REMOVAL)
(10) Perform fuel system pressure rel ease proce-
dure before attempting any repairs. (Refer to 14 -
FUEL SYSTEM/FUEL DELI VERY - STANDARD
PROCEDURE)
(11) Di sconnect fuel l i ne. (Refer to 14 - FUEL SYS-
TEM/FUEL DELI VERY/QUI CK CONNECT FI T-
TI NG - STANDARD PROCEDURE)
(12) Di sconnect cool ant temperature sensor/fuel
i njector wi re harness connector.
(13) Di sconnect fuel i njector harness.
(14) Remove i ntake mani fol d to cyl i nder head fas-
teners.
(15) Remove the mani fol d from engi ne.
CAUTION: Cover intake manifold openings to pre-
vent foreign material from entering engine.
(16) I nspect the mani fol d. (Refer to 9 - ENGI NE/
MANI FOLDS/I NTAKE MANI FOLD - I NSPECTI ON)
INSPECTION
(1) Check mani fol d surfaces for fl atness wi th
strai ght edge. Surface must be fl at wi thi n 0.15 mm
per 300 mm (0.006 i n. per foot) of mani fol d l ength.
(2) I nspect mani fol d for cracks or di storti on.
Repl ace mani fol d i f necessary.
Fig. 93 Crankshaft Sprocket - Installation
1 - SPECIAL TOOL 6792
2 - TIGHTEN NUT TO INSTALL
9 - 54 ENGINE 2. 4L TJ
OIL PUMP (Continued)
INSTALLATION
(1) Cl ean mani fol d seal i ng surfaces.
(2) I nstal l new mani fol d to cyl i nder head seal s.
(3) I nstal l mani fol d to head.
(4) I nstal l and ti ghten i ntake mani fol d fasteners to
28 N·m (250 i n. l bs.) i n the sequence shown (Fi g. 94).
Repeat procedure unti l al l bol ts are at speci fi ed
torque.
(5) I nstal l throttl e cabl es i n bracket.
(6) Connect throttl e, speed control , (i f equi pped),
cabl es to throttl e l ever.
(7) Connect vacuum l i nes for power brake booster,
LDP, EGR transducer, and speed control vacuum res-
ervoi r (i f equi pped) at upper i ntake mani fol d fi tti ngs.
(8) Connect vacuum l i nes for purge sol enoi d and
PCV val ve.
(9) Connect el ectri cal connectors for MAP sensor,
throttl e posi ti on sensor (TPS), and i dl e ai r control
(I AC) motor.
(10) Connect the fuel l i ne. (Refer to 14 - FUEL
SYSTEM/FUEL DELI VERY/QUI CK CONNECT FI T-
TI NG - STANDARD PROCEDURE)
(11) Connect cool ant temperature sensor/fuel i njec-
tor wi ri ng harness el ectri cal connector.
(12) I nstal l the ai r cl eaner housi ng and ai r i ntake
tube to throttl e body.
(13) Connect i nl et ai r temperature sensor connec-
tor.
(14) Connect negati ve cabl e to battery.
EXHAUST MANIFOLD
DESCRIPTION
The exhaust mani fol d i s made of Hi -Si l i cone Mol y
nodul ar cast i ron for strength and hi gh tempera-
tures. The mani fol d attaches to the cyl i nder head.
OPERATION
The exhaust mani fol d col l ects the exhaust gasses
exi ti ng the combusti on chambers. Then i t channel s
the exhaust gasses to the exhaust pi pe attached to
the mani fol d.
REMOVAL
(1) Rai se vehi cl e and di sconnect exhaust pi pe from
the exhaust mani fol d.
(2) Lower the vehi cl e.
(3) Di sconnect upstream oxygen sensor connector
at the rear of exhaust mani fol d.
(4) Remove the ai r cl eaner bracket (Fi g. 95).
(5) Remove the heat shi el d.
(6) Remove the bol ts attachi ng the mani fol d to the
cyl i nder head.
(7) Remove exhaust mani fol d.
(8) I nspect the mani fol d. (Refer to 9 - ENGI NE/
MANI FOLDS/EXHAUST MANI FOLD - I NSPEC-
TI ON)
Fig. 94 LOWER INTAKE MANIFOLD TIGHTENING
SEQUENCE
Fig. 95 AIR CLEANER BRACKET
1 - AIR CLEANER BRACKET
2 - BOLT (2)
TJ ENGINE 2. 4L 9 - 55
INTAKE MANIFOLD (Continued)
CLEANING
(1) Di scard gasket (i f equi pped) and cl ean al l sur-
faces of mani fol d and cyl i nder head.
INSPECTION
(1) I nspect mani fol d gasket surfaces for fl atness
wi th strai ght edge. Surface must be fl at wi thi n 0.15
mm per 300 mm (0.006 i n. per foot) of mani fol d
l ength.
(2) I nspect mani fol ds for cracks or di storti on.
Repl ace mani fol d as necessary.
INSTALLATION
(1) Cl ean the mani fol d mati ng surfaces.
(2) I nstal l exhaust mani fol d wi th a new gasket.
Ti ghten attachi ng nuts to 20 N·m (175 i n. l bs.).
(3) Attach exhaust pi pe to exhaust mani fol d and
ti ghten fasteners to 37 N·m (27 ft. l bs.).
(4) I nstal l and connect the oxygen sensor. (Refer to
14 - FUEL SYSTEM/FUEL I NJECTI ON/O2 SENSOR
- COMPONENT LOCATI ON)
(5) I nstal l the heat shi el d.
(6) I nstal l the ai r cl eaner bracket.
TIMING BELT COVER(S)
REMOVAL
FRONT COVER
(1) Remove crankshaft vi brati on damper. (Refer to
9 - ENGI NE/ENGI NE BLOCK/VI BRATI ON
DAMPER - REMOVAL)
(2) Remove generator dri ve bel t tensi oner assem-
bl y. (Refer to 7 - COOLI NG/ACCESSORY DRI VE/
BELT TENSI ONERS - REMOVAL)
(3) Remove ti mi ng bel t front cover bol ts, and
remove covers.
REAR COVER
(1) Remove front covers.
(2) Remove ti mi ng bel t. (Refer to 9 - ENGI NE/
VALVE TI MI NG/TI MI NG BELT/CHAI N AND
SPROCKETS - REMOVAL)
(3) Hol d camshaft sprocket wi th Speci al Tool 6847
whi l e removi ng center bol t.
(4) Remove ti mi ng bel t i dl er pul l ey.
(5) Remove rear cover fasteners and remove cover
from engi ne.
INSTALLATION
REAR COVER
(1) I nstal l ti mi ng bel t rear cover and bol ts (Fi g.
96). Torque bol ts to 12 N·m (105 i n. l bs).
CAUTION: Do not use an impact wrench for tighten-
ing camshaft sprocket bolt. Damage to the timing
locating pin can occur. Hand tighten using a
wrench ONLY.
(2) I nstal l camshaft sprockets, and camshaft target
ri ng. Hol d sprockets wi th Speci al Tool 6848 and
ti ghten center bol t to 101 N·m (75 ft. l bs.).
(3) I nstal l ti mi ng bel t i dl er pul l ey and ti ghten
mounti ng bol t to 61 N·m (45 ft. l bs.).
(4) I nstal l ti mi ng bel t. (Refer to 9 - ENGI NE/
VALVE TI MI NG/TI MI NG BELT/CHAI N AND
SPROCKETS - I NSTALLATI ON)
(5) I nstal l accessory dri ve bracket (Fi g. 97).
(6) I nstal l front covers.
FRONT COVER
(1) I nstal l ti mi ng bel t front covers (Fi g. 98).
Ti ghten fasteners to 7 N·m (60 i n. l bs.).
(2) I nstal l generator dri ve bel t tensi oner. (Refer to
7 - COOLI NG/ACCESSORY DRI VE/BELT TEN-
SI ONERS - I NSTALLATI ON)
(3) I nstal l crankshaft vi brati on damper. (Refer to 9
- ENGI NE/ENGI NE BLOCK/VI BRATI ON DAMPER -
I NSTALLATI ON)
Fig. 96 TIMING BELT REAR COVER FASTENERS
1 - OUTER COVER TO REAR COVER FASTENERS (3)
2 - REAR COVER TO CYLINDER HEAD FASTENERS
3 - OUTER COVER TO REAR COVER FASTENERS (3)
4 - INNER COVER TO BLOCK FASTENERS
9 - 56 ENGINE 2. 4L TJ
EXHAUST MANIFOLD (Continued)
TIMING BELT AND
SPROCKET(S)
REMOVAL
REMOVAL - TIMING BELT
(1) Remove ai r cl eaner upper cover, housi ng, and
cl ean ai r tube.
(2) Rai se vehi cl e on hoi st.
(3) Remove accessory dri ve bel ts. (Refer to 7 -
COOLI NG/ACCESSORY DRI VE/BELT TENSI ON-
ERS - REMOVAL)
(4) Remove crankshaft vi brati on damper. (Refer to
9 - ENGI NE/ENGI NE BLOCK/VI BRATI ON
DAMPER - REMOVAL)
(5) Remove ai r condi ti oner/generator bel t tensi oner
and pul l ey assembl y. (Refer to 7 - COOLI NG/ACCES-
SORY DRI VE/BELT TENSI ONERS - REMOVAL)
(6) Remove ti mi ng bel t l ower front cover bol ts and
remove cover. (Refer to 9 - ENGI NE/VALVE TI MI NG/
TI MI NG BELT / CHAI N COVER(S) - REMOVAL)
(7) Lower vehi cl e.
(8) Remove bol ts attachi ng ti mi ng bel t upper front
cover and remove cover. (Refer to 9 - ENGI NE/
VALVE TI MI NG/TI MI NG BELT / CHAI N COVER(S)
- REMOVAL)
CAUTION: When aligning crankshaft and camshaft
timing marks always rotate engine from crankshaft.
Camshaft should not be rotated after timing belt is
removed. Damage to valve components may occur.
Always align timing marks before removing timing
belt.
(9) Before the removal of the ti mi ng bel t, rotate
crankshaft unti l the TDC mark on oi l pump housi ng
al i gns wi th the TDC mark on crankshaft sprocket
(trai l i ng edge of sprocket tooth) (Fi g. 99).
NOTE: The crankshaft sprocket TDC mark is
located on the trailing edge of the sprocket tooth.
Failure to align trailing edge of sprocket tooth to
TDC mark on oil pump housing will cause the cam-
shaft timing marks to be misaligned.
(10) I nstal l 6 mm Al l en wrench i nto bel t tensi oner.
Before rotati ng the tensi oner, i nsert the l ong end of a
1/8” or 3 mm Al l en wrench i nto the pi n hol e on the
front of the tensi oner (Fi g. 100). Whi l e rotati ng the
tensi oner countercl ockwi se, push i n l i ghtl y on the
1/8” or 3 mm Al l en wrench, unti l i t sl i des i nto the
l ocki ng hol e.
(11) Remove ti mi ng bel t.
Fig. 97 ACCESSORY DRIVE BRACKET
1- UPPER TIMING BELT COVER
2- LOWER TIMING BELT COVER
3- BELT TENSIONER
4- ACCESSORY DRIVE BRACKET
Fig. 98 TIMING BELT COVERS
1- UPPER TIMING BELT COVER
2- REAR TIMING BELT COVER
3- LOWER TIMING BELT COVER
4- ACCESSORY DRIVE BRACKET NOT SHOWN
TJ ENGINE 2. 4L 9 - 57
TIMING BELT COVER(S) (Continued)
REMOVAL - CRANKSHAFT SPROCKET
(1) Di sconnect negati ve battery cabl e.
(2) Remove ti mi ng bel t (Refer to 9 - ENGI NE/
VALVE TI MI NG/TI MI NG BELT/CHAI N AND
SPROCKETS - REMOVAL).
(3) Remove crankshaft sprocket usi ng Speci al
Tool s 6793 and i nsert C-4685-C2 (Fi g. 101).
CLEANING
Do Not attempt to cl ean a ti mi ng bel t. I f contami -
nati on from oi l , grease, or cool ants have occurred, the
ti mi ng bel t shoul d be repl aced.
Cl ean al l sprockets usi ng a sui tabl e sol vent. Cl ean
al l sprocket grooves of any debri s.
INSTALLATION
INSTALLATION - CRANKSHAFT SPROCKET
CAUTION: The crankshaft sprocket is set to a pre-
determined depth from the factory for correct tim-
ing belt tracking. If removed, use of Special Tool
6792 is required to set the sprocket to original
installation depth. An incorrectly installed sprocket
will result in timing belt and engine damage.
(1) I nstal l crankshaft sprocket usi ng Speci al Tool
6792 (Fi g. 102).
(2) I nstal l ti mi ng bel t. (Refer to 9 - ENGI NE/
VALVE TI MI NG/TI MI NG BELT/CHAI N AND
SPROCKETS - I NSTALLATI ON)
Fig. 99 Crankshaft and Camshaft Timing
1 - CAMSHAFT TIMING MARKS
2 - CRANKSHAFT TDC MARKS
3 - TRAILING EDGE OF SPROCKET TOOTH
Fig. 100 Locking Timing Tensioner
1 - 1/8 OR 3mm ALLEN WRENCH
2 - BELT TENSIONER
3 - 6mm ALLEN WRENCH
Fig. 101 Crankshaft Sprocket - Removal
1 - SPECIAL TOOL 6793
2 - SPECIAL TOOL C-4685–C2
3 - CRANKSHAFT SPROCKET
9 - 58 ENGINE 2. 4L TJ
TIMING BELT AND SPROCKET(S) (Continued)
INSTALLATION - TIMING BELT
CAUTION: The crankshaft sprocket is set to a pre-
determined depth from the factory for correct tim-
ing belt tracking. If removed, use of Special Tool
6792 is required to set the sprocket to original
installation depth. An incorrectly installed sprocket
will result in timing belt and engine damage.
(1) Set crankshaft sprocket to TDC by al i gni ng the
sprocket wi th the arrow on the oi l pump housi ng.
(2) Set camshafts ti mi ng marks so that the
exhaust camshaft sprocket i s a 1/2 notch bel ow the
i ntake camshaft sprocket (Fi g. 103).
CAUTION: Ensure that the arrows on both camshaft
sprockets are facing up.
(3) I nstal l ti mi ng bel t. Starti ng at the crankshaft,
go around the water pump sprocket, i dl er pul l ey,
camshaft sprockets and then around the tensi oner
(Fi g. 104).
(4) Move the exhaust camshaft sprocket counter-
cl ockwi se (Fi g. 104) to al i gn marks and take up bel t
sl ack.
(5) I nsert a 6 mm Al l en wrench i nto the hexagon
openi ng l ocated on the top pl ate of the bel t tensi oner
pul l ey. Rotate the top pl ate COUNTERCLOCK-
WISE. The tensi oner pul l ey wi l l move agai nst the
bel t and the tensi oner setti ng notch wi l l eventual l y
start to move cl ockwi se. Watchi ng the movement of
the setti ng notch, conti nue rotati ng the top pl ate
countercl ockwi se unti l the setti ng notch i s al i gned
wi th the spri ng tang (Fi g. 105). Usi ng the al l en
wrench to prevent the top pl ate from movi ng, torque
the tensi oner l ock nut to 30 N·m (22 ft. l bs.). Setti ng
notch and spri ng tang shoul d remai n al i gned after
l ock nut i s torqued.
Fig. 102 Crankshaft Sprocket - Installation
1 - SPECIAL TOOL 6792
2 - TIGHTEN NUT TO INSTALL
Fig. 103 Camshaft Sprocket Alignment
1 - CAMSHAFT SPROCKET-EXHAUST
2 - CAMSHAFT SPROCKET-INTAKE
3 - 1/2 NOTCH LOCATION
Fig. 104 Timing Belt - Installation - Typical
1 - ROTATE CAMSHAFT SPROCKET TO TAKE UP BELT SLACK
2 - CAMSHAFT TIMING MARKS 1/2 NOTCH LOCATION
3 - CRANKSHAFT AT TDC
4 - INSTALL BELT IN THIS DIRECTION
TJ ENGINE 2. 4L 9 - 59
TIMING BELT AND SPROCKET(S) (Continued)
(6) Remove al l en wrench and torque wrench.
NOTE: Repositioning the crankshaft to the TDC posi-
tion must be done only during the CLOCKWISE rota-
tion movement. If TDC is missed, rotate a further two
revolutions until TDC is achieved. DO NOT rotate
crankshaft counterclockwise as this will make verifi-
cation of proper tensioner setting impossible.
(7) Once the ti mi ng bel t has been i nstal l ed and
tensi oner adjusted, rotate the crankshaft CLOCK-
WI SE two compl ete revol uti ons manual l y for seati ng
of the bel t, unti l the crankshaft i s reposi ti oned at the
TDC posi ti on. Veri fy that the camshaft and crank-
shaft ti mi ng marks are i n proper posi ti on (Fi g. 106).
(8) Check i f the spri ng tang i s wi thi n the tol erance
wi ndow (Fi g. 107). I f the spri ng tang i s wi thi n the
tol erance wi ndow, the i nstal l ati on process i s compl ete
and nothi ng further i s requi red. I f the spri ng tang i s
not wi thi n the tol erance wi ndow, repeat Steps 5
through 7.
(9) I nstal l ti mi ng bel t front covers and bol ts.
(Refer to 9 - ENGI NE/VALVE TI MI NG/TI MI NG
BELT / CHAI N COVER(S) - I NSTALLATI ON)
(10) I nstal l ai r condi ti oni ng/generator bel t ten-
si oner and pul l ey. (Refer to 7 - COOLI NG/ACCES-
SORY DRI VE/BELT TENSI ONERS -
I NSTALLATI ON)
Fig. 105 Timing Belt Tension Adjustment
1 - ALIGN SETTING NOTCH WITH SPRING TANG
2 - TOP PLATE
3 - 6mm ALLEN WRENCH
4 - LOCK NUT
5 - SETTING NOTCH
6 - SPRING TANG
Fig. 106 Crankshaft and Camshaft Timing
1 - CAMSHAFT TIMING MARKS
2 - CRANKSHAFT TDC MARKS
3 - TRAILING EDGE OF SPROCKET TOOTH
Fig. 107 Timing Belt Tension Verification
1 - SPRING TANG
2 - TOLERANCE WINDOW
9 - 60 ENGINE 2. 4L TJ
TIMING BELT AND SPROCKET(S) (Continued)
(11) I nstal l crankshaft vi brati on damper. (Refer to
9 - ENGI NE/ENGI NE BLOCK/VI BRATI ON
DAMPER - I NSTALLATI ON)
(12) I nstal l accessory dri ve bel ts. (Refer to 7 -
COOLI NG/ACCESSORY DRI VE/DRI VE BELTS -
I NSTALLATI ON)
(13) I nstal l dri ve bel t spl ash shi el d.
(14) I nstal l ai r cl eaner housi ng, upper cover, and
cl ean ai r tube.
TIMING BELT TENSIONER &
PULLEY
REMOVAL
(1) Remove the ti mi ng bel t. (Refer to 9 - ENGI NE/
VALVE TI MI NG/TI MI NG BELT/CHAI N AND
SPROCKETS - REMOVAL)
(2) Remove ti mi ng bel t i dl er pul l ey.
(3) Hol d camshaft sprocket wi th Speci al Tool 6847
whi l e removi ng bol t (Fi g. 108). Remove both cam
sprockets.
(4) Remove rear ti mi ng bel t cover fasteners and
remove cover from engi ne (Fi g. 109).
(5) Remove l ower bol t attachi ng ti mi ng bel t ten-
si oner assembl y to engi ne and remove tensi oner as
an assembly.
INSTALLATION
(1) Al i gn ti mi ng bel t tensi oner assembl y to engi ne
and i nstal l l ower mounti ng bol t but do not tighten.
To properl y al i gn tensi oner assembl y—i nstal l one of
the engi ne bracket mounti ng bol ts (M10) 5 to 7 turns
i nto the tensi oner’s upper mounti ng l ocati on.
(2) Torque the tensi oner’s l ower mounti ng bol t to
61 N·m (45 ft. l bs.). Remove the upper bol t used for
tensi oner al i gnment.
(3) I nstal l rear ti mi ng bel t cover and fasteners.
(4) I nstal l ti mi ng bel t i dl er pul l ey and torque
mounti ng bol t to 61 N·m (45 ft. l bs.).
(5) I nstal l camshaft sprockets. Use Speci al Tool
6847 to hol d sprockets, torque bol ts to 101 N·m (75
ft. l bs.).
(6) I nstal l the ti mi ng bel t. (Refer to 9 - ENGI NE/
VALVE TI MI NG/TI MI NG BELT/CHAI N AND
SPROCKETS - I NSTALLATI ON)
BALANCE SHAFTS AND
CARRIER ASSEMBLY
DESCRIPTION
The 2.4L engi ne i s equi pped wi th two nodul ar cast
i ron bal ance shafts i nstal l ed i n a cast al umi num car-
ri er attached to the l ower cyl i nder bl ock (Fi g. 110).
OPERATION
The bal ance shafts are dri ven by the crankshaft
vi a a rol l er chai n and sprockets. The bal ance shafts
are connected by hel i cal gears. The dual counter
rotati ng shafts decrease second order verti cal shak-
i ng forces caused by component movement.
Fig. 108 Camshaft Sprocket - Removal/Installation
1 - SPECIAL TOOL 6847
Fig. 109 TIMING BELT REAR COVER FASTENERS
1 - OUTER COVER TO REAR COVER FASTENERS (3)
2 - REAR COVER TO CYLINDER HEAD FASTENERS
3 - OUTER COVER TO REAR COVER FASTENERS (3)
4 - INNER COVER TO BLOCK FASTENERS
TJ ENGINE 2. 4L 9 - 61
TIMING BELT AND SPROCKET(S) (Continued)
REMOVAL
BALANCE SHAFTS/CHAIN/SPROCKETS
NOTE: For service procedures requiring only tem-
porary relocation of carrier assembly refer to BAL-
ANCE SHAFT CARRIER procedure below.
(1) Drai n engi ne oi l .
(2) Remove the oi l pan and pi ck-up tube (Refer to
9 - ENGI NE/LUBRI CATI ON/OI L PAN - REMOVAL).
(3) I f repl aci ng crankshaft sprocket, remove oi l
pump (Refer to 9 - ENGI NE/LUBRI CATI ON/OI L
PUMP - REMOVAL).
(4) Remove chai n cover, gui de and tensi oner. Di s-
card pi vot screw and adjuster screw. (Fi g. 111).
(5) Remove screw retai ni ng bal ance shaft dri ve
sprocket (Fi g. 112). Remove chai n and sprocket.
(6) Usi ng two wi de pry bars, work the crankshaft
sprocket back and forth unti l i t i s off the crankshaft-
shaft.
(7) Remove gear cover retai ni ng stud (doubl e
ended to al so retai n chai n gui de). Remove cover and
bal ance shaft gears (Fi g. 113).
(8) Remove rear cover and bal ance shafts (Fi g.
114).
(9) Remove four carri er to crankcase attachi ng
bol ts to separate carri er from engi ne bedpl ate.
Fig. 110 Balance Shafts and Carrier Assembly
1 - SPROCKET 7 - GEARS
2 - TENSIONER 8 - GEAR COVER
3 - PLUG 9 - CHAIN COVER
4 - CARRIER 10 - SPROCKET
5 - REAR COVER 11 - GUIDE
6 - BALANCE SHAFTS 12 - CHAIN
Fig. 111 Chain Cover, Guide and Tensioner
1 - STUD
2 - TENSIONER (ADJUSTER)
3 - GEAR COVER
4 - ADJUSTER SCREW
5 - SHOULDERED PIVOT SCREW
6 - CHAIN COVER (CUTAWAY)
7 - GUIDE
Fig. 112 Drive Chain and Sprockets
1 - NICKEL PLATED LINK AND MARK
2 - GEAR/SPROCKET SCREWS
3 - NICKEL PLATED LINK AND DOT
9 - 62 ENGINE 2. 4L TJ
BALANCE SHAFTS AND CARRIER ASSEMBLY (Continued)
BALANCE SHAFT CARRIER
The fol l owi ng components wi l l remai n i ntact dur-
i ng carri er removal : Gear cover, gears, bal ance shafts
and the rear cover (Fi g. 110).
(1) Drai n engi ne oi l .
(2) Remove the oi l pan and pi ck-up tube (Refer to
9 - ENGI NE/LUBRI CATI ON/OI L PAN - I NSTALLA-
TI ON).
(3) Remove chai n cover, gui de and tensi oner (Fi g.
111).
(4) Remove screw retai ni ng bal ance shaft dri ve
sprocket (Fi g. 112).
(5) Move bal ance shaft i nboard through dri ve
chai n sprocket. Sprocket wi l l hang i n l ower chai n
l oop.
(6) Remove carri er to crankcase attachi ng bol ts to
remove carri er.
INSTALLATION
BALANCE SHAFT INSTALLATION/TIMING
Bal ance shaft and carri er assembl y i nstal l ati on i s
the reverse of the removal procedure. During instal-
lation crankshaft-to-balance shaft timing must
be established. Refer to Timing procedure in
this section.
(1) Wi th bal ance shafts i nstal l ed i n carri er (Fi g.
110) posi ti on carri er on crankcase and i nstal l four
attachi ng bol ts and ti ghten to 54 N·m (40 ft. l bs.).
(2) Turn bal ance shafts unti l both shaft key ways
are up, paral l el to verti cal centerl i ne of engi ne.
I nstal l short hub dri ve gear on sprocket dri ven shaft
and l ong hub gear on gear dri ven shaft. After i nstal -
l ati on gear and bal ance shaft keyways must be up
wi th gear ti mi ng marks meshed as shown i n (Fi g.
115).
Fig. 113 Gear Cover and Gears
1 - STUD (DOUBLE ENDED)
2 - DRIVE GEAR
3 - DRIVEN GEAR
4 - CARRIER DOWEL
5 - GEAR(S)
6 - GEAR COVER
Fig. 114 Balance Shaft(s)—Removal/Installation
1 - REAR COVER
2 - CARRIER
3 - BALANCE SHAFT
Fig. 115 Gear Timing
1 - KEY WAYS UP
2 - GEAR ALIGNMENT DOTS
TJ ENGINE 2. 4L 9 - 63
BALANCE SHAFTS AND CARRIER ASSEMBLY (Continued)
(3) I nstal l gear cover and ti ghten doubl e ended
stud/washer fastener to 12 N·m (105 i n. l bs.).
(4) Al i gn fl at on bal ance shaft dri ve sprocket to the
fl at on crankshaft (Fi g. 116).
(5) I nstal l bal ance shaft dri ve sprocket on crank-
shaft usi ng Speci al Tool 6052 (Fi g. 117).
(6) Turn crankshaft unti l number 1 cyl i nder i s at
top dead center (TDC). The ti mi ng marks on the
chai n sprocket shoul d l i ne up wi th the parti ng l i ne
on the l eft si de of number one mai n beari ng cap.
(Fi g. 118).
(7) Pl ace chai n over crankshaft sprocket so that
the pl ated l i nk of the chai n i s over the number 1 cyl -
i nder ti mi ng mark on the bal ance shaft crankshaft
sprocket (Fi g. 118).
(8) Pl ace bal ance shaft sprocket i nto the ti mi ng
chai n (Fi g. 118) and al i gn the ti mi ng mark on the
sprocket (dot) wi th the (l ower) pl ated l i nk on the
chai n.
NOTE: The lower plated link is 8 links from the
upper link.
(9) Wi th bal ance shaft keyways poi nti ng up (12
o’cl ock) sl i de the bal ance shaft sprocket onto the nose
of the bal ance shaft. The bal ance shaft may have to
be pushed i n sl i ghtl y to al l ow for cl earance.
NOTE: THE TIMING MARK ON THE SPROCKET, THE
(LOWER) NICKEL PLATED LINK, AND THE ARROW
ON THE SIDE OF THE GEAR COVER SHOULD LINE
UP WHEN THE BALANCE SHAFTS ARE TIMED
CORRECTLY.
Fig. 116 Balance Shaft Sprocket Alignment to
Crankshaft
1 - ALIGN FLATS
Fig. 117 Balance Shaft Drive Sprocket - Installation
1 - SPROCKET
2 - SPECIAL TOOL 6052
Fig. 118 Balance Shaft Timing
1 - MARK ON SPROCKET
2 - KEYWAYS UP
3 - ALIGN MARKS
4 - PLATED LINK
5 - PARTING LINE (BEDPLATE TO BLOCK)
6 - PLATED LINK
9 - 64 ENGINE 2. 4L TJ
BALANCE SHAFTS AND CARRIER ASSEMBLY (Continued)
(10) I f the sprockets are ti med correctl y, i nstal l the
bal ance shaft bol ts and ti ghten to 28 N·m (250 i n.
l bs.). A wood bl ock pl aced between crankcase and
crankshaft counterbal ance wi l l prevent crankshaft
and gear rotati on.
(11) CHAIN TENSIONING:
(a) I nstal l chai n tensi oner l oosel y assembl ed
wi th new adjuster screw and shoul dered pi vot
screw.
(b) Posi ti on gui de on doubl e ended stud maki ng
sure tab on the gui de fi ts i nto sl ot on the gear
cover. I nstal l and ti ghten nut/washer assembl y to
12 N·m (105 i n. l bs.).
(c) Pl ace a shi m 1 mm (0.039 i n.) thi ck x 70 mm
(2.75 i n.) l ong between tensi oner and chai n. Push
tensi oner and shi m up agai nst the chai n. Apply
firm pressure 2.5–3 Kg (5.5–6.6 lbs.) directly
behind the adjustment slot to take up all
slack. Chai n must have shoe radi us contact as
shown i n (Fi g. 119).
(d) Wi th the l oad appl i ed, ti ghten top tensi oner
adjuster bol t fi rst, then bottom shoul dered pi vot
bol t. Ti ghten bol ts to 12 N·m (105 i n. l bs.). Remove
shi m.
(e) I nstal l carri er covers and ti ghten screws to
12 N·m (105 i n. l bs.).
(12) I f removed, i nstal l oi l pump (Refer to 9 -
ENGI NE/LUBRI CATI ON/OI L PUMP - I NSTALLA-
TI ON).
(13) I nstal l pi ck-up tube and oi l pan (Refer to 9 -
ENGI NE/LUBRI CATI ON/OI L PAN - I NSTALLA-
TI ON).
(14) Fi l l engi ne crankcase wi th proper oi l to cor-
rect l evel .
BALANCE SHAFT CARRIER
DESCRIPTION
The 2.4L engi ne i s equi pped wi th two nodul ar cast
i ron bal ance shafts i nstal l ed i n a cast al umi num car-
ri er attached to the l ower cyl i nder bl ock (Fi g. 120).
OPERATION
The bal ance shafts are dri ven by the crankshaft
vi a a rol l er chai n and sprockets. The bal ance shafts
are connected by hel i cal gears. The dual counter
rotati ng shafts decrease second order verti cal shak-
i ng forces caused by component movement.
REMOVAL
(Refer to 9 - ENGI NE/VALVE TI MI NG/BALANCE
SHAFT - REMOVAL)
INSTALLATION
(Refer to 9 - ENGI NE/VALVE TI MI NG/BALANCE
SHAFT - I NSTALLATI ON)
Fig. 119 Chain Tension Adjustment
1 - 1MM (0.039 IN.) SHIM
2 - TENSIONER (ADJUSTER) BOLT
3 - SHOULDERED PIVOT BOLT
TJ ENGINE 2. 4L 9 - 65
BALANCE SHAFTS AND CARRIER ASSEMBLY (Continued)
BALANCE SHAFT CHAIN
REMOVAL
(Refer to 9 - ENGI NE/VALVE TI MI NG/BALANCE
SHAFT - REMOVAL)
INSTALLATION
(Refer to 9 - ENGI NE/VALVE TI MI NG/BALANCE
SHAFT - I NSTALLATI ON)
Fig. 120 Balance Shafts and Carrier Assembly
1 - SPROCKET 7 - GEARS
2 - TENSIONER 8 - GEAR COVER
3 - PLUG 9 - CHAIN COVER
4 - CARRIER 10 - SPROCKET
5 - REAR COVER 11 - GUIDE
6 - BALANCE SHAFTS 12 - CHAIN
9 - 66 ENGINE 2. 4L TJ
BALANCE SHAFT CARRIER (Continued)
ENGINE 4.0L
TABLE OF CONTENTS
page page
ENGINE 4.0L
DESCRIPTION
DESCRIPTION - ENGINE BLOCK . . . . . . . . . 68
DESCRIPTION - ENGINE . . . . . . . . . . . . . . . 68
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - INTRODUCTION . . . . . . . . . . . 69
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - PERFORMANCE . . . . . . . . . . . 70
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - MECHANICAL . . . . . . . . . . . . . 72
DIAGNOSIS AND TESTING—CYLINDER
COMPRESSION PRESSURE . . . . . . . . . . . . . 74
DIAGNOSIS AND TESTING - CYLINDER
COMBUSTION PRESSURE LEAKAGE . . . . . . 74
STANDARD PROCEDURE
STANDARD PROCEDURE - FORM-IN-
PLACE GASKETS . . . . . . . . . . . . . . . . . . . . . 75
STANDARD PROCEDURE - HYDROSTATIC
LOCK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
STANDARD PROCEDURE - SERVICE
ENGINE ASSEMBLY (SHORT BLOCK) . . . . . . 76
STANDARD PROCEDURE - REPAIR
DAMAGED OR WORN THREADS . . . . . . . . . 76
STANDARD PROCEDURE - ENGINE
PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . 76
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 78
SPECIFICATIONS
ENGINE - 4.0L . . . . . . . . . . . . . . . . . . . . . . . . 79
TORQUE - 4.0L ENGINE . . . . . . . . . . . . . . . . 83
AIR CLEANER ELEMENT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 84
AIR CLEANER HOUSING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 84
CYLINDER HEAD
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 85
DIAGNOSIS AND TESTING - ENGINE
CYLINDER HEAD GASKET FAILURE . . . . . . . 85
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 86
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 86
CYLINDER HEAD COVER(S)
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 88
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 88
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 88
INTAKE/EXHAUST VALVES & SEATS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 89
STANDARD PROCEDURE - VALVE SERVICE . . 89
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 91
ROCKER ARM / ADJUSTER ASSEMBLY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 91
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 92
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 92
VALVE STEM SEALS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 93
VALVE SPRINGS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 93
STANDARD PROCEDURE - VALVE SPRING
TENSION TEST . . . . . . . . . . . . . . . . . . . . . . . 93
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 95
ENGINE BLOCK
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 95
CAMSHAFT & BEARINGS (IN BLOCK)
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 96
REMOVAL
REMOVAL - CAMSHAFT BEARINGS . . . . . . . 96
REMOVAL - CAMSHAFT . . . . . . . . . . . . . . . . 96
INSTALLATION
INSTALLATION - CAMSHAFT BEARINGS . . . 97
INSTALLATION - CAMSHAFT . . . . . . . . . . . . 97
CONNECTING ROD BEARINGS
STANDARD PROCEDURE - FITTING
CONNECTING ROD BEARINGS . . . . . . . . . . 98
CRANKSHAFT
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 101
CRANKSHAFT MAIN BEARINGS
STANDARD PROCEDURE - FITTING
CRANKSHAFT MAIN BEARINGS . . . . . . . . . 101
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 104
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 105
CRANKSHAFT OIL SEAL - FRONT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 106
CRANKSHAFT OIL SEAL - REAR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
TJ ENGINE 4. 0L 9 - 67
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 107
HYDRAULIC LIFTERS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 107
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 108
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 108
PISTON & CONNECTING ROD
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 109
STANDARD PROCEDURE - PISTON FITTING . 109
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 111
PISTON RINGS
STANDARD PROCEDURE - PISTON RING
FITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
VIBRATION DAMPER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 114
STRUCTURAL SUPPORT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 115
FRONT MOUNT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 115
REAR MOUNT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 117
LUBRICATION
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 117
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 117
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ENGINE OIL
PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . 119
DIAGNOSIS AND TESTING - ENGINE OIL
LEAK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
OIL
STANDARD PROCEDURE - ENGINE OIL
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
OIL FILTER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 121
OIL PAN
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 121
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 122
ENGINE OIL PRESSURE SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 123
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 123
OIL PUMP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 123
VALVE TIMING
STANDARD PROCEDURE - VALVE TIMING . . 124
TIMING BELT / CHAIN COVER(S)
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 124
TIMING BELT/CHAIN AND SPROCKETS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 126
INTAKE MANIFOLD
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 126
DIAGNOSIS AND TESTING - INTAKE
MANIFOLD LEAKAGE . . . . . . . . . . . . . . . . . 126
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 127
EXHAUST MANIFOLD
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 128
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
ENGINE 4.0L
DESCRIPTION
DESCRIPTION - ENGINE BLOCK
The cyl i nder bl ock i s a cast i ron i nl i ne si x cyl i nder
desi gn. The cyl i nder bl ock i s dri l l ed formi ng gal l eri es
for both oi l and cool ant (Fi g. 1).
DESCRIPTION - ENGINE
The 4.0 Li ter (242 CI D) si x-cyl i nder engi ne i s an
I n-l i ne, l i ghtwei ght, overhead val ve engi ne.
Thi s engi ne i s desi gned for unl eaded fuel . The
engi ne cyl i nder head has dual quench-type combus-
ti on chambers that create turbul ence and fast burn-
i ng of the ai r/fuel mi xture. Thi s resul ts i n good fuel
economy.
The cyl i nders are numbered 1 through 6 from front
to rear. The fi ri ng order i s 1-5-3-6-2-4 (Fi g. 2).
The crankshaft rotati on i s cl ockwi se, when vi ewed
from the front of the engi ne. The crankshaft rotates
wi thi n seven mai n beari ngs. The camshaft rotates
wi thi n four beari ngs.
BUI LD DATE CODE
The engi ne Bui l d Date Code i s l ocated on a
machi ned surface on the ri ght si de of the cyl i nder
bl ock between the No.2 and No.3 cyl i nders (Fi g. 3).
The di gi ts of the code i denti fy:
• 1st Di gi t—The year (0 = 2000).
• 2nd & 3rd Di gi ts—The month (01 - 12).
• 4th & 5th Di gi ts—The engi ne type/fuel system/
compressi on rati o (MX = A 4.0 Li ter (242 CI D) engi ne
wi th a mul ti -poi nt fuel i njecti on system).
• 6th & 7th Di gi ts—The day of engi ne bui l d (01 -
31).
(1) FOR EXAMPLE: Code * 001MX12 * i denti fi es
a 4.0 Li ter (242 CI D) engi ne wi th a mul ti -poi nt fuel
i njecti on system, and bui l t on January 12, 2000.
9 - 68 ENGINE 4. 0L TJ
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - INTRODUCTION
Engi ne di agnosi s i s hel pful i n determi ni ng the
causes of mal functi ons not detected and remedi ed by
routi ne mai ntenance.
These mal functi ons may be cl assi fi ed as ei ther per-
formance (e.g., engi ne i dl es rough and stal l s) or
mechani cal (e.g., a strange noi se).
(Refer to 9 - ENGI NE - DI AGNOSI S AND TEST-
I NG) (PERFORMANCE) or (Refer to 9 - ENGI NE -
DI AGNOSI S AND TESTI NG) (MECHANI CAL) for
possi bl e causes and correcti ons of mal functi ons.
Addi ti onal tests and di agnosti c procedures may be
necessary for speci fi c engi ne mal functi ons that can
not be i sol ated wi th the Servi ce Di agnosi s charts.
I nformati on concerni ng addi ti onal tests and di agno-
si s i s provi ded wi thi n the fol l owi ng di agnosi s:
• (Refer to 9 - ENGI NE - DI AGNOSI S AND TEST-
I NG) (PERFORMANCE)
• (Refer to 9 - ENGI NE - DI AGNOSI S AND TEST-
I NG) (MECHANI CAL)
Fig. 1 4.0L Cylinder Block with Main Bearing Caps
and Cap Brace
1 - BLOCK
2 - MAIN BEARING CAP BRACE
Fig. 2 Engine Firing Order
Fig. 3 Build Date Code Location
1 - YEAR
2 - MONTH
3 - DAY
TJ ENGINE 4. 0L 9 - 69
ENGINE 4.0L (Continued)
DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - PERFORMANCE
ENGINE PERFORMANCE DIAGNOSIS CHART
CONDITION POSSIBLE CAUSES CORRECTION
ENGINE WILL NOT
CRANK
1. Weak or dead battery 1. Charge/Replace Battery. (Refer to 8 -
ELECTRICAL/BATTERY SYSTEM/
BATTERY - STANDARD PROCEDURE),
for correct procedures. Check charging
system. (Refer to 8 - ELECTRICAL/
CHARGING - DIAGNOSIS AND
TESTING), for correct procedures.
2. Corroded or loose battery
connections
2. Clean/tighten suspect battery/starter
connections
3. Faulty starter or related circuit(s) 3. Check starting system. (Refer to 8 -
ELECTRICAL/STARTING - DIAGNOSIS
AND TESTING), for correct diagnostics/
procedures
4. Siezed accessory drive component 4. Remove accessory drive belt and
attempt to start engine. If engine starts,
repair/replace siezed component.
5. Engine internal mechanical failure or
hydro-static lock
5. (Refer to 9 - ENGINE - DIAGNOSIS
AND TESTING), for correct diagnostics/
procedures
ENGINE CRANKS BUT
WILL NOT START
1. No spark 1. Check for spark. (Refer to 8 -
ELECTRICAL/IGNITION CONTROL -
SPECIFICATIONS), for correct
procedures.
2. No fuel 2. Perform fuel pressure test (Refer to
14 - FUEL SYSTEM/FUEL DELIVERY/
FUEL PUMP - DIAGNOSIS AND
TESTING), and if necessary, inspect fuel
injector(s) and driver circuits. (Refer to
14 - FUEL SYSTEM/FUEL INJECTION/
FUEL INJECTOR - DIAGNOSIS AND
TESTING), for correct procedures.
3. Low or no engine compression 3. Perform cylinder compression
pressure test. (Refer to 9 - ENGINE -
DIAGNOSIS AND TESTING).
ENGINE LOSS OF
POWER
1. Worn or burned distributor rotor 1. Install new distributor rotor
2. Worn camshaft position sensor shaft 2. Remove and repair camshaft position
sensor.(Refer to 8 - ELECTRICAL/
IGNITION CONTROL/CAMSHAFT
POSITION SENSOR - REMOVAL).
3. Worn or incorrect gapped spark plugs 3. Clean plugs and set gap. (Refer to 8 -
ELECTRICAL/IGNITION CONTROL/
SPARK PLUG - CLEANING).
4. Dirt or water in fuel system 4. Clean system and replace fuel filter
5. Faulty fuel pump 5. Install new fuel pump
9 - 70 ENGINE 4. 0L TJ
ENGINE 4.0L (Continued)
CONDITION POSSIBLE CAUSES CORRECTION
6. Incorrect valve timing 6. Correct valve timing
7. Blown cylinder head gasket 7. Install new cylinder head gasket
8. Low compression 8. Test cylinder compression. (Refer to 9
- ENGINE - DIAGNOSIS AND
TESTING).
9. Burned, warped, or pitted valves 9. Install/Reface valves as necessary
10. Plugged or restricted exhaust
system
10. Install new parts as necessary
11. Faulty ignition coil rail 11. Test and replace, as necessary.
(Refer to 8 - ELECTRICAL/IGNITION
CONTROL/COIL RAIL - REMOVAL).
ENGINE STALLS OR
ROUGH IDLE
1. Carbon build-up on throttle plate 1. Remove throttle body and de-carbon.
(Refer to 14 - FUEL SYSTEM/FUEL
INJECTION/THROTTLE BODY -
REMOVAL) for correct procedure.
2. Engine idle speed too low 2. Check Idle Air Control circuit.
3. Worn or incorrectly gapped spark
plugs
3. Replace or clean and re-gap spark
plugs. (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/SPARK PLUG -
CLEANING)
4. Faulty coil rail 4. Test and replace, if necessary. (Refer
to 8 - ELECTRICAL/IGNITION
CONTROL/COIL RAIL - REMOVAL)
5. Intake manifold vacuum leak 5. Inspect intake manifold gasket and
vacuum hoses. Replace if necessary.
(Refer to 9 - ENGINE/MANIFOLDS/
INTAKE MANIFOLD - DIAGNOSIS AND
TESTING).
ENGINE MISSES ON
ACCELERATION
1. Worn or incorrectly gapped spark
plugs
1. Replace spark plugs or clean and set
gap.
2. Spark plug cables defective or
crossed
2. Replace spark plug cables.
3. Dirt in fuel system 3. Clean fuel system
4. Burned, warped or pitted valves 4. Install new valves
5. Faulty coil rail 5. Test and replace as necessary. (Refer
to 8 - ELECTRICAL/IGNITION
CONTROL/COIL RAIL - REMOVAL)
TJ ENGINE 4. 0L 9 - 71
ENGINE 4.0L (Continued)
DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - MECHANICAL
ENGINE MECHANICAL DIAGNOSIS CHART
CONDITION POSSIBLE CAUSES CORRECTION
NOISY VALVES/LIFTERS 1. High or low oil level in crankcase 1. Check for correct oil level. Adjust
oil level by draining or adding as
needed
2. Thin or diluted oil 2. Change oil. (Refer to 9 -
ENGINE/LUBRICATION/OIL -
STANDARD PROCEDURE)
3. Low oil pressure 3. Check engine oil level. If ok,
Perform oil pressure test. (Refer to
9 - ENGINE/LUBRICATION -
DIAGNOSIS AND TESTING) for
engine oil pressure test/
specifications
4. Dirt in tappets/lash adjusters 4. Clean/replace hydraulic
tappets/lash adjusters
5. Bent push rod(s) 5. Install new push rods
6. Worn rocker arms 6. Inspect oil supply to rocker arms
and replace worn arms as needed
7. Worn tappets/lash adjusters 7. Install new hydraulic tappets/lash
adjusters
8. Worn valve guides 8. Inspect all valve guides and
replace as necessary
9. Excessive runout of valve seats
or valve faces
9. Grind valves and seats
CONNECTING ROD NOISE 1. Insufficient oil supply 1. Check engine oil level.
2. Low oil pressure 2. Check engine oil level. If ok,
Perform oil pressure test. (Refer to
9 - ENGINE/LUBRICATION -
DIAGNOSIS AND TESTING) engine
oil pressure test/specifications
3. Thin or diluted oil 3. Change oil to correct viscosity.
(Refer to 9 - ENGINE/
LUBRICATION/OIL - STANDARD
PROCEDURE) for correct
procedure/engine oil specifications
4. Excessive connecting rod
bearing clearance
4. Measure bearings for correct
clearance with plasti-gage. Repair
as necessary
5. Connecting rod journal out of
round
5. Replace crankshaft or grind
journals
6. Misaligned connecting rods 6. Replace bent connecting rods
9 - 72 ENGINE 4. 0L TJ
ENGINE 4.0L (Continued)
CONDITION POSSIBLE CAUSES CORRECTION
MAIN BEARING NOISE 1. Insufficient oil supply 1. Check engine oil level.
2. Low oil pressure 2. Check engine oil level. If ok,
Perform oil pressure test. (Refer to
9 - ENGINE/LUBRICATION -
DIAGNOSIS AND TESTING)
3. Thin or diluted oil 3. Change oil to correct viscosity.
4. Excessive main bearing
clearance
4. Measure bearings for correct
clearance. Repair as necessary
5. Excessive end play 5. Check crankshaft thrust bearing
for excessive wear on flanges
6. Crankshaft main journal out of
round or worn
6. Grind journals or replace
crankshaft
7. Loose flywheel or torque
converter
7. Inspect crankshaft, flexplate/
flywheel and bolts for damage.
Tighten to correct torque
LOW OIL PRESSURE 1. Low oil level 1. Check oil level and fill if
necessary
2. Faulty oil pressure sending unit 2. Install new sending unit
3. Clogged oil filter 3. Install new oil filter
4. Worn oil pump 4. Replace oil pump assembly.
5. Thin or diluted oil 5. Change oil to correct viscosity.
6. Excessive bearing clearance 6. Measure bearings for correct
clearance
7. Oil pump relief valve stuck 7. Remove valve to inspect, clean
and reinstall
8. Oil pickup tube loose, broken,
bent or clogged
8. Inspect oil pickup tube and pump,
and clean or replace if necessary
9. Oil pump cover warped or
cracked
9. Install new oil pump
OIL LEAKS 1. Misaligned or deteriorated
gaskets
1. Replace gasket
2. Loose fastener, broken or porous
metal part
2. Tighten, repair or replace the part
3. Front or rear crankshaft oil seal
leaking
3. Replace seal
4. Leaking oil gallery plug or cup
plug
4. Remove and reseal threaded
plug. Replace cup style plug
TJ ENGINE 4. 0L 9 - 73
ENGINE 4.0L (Continued)
CONDITION POSSIBLE CAUSES CORRECTION
EXCESSIVE OIL CONSUMPTION
OR SPARK PLUGS OIL FOULED
1. CCV System malfunction 1. (Refer to 25 - EMISSIONS
CONTROL/EVAPORATIVE
EMISSIONS - DESCRIPTION) for
correct operation
2. Defective valve stem seal(s) 2. Repair or replace seal(s)
3. Worn or broken piston rings 3. Hone cylinder bores. Install new
rings
4. Scuffed pistons/cylinder walls 4. Hone cylinder bores and replace
pistons as required
5. Carbon in oil control ring groove 5. Remove rings and de-carbon
piston
6. Worn valve guides 6. Inspect/replace valve guides as
necessary
7. Piston rings fitted too tightly in
grooves
7. Remove rings and check ring end
gap and side clearance. Replace if
necessary
DIAGNOSIS AND TESTING— CYLINDER
COMPRESSION PRESSURE
The resul ts of a cyl i nder compressi on pressure test
can be uti l i zed to di agnose several engi ne mal func-
ti ons.
Ensure the battery i s compl etel y charged and the
engi ne starter motor i s i n good operati ng condi ti on.
Otherwi se, the i ndi cated compressi on pressures may
not be val i d for di agnosi s purposes.
(1) Cl ean the spark pl ug recesses wi th compressed
ai r.
(2) Remove the spark pl ugs (Refer to 8 - ELEC-
TRI CAL/I GNI TI ON CONTROL/SPARK PLUG -
REMOVAL).
(3) Secure the throttl e i n the wi de-open posi ti on.
(4) Di sconnect the i gni ti on coi l .
(5) I nsert a compressi on pressure gauge and rotate
the engi ne wi th the engi ne starter motor for three
revol uti ons.
(6) Record the compressi on pressure on the thi rd
revol uti on. Conti nue the test for the remai ni ng cyl i n-
ders.
(Refer to 9 - ENGI NE - SPECI FI CATI ONS) for the
correct engi ne compressi on pressures.
DIAGNOSIS AND TESTING - CYLINDER
COMBUSTION PRESSURE LEAKAGE
The combusti on pressure l eakage test provi des an
accurate means for determi ni ng engi ne condi ti on.
Combusti on pressure l eakage testi ng wi l l detect:
• Exhaust and i ntake val ve l eaks (i mproper seat-
i ng).
• Leaks between adjacent cyl i nders or i nto water
jacket.
• Any causes for combusti on/compressi on pressure
l oss.
(1) Check the cool ant l evel and fi l l as requi red. DO
NOT i nstal l the radi ator cap.
(2) Start and operate the engi ne unti l i t attai ns
normal operati ng temperature, then turn the engi ne
OFF.
(3) Remove the spark pl ugs (Refer to 8 - ELEC-
TRI CAL/I GNI TI ON CONTROL/SPARK PLUG -
REMOVAL).
(4) Remove the oi l fi l l er cap.
(5) Remove the ai r cl eaner.
(6) Cal i brate the tester accordi ng to the manufac-
turer’s i nstructi ons. The shop ai r source for testi ng
shoul d mai ntai n 483 kPa (70 psi ) mi ni mum, 1,379
kPa (200 psi ) maxi mum and 552 kPa (80 psi ) recom-
mended.
(7) Perform the test procedures on each cyl i nder
accordi ng to the tester manufacturer’s i nstructi ons.
Whi l e testi ng, l i sten for pressuri zed ai r escapi ng
through the throttl e body, tai l pi pe and oi l fi l l er cap
openi ng. Check for bubbl es i n the radi ator cool ant.
Al l gauge pressure i ndi cati ons shoul d be equal ,
wi th no more than 25% l eakage.
FOR EXAMPLE: At 552 kPa (80 psi ) i nput pres-
sure, a mi ni mum of 414 kPa (60 psi ) shoul d be mai n-
tai ned i n the cyl i nder.
Refer to CYLI NDER COMBUSTI ON PRESSURE
LEAKAGE DI AGNOSI S CHART
9 - 74 ENGINE 4. 0L TJ
ENGINE 4.0L (Continued)
CYLINDER COMBUSTION PRESSURE LEAKAGE DIAGNOSIS CHART
CONDITION POSSIBLE CAUSE CORRECTION
AIR ESCAPES THROUGH
THROTTLE BODY
Intake valve bent, burnt, or not
seated properly
Inspect valve and valve seat.
Reface or replace, as necessary
AIR ESCAPES THROUGH
TAILPIPE
Exhaust valve bent, burnt, or not
seated properly
Inspect valve and valve seat.
Reface or replace, as necessary
AIR ESCAPES THROUGH
RADIATOR
Head gasket leaking or cracked
cylinder head or block
Remove cylinder head and inspect.
Replace defective part
MORE THAN 50% LEAKAGE
FROM ADJACENT CYLINDERS
Head gasket leaking or crack in
cylinder head or block between
adjacent cylinders
Remove cylinder head and inspect.
Replace gasket, head, or block as
necessary
MORE THAN 25% LEAKAGE AND
AIR ESCAPES THROUGH OIL
FILLER CAP OPENING ONLY
Stuck or broken piston rings;
cracked piston; worn rings and/or
cylinder wall
Inspect for broken rings or piston.
Measure ring gap and cylinder
diameter, taper and out-of-round.
Replace defective part as necessary
STANDARD PROCEDURE
STANDARD PROCEDURE - FORM-IN-PLACE
GASKETS
There are several pl aces where form-i n-pl ace gas-
kets are used on the engi ne. DO NOT use form-in-
place gasket material unless specified.Care must
be taken when appl yi ng form-i n-pl ace gaskets. Bead
si ze, conti nui ty and l ocati on are of great i mportance.
Too thi n a bead can resul t i n l eakage whi l e too much
can resul t i n spi l l -over. A conti nuous bead of the
proper wi dth i s essenti al to obtai n a l eak-free joi nt.
Two types of form-i n-pl ace gasket materi al s are
used i n the engi ne area (Mopar௡ Si l i cone Rubber
Adhesi ve Seal ant and Mopar௡ Gasket Maker). Each
have di fferent properti es and cannot be used i nter-
changeabl y.
MOPARா SILICONE RUBBER ADHESIVE SEALANT
Mopar௡ Si l i cone Rubber Adhesi ve Seal ant, nor-
mal l y bl ack i n col or, i s avai l abl e i n 3 ounce tubes.
Moi sture i n the ai r causes the seal ant materi al to
cure. Thi s materi al i s normal l y used on fl exi bl e metal
fl anges. I t has a shel f l i fe of a year and wi l l not prop-
erl y cure i f over aged. Al ways i nspect the package for
the expi rati on date before use.
MOPARா GASKET MAKER
Mopar௡ Gasket Maker, normal l y red i n col or, i s
avai l abl e i n 6 cc tubes. Thi s anaerobi c type gasket
materi al cures i n the absence of ai r when squeezed
between smooth machi ned metal l i c surfaces. I t wi l l
not cure i f l eft i n the uncovered tube. DO NOT use
on fl exi bl e metal fl anges.
SURFACE PREPARATION
Parts assembl ed wi th form-i n-pl ace gaskets may be
di sassembl ed wi thout unusual effort. I n some
i nstances, i t may be necessary to l i ghtl y tap the part
wi th a mal l et or other sui tabl e tool to break the seal
between the mati ng surfaces. A fl at gasket scraper
may al so be l i ghtl y tapped i nto the joi nt but care
must be taken not to damage the mati ng surfaces.
Scrape or wi re brush al l gasket surfaces to remove
al l l oose materi al . I nspect stamped parts to ensure
gasket rai l s are fl at. Fl atten rai l s wi th a hammer on
a fl at pl ate, i f requi red. Gasket surfaces must be free
of oi l and di rt. Make sure the ol d gasket materi al i s
removed from bl i nd attachi ng hol es.
GASKET APPLICATION
Assembl i ng parts usi ng a form-i n-pl ace gasket
requi res care.
Mopar௡ Si l i cone Rubber Adhesi ve Seal ant shoul d
be appl i ed i n a conti nuous bead approxi matel y 3 mm
(0.12 i nch) i n di ameter. Al l mounti ng hol es must be
ci rcl ed. For corner seal i ng, a 3 or 6 mm (1/8 or 1/4
i nch) drop i s pl aced i n the center of the gasket con-
tact area. Uncured seal ant may be removed wi th a
shop towel . Components shoul d be torqued i n pl ace
whi l e the seal ant i s sti l l wet to the touch (wi thi n 10
mi nutes). The use of a l ocati ng dowel i s recom-
mended duri ng assembl y to prevent smeari ng the
materi al off l ocati on.
Mopar௡ Gasket Maker shoul d be appl i ed spari ngl y
to one gasket surface. The seal ant di ameter shoul d
be 1.00 mm (0.04 i nch) or l ess. Be certai n the mate-
ri al surrounds each mounti ng hol e. Excess materi al
can easi l y be wi ped off. Components shoul d be
torqued i n pl ace wi thi n 15 mi nutes. The use of a
l ocati ng dowel i s recommended duri ng assembl y to
prevent smeari ng the materi al off l ocati on.
TJ ENGINE 4. 0L 9 - 75
ENGINE 4.0L (Continued)
STANDARD PROCEDURE - HYDROSTATIC
LOCK
When an engi ne i s suspected of hydrostati c l ock
(regardl ess of what caused the probl em), fol l ow the
steps bel ow.
(1) Perform the Fuel Pressure Rel ease Procedure .
(2) Di sconnect the negati ve cabl e from the battery.
(3) I nspect ai r cl eaner, i nducti on system and
i ntake mani fol d to ensure system i s dry and cl ear of
forei gn materi al .
(4) Pl ace a shop towel around the spark pl ugs to
catch any fl ui d that may possi bl y be under pressure
i n the cyl i nder head. Remove the pl ugs from the
engi ne.
CAUTION: DO NOT use the starter motor to rotate
the crankshaft. Severe damage could occur.
(5) Wi th al l spark pl ugs removed, rotate the crank-
shaft usi ng a breaker bar and socket.
(6) I denti fy the fl ui d i n the cyl i nders (i .e. cool ant,
fuel , oi l , etc.).
(7) Make sure al l fl ui d has been removed from the
cyl i nders.
(8) Repai r engi ne or components as necessary to
prevent thi s probl em from occurri ng agai n.
(9) Squi rt engi ne oi l i nto the cyl i nders to l ubri cate
the wal l s. Thi s wi l l prevent damage on restart.
(10) I nstal l new spark pl ugs. Ti ghten the spark
pl ugs to 37 N·m (27 ft. l bs.) torque.
(11) Drai n engi ne oi l . Remove and di scard the oi l
fi l ter.
(12) I nstal l the drai n pl ug. Ti ghten the pl ug to 34
N·m (25 ft. l bs.) torque.
(13) I nstal l a new oi l fi l ter.
(14) Fi l l engi ne crankcase wi th the speci fi ed
amount and grade of oi l .
(15) Connect the negati ve cabl e to the battery.
(16) Start the engi ne and check for any l eaks.
STANDARD PROCEDURE - SERVICE ENGINE
ASSEMBLY (SHORT BLOCK)
A servi ce repl acement engi ne assembl y (short
bl ock) may be i nstal l ed whenever the ori gi nal cyl i n-
der bl ock i s defecti ve or damaged beyond repai r. I t
consi sts of the cyl i nder bl ock, crankshaft, pi ston and
rod assembl i es. I f needed, the camshaft must be pro-
cured separatel y and i nstal l ed before the engi ne i s
i nstal l ed i n the vehi cl e.
A short bl ock i s i denti fi ed wi th the l etter “S”
stamped on the same machi ned surface where the
bui l d date code i s stamped for compl ete engi ne
assembl i es.
I nstal l ati on i ncl udes the transfer of components
from the defecti ve or damaged ori gi nal engi ne. Fol -
l ow the appropri ate procedures for cl eani ng, i nspec-
ti on and torque ti ghteni ng.
STANDARD PROCEDURE - REPAIR DAMAGED
OR WORN THREADS
CAUTION: Be sure that the tapped holes maintain
the original center line.
Damaged or worn threads can be repai red. Essen-
ti al l y, thi s repai r consi sts of:
• Dri l l i ng out worn or damaged threads.
• Tappi ng the hol e wi th a speci al Hel i -Coi l Tap, or
equi val ent.
• I nstal l i ng an i nsert i nto the tapped hol e to bri ng
the hol e back to i ts ori gi nal thread si ze.
STANDARD PROCEDURE - ENGINE
PERFORMANCE
I t i s i mportant that the vehi cl e i s operati ng to i ts
opti mum performance l evel to mai ntai n fuel economy
and the l owest emi ssi on l evel s. I f vehi cl e i s not oper-
ati ng to these standards, refer to Engi ne Di agnosi s
outl i ned i n thi s secti on. The fol l owi ng procedures can
assi st i n achi evi ng the proper engi ne di agnosi s.
(1) Test cranki ng amperage draw. (Refer to 8 -
ELECTRI CAL/STARTI NG - DI AGNOSI S AND TEST-
I NG).
(2) Check i ntake mani fol d bol t torque (Refer to 9 -
ENGI NE/MANI FOLDS/I NTAKE MANI FOLD -
I NSTALLATI ON).
(3) Perform cyl i nder compressi on test. (Refer to 9 -
ENGI NE - DI AGNOSI S AND TESTI NG).
(4) Cl ean (Refer to 8 - ELECTRI CAL/I GNI TI ON
CONTROL/SPARK PLUG - CLEANI NG) or repl ace
spark pl ugs (Refer to 8 - ELECTRI CAL/I GNI TI ON
CONTROL/SPARK PLUG - REMOVAL) as necessary.
(5) Test coi l output vol tage and pri mary resi stance.
(Refer to 8 - ELECTRI CAL/I GNI TI ON CONTROL -
SPECI FI CATI ONS) Repl ace parts as necessary.
(6) Test fuel pump for pressure. (Refer to 14 -
FUEL SYSTEM/FUEL DELI VERY/FUEL PUMP -
DI AGNOSI S AND TESTI NG).
(7) The ai r fi l ter el ements shoul d be repl aced as
speci fi ed.
(8) I nspect crankcase venti l ati on system.
(9) Road test vehi cl e as a fi nal test.
REMOVAL
(1) Di sconnect the battery negati ve cabl e.
(2) Mark the hi nge l ocati ons on the hood panel for
al i gnment reference duri ng i nstal l ati on. Remove the
engi ne compartment l amp. Remove the hood.
(3) Drai n engi ne cool ant (Refer to 7 - COOLI NG -
STANDARD PROCEDURE), drai n the cool ant i nto a
cl ean contai ner for reuse.
9 - 76 ENGINE 4. 0L TJ
ENGINE 4.0L (Continued)
(4) Remove the upper radi ator hose and cool ant
recovery hose (Fi g. 4).
(5) Remove the l ower radi ator hose.
(6) Remove upper radi ator support retai ni ng bol ts
and remove radi ator support.
(7) Remove the fan assembl y from the water pump
(Refer to 7 - COOLI NG/ENGI NE/FAN DRI VE VI S-
COUS CLUTCH - REMOVAL).
(8) Remove the fan shroud (Fi g. 4).
(9) Di sconnect the transmi ssi on fl ui d cool er l i nes
(automati c transmi ssi on).
(10) Di scharge the A/C system (Refer to 24 -
HEATI NG & AI R CONDI TI ONI NG/PLUMBI NG -
STANDARD PROCEDURE).
(11) Remove the servi ce val ves and cap the com-
pressor ports.
(12) Remove the radi ator (Refer to 7 - COOLI NG/
ENGI NE/RADI ATOR - REMOVAL) or radi ator/con-
denser (i f equi pped wi th A/C).
(13) Di sconnect the heater hoses at the engi ne
thermostat housi ng and water pump (Fi g. 4).
(14) Di sconnect the accel erator cabl e, transmi ssi on
l i ne pressure cabl e and speed control cabl e (i f
equi pped) from the throttl e body (Fi g. 5).
(15) Remove cabl es from the bracket and secure
out of the way.
(16) Di sconnect the body ground at the engi ne.
(17) Di sconnect the fol l owi ng connectors and
secure thei r harness out of the way.
• Power steeri ng pressure swi tch
• Cool ant temperature sensor
• Si x (6) fuel i njector connectors
• I ntake ai r temperature sensor
• Throttl e posi ti on sensor
• Map sensor
• Crankshaft posi ti on sensor
• Oxygen sensor
• Camshaft posi ti on sensor
• Generator connector and B+ termi nal wi re
(18) Di sconnect the coi l rai l el ectri cal connecti ons
and the oi l pressure swi tch connector.
(19) Perform the fuel pressure rel ease procedure
(Refer to 14 - FUEL SYSTEM/FUEL DELI VERY -
STANDARD PROCEDURE).
(20) Di sconnect the fuel suppl y l i ne at the i njector
rai l (Refer to 14 - FUEL SYSTEM/FUEL DELI VERY/
QUI CK CONNECT FI TTI NG - STANDARD PROCE-
DURE).
(21) Remove the fuel l i ne bracket from the i ntake
mani fol d.
(22) Remove the ai r cl eaner assembl y (Fi g. 6).
(23) Di sconnect the hoses from the fi tti ngs at the
steeri ng gear.
(24) Drai n the pump reservoi r.
Fig. 4 Upper Radiator Hose, Coolant Recovery
Hose, Fan Shroud
1 - UPPER RADIATOR HOSE
2 - HEATER HOSES
3 - FAN SHROUD
4 - COOLANT RECOVERY HOSE
Fig. 5 Accelerator Cable, Vehicle Speed Control
Cable, Automatic Transmission
1 - ACCELERATOR CABLE
2 - SPEED CONTROL CABLE
3 - QUICK-CONNECT FUEL LINES
4 - AUTOMATIC TRANSMISSION CONTROL CABLE
TJ ENGINE 4. 0L 9 - 77
ENGINE 4.0L (Continued)
(25) Cap the fi tti ngs on the hoses and steeri ng
gear to prevent forei gn objects from enteri ng the sys-
tem.
(26) Rai se and support the vehi cl e.
(27) Di sconnect the wi res from the engi ne starter
motor sol enoi d.
(28) Remove the engi ne starter motor (Refer to 8 -
ELECTRI CAL/STARTI NG/STARTER MOTOR -
REMOVAL).
(29) Di sconnect the oxygen sensor from the
exhaust pi pe.
(30) Di sconnect the exhaust pi pe from the mani -
fol d.
(31) Remove the exhaust pi pe support.
(32) Remove the bendi ng brace (Refer to 9 -
ENGI NE/ENGI NE BLOCK/WI NDAGE TRAY /
STRUCT SUPPORT - REMOVAL).
(33) Remove the engi ne fl ywheel /converter housi ng
access cover.
(34) Mark the converter and dri ve pl ate l ocati on.
(35) Remove the converter-to-dri ve pl ate bol ts.
(36) Remove the upper engi ne fl ywheel /converter
housi ng bol ts and l oosen the bottom bol ts.
(37) Remove the engi ne mount cushi on-to-engi ne
compartment bracket bol ts.
(38) Lower the vehi cl e.
(39) Attach a l i fti ng devi ce to the engi ne.
(40) Rai se the engi ne off the front supports.
(41) Pl ace a support or fl oor jack under the con-
verter (or engi ne fl ywheel ) housi ng.
(42) Remove the remai ni ng converter (or engi ne
fl ywheel ) housi ng bol ts.
(43) Li ft the engi ne out of the engi ne compart-
ment.
INSTALLATION
CAUTION: When installing the engine into a vehicle
equipped with an automatic transmission, be care-
ful not to damage the trigger wheel on the engine
flywheel.
(1) Attach a l i fti ng devi ce to the engi ne and l ower
the engi ne i nto the engi ne compartment. For easi er
i nstal l ati on, i t may be necessary to remove the
engi ne mount bracket as an ai d i n al i gnment of the
engi ne to the transmi ssi on.
(2) Al i gn the transmi ssi on torque converter hous-
i ng wi th the engi ne.
(3) Loosel y i nstal l the converter housi ng l ower
bol ts and i nstal l the next hi gher bol t and nut on each
si de.
(4) Ti ghten al l 4 bol ts fi nger ti ght.
(5) I nstal l the engi ne mount brackets (i f removed).
(6) Lower the engi ne and engi ne mount brackets
onto the engi ne compartment cushi ons. I nstal l the
bol ts and fi nger ti ghten the nuts.
(7) Remove the engi ne l i fti ng devi ce.
(8) Rai se and support the vehi cl e.
(9) I nstal l the remai ni ng engi ne fl ywheel /converter
housi ng bol ts. Ti ghten al l bol ts to 38 N·m (28 ft. l bs.)
torque.
(10) I nstal l the converter-to-dri ve pl ate bol ts.
(11) Ensure the i nstal l ati on reference marks are
al i gned.
(12) I nstal l the engi ne fl ywheel /converter housi ng
access cover.
(13) I nstal l the exhaust pi pe support and ti ghten
the screw.
(14) I nstal l the engi ne bendi ng brace (Refer to 9 -
ENGI NE/ENGI NE BLOCK/WI NDAGE TRAY /
STRUCT SUPPORT - I NSTALLATI ON).
(15) Ti ghten the engi ne mount-to-bracket bol ts.
(16) Connect the vehi cl e speed sensor wi re connec-
ti ons and ti ghten the screws.
(17) Connect the exhaust pi pe to the mani fol d.
(18) I nstal l the engi ne starter motor (Refer to 8 -
ELECTRI CAL/STARTI NG/STARTER MOTOR -
I NSTALLATI ON).
(19) Connect the wi res to the engi ne starter motor
sol enoi d.
(20) Lower the vehi cl e.
(21) Connect vacuum hoses and wi re connectors
di sconnected duri ng engi ne removal .
(22) Remove protecti ve caps from the power steer-
i ng hoses.
Fig. 6 Air Cleaner Assembly & Power Steering Pump
1 - POWER STEERING PUMP
2 - AIR CLEANER ASSEMBLY
9 - 78 ENGINE 4. 0L TJ
ENGINE 4.0L (Continued)
(23) Connect the hoses to the fi tti ngs at the steer-
i ng gear. Ti ghten the nut to 52 N·m (38 ft. l bs.)
torque.
(24) Fi l l the pump reservoi r wi th fl ui d (Refer to 19
- STEERI NG/PUMP - STANDARD PROCEDURE).
(25) I nspect the fuel suppl y l i ne o-ri ng(s) and
repl ace i f necessary. Connect fuel suppl y l i ne to i njec-
ti or rai l and veri fy connecti on by pul l i ng outward on
the l i ne.
(26) I nstal l the fuel l i ne bracket to the i ntake
mani fol d.
(27) Connect the coi l rai l el ectri cal connectors and
oi l pressure swi tch connector.
(28) Connect the fol l owi ng el ectri cal connectors:
• Power steeri ng pressure swi tch
• Cool ant temperature sensor
• Si x (6) fuel i njector connectors
• I ntake ai r temperature sensor
• Throttl e posi ti on sensor
• Map sensor
• Crankshaft posi ti on sensor
• Oxygen sensor
• Camshaft posi ti on sensor
• Generator connector and B+ termi nal wi re
(29) Connect al l previ ousl y removed vacuum hoses.
(30) Connect the body ground strap.
(31) I nstal l the throttl e, transmi ssi on l i ne pres-
sure, and speed control cabl es to thei r mounti ng
bracket and connect them to the throttl e body.
(32) Connect the heater hoses at the engi ne ther-
mostat housi ng and water pump.
(33) I nstal l the fan assembl y to the water pump
(Refer to 7 - COOLI NG/ENGI NE/FAN DRI VE VI S-
COUS CLUTCH - I NSTALLATI ON).
(34) Pl ace the fan shroud i n posi ti on over the fan.
(35) I nstal l the radi ator or radi ator/condenser
(Refer to 7 - COOLI NG/ENGI NE/RADI ATOR -
I NSTALLATI ON).
(36) Connect the servi ce val ves to the A/C com-
pressor ports, i f equi pped wi th A/C.
(37) Charge the ai r condi ti oner system (Refer to 24
- HEATI NG & AI R CONDI TI ONI NG/PLUMBI NG -
STANDARD PROCEDURE).
(38) Connect the radi ator hoses and automati c
transmi ssi on fl ui d cool er pi pes, i f equi pped.
(39) I nstal l the fan shroud to the radi ator or radi -
ator/condenser (i f equi pped wi th A/C).
(40) I nstal l upper radi ator support.
(41) Connect the upper radi ator hose and ti ghten
the cl amp.
(42) Connect the l ower radi ator hose and ti ghten
the cl amp.
(43) Fi l l crankcase wi th engi ne oi l (Refer to
LUBRI CATI ON & MAI NTENANCE - SPECI FI CA-
TI ONS).
(44) Fi l l the cool i ng system (Refer to 7 - COOLI NG
- STANDARD PROCEDURE).
(45) Al i gn the hood to the scri be marks. I nstal l the
hood.
(46) I nstal l the ai r cl eaner assembl y.
(47) I nstal l the battery and connect the battery
cabl e.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHING.
(48) Start the engi ne, i nspect for l eaks and correct
the fl ui d l evel s, as necessary.
SPECIFICATIONS
ENGINE - 4. 0L
GENERAL DESCRIPTION
DESCRIPTION SPECIFICATION
Engine Type In-Line 6 Cylinder
Displacement 4.0 Liters / 4000 cc
242 ( Cubic Inches)
Bore 98.4 mm (3.88 in.)
Stroke 86.69 mm (3.413 in.)
Compression Ratio 8.8:1
Firing Order 1-5-3-6-2-4
Lubrication Pressure Feed-Full
Flow-Filtration
Cooling System Liquid Cooled-Forced
Circulation
Cylinder Block Cast Iron
Crankshaft Cast Nodular Iron
Cylinder Head Cast Iron
Camshaft Cast Iron
Pistons Aluminum Alloy
Combustion Chamber Dual-Quench
Connecting Rods Cast Malleable Iron
TJ ENGINE 4. 0L 9 - 79
ENGINE 4.0L (Continued)
CYLINDER BLOCK
DESCRIPTION SPECIFICATION
Metric Standard
CylinderBore
Diameter
98.45 - 98.48
mm
3.8759 - 3.8775
in.
Out of Round
(MAX)
0.025 mm 0.001 in.
Taper (MAX) 0.025 mm 0.001 in.
Deck Height 240.03 - 240.18
mm
9.450 - 9.456 in.
Deck Clearance
(Below Deck)
0.546 mm 0.0215 in.
Tappet Bore
Diameter
23.000 - 23.025
mm
0.9055 - 0.9065
Flatness 0.03 mm per 25
mm
0.001 in. per 1
in.
0.05 mm per
152 mm
0.002 in. per 6
in.
Flatness (MAX) 0.20 mm (MAX)
for total length
0.008 in. MAX)
for total length
Main Bearing
Bore Diameter
68.351 - 68.376
mm
2.691 - 2.692 in.
PISTONS
DESCRIPTION SPECIFICATION
Metric Standard
Weight (Less
Pin)
417 - 429
grams
14.7 - 15.1 oz
Piston Pin Bore
Diameter
23.650 - 23.658
mm
0.9312 - 0.9315
in.
Piston Pin To
Bore (
Centerline To
Piston Top)
40.61 - 40.72
mm
1.599 - 1.603 in.
Piston To Bore
Clearance
0.018 - 0.038
mm
0.0008 - 0.0015
in.
Piston Ring
Groove Height
Compression
Rings
1.530 - 1.555
mm
0.0602 - 0.0612
in.
Oil Control
Rings
4.035 - 4.060
mm
0.1589 - 0.1598
in.
Piston Ring
Groove
Diameter
No. 1
Compression
88.39 - 88.65
mm
3.48 - 3.49 in
No. 2
Compression
87.63 - 87.88
mm
3.45 - 3.46 in.
No. 3 Oil
Control
89.66 - 89.92
mm
3.53 - 3.54 in.
PISTON PINS
DESCRIPTION SPECIFICATION
Metric Standard
Piston To Pin
Clearance
0.0102 - 0.0208
mm
0.0005 - 0.0009
in.
Diameter 23.637 - 23.640
mm
0.9306 - 0.9307
in.
Piston-Pin To
Connecting Rod
(Press Fit)
8.9kN 2000 lbf.
PISTON RINGS
DESCRIPTION SPECIFICATION
Metric Standard
Ring Gap
Top
Compression
Ring
0.229 - 0.610
mm
0.0090 - 0.0240
in.
Second
Compression
Ring
0.483 - 0.965
mm
0.0190 - 0.0380
in.
Oil Control
(Steel Rails)
0.254 - 1.500
mm
0.010 - 0.060 in.
Side Clearance
Top
Compression
Ring
.042 - .084 mm 0.0017 - 0.0033
in.
Second
Compression
Ring
0.042 - 0.084
mm
0.0017 - 0.0033
in.
Oil Ring (Steel
Ring)
.06 - .21 mm .0024 - .0083 in.
9 - 80 ENGINE 4. 0L TJ
ENGINE 4.0L (Continued)
CONNECTING RODS
DESCRIPTION SPECIFICATION
Metric Standard
Bearing
Clearance
0.025 - 0.076
mm
0.001 - 0.003 in.
Preferred 0.044 - 0.050 0.0015 - 0.0020
Side Clearance 0.25 - 0.48 mm 0.010 - 0.019 in.
Piston Pin Bore
Diameter
.023.59 - 23.62
mm
0.9288 - 0.9298
in.
Bearing Bore
( Less Bearings)
56.08 -
56.09mm
2.2080 - 2.2085
in.
Total Weight
(Less Bearing)
663 - 671
grams
23.39 - 23.67
oz.
Length ( Center
To Center)
155.52 - 155.62
mm
6.123 - 6.127 in.
Twist ( MAX.) 0.002 mm per
mm
0.002 in. per
inch
Bend (MAX.) 0.002 mm per
mm
0.002 in. per
inch.
CRANKSHAFT
DESCRIPTION SPECIFICATION
Metric Standard
Main Bearing
Journal
Diameter
No. 1-6 63.489 - 63.502
mm
2.499 - 2.500 in.
No. 7 63.449 - 63.487 2.498 - 2.499 in.
Bearing
Clearance
0.03 - 0.06 mm 0.001 - 0.0025
in.
Preferred 0.051 mm 0.002 in.
Out of Round
(MAX)
0.013 mm 0.0005 in.
Taper (MAX) 0.013 mm 0.0005 in.
End Play 0.038 - 0.165
mm
0.0015 - 0.0065
in.
Connecting Rod
Journal
Diameter
53.17 - 53.23
mm
2.0934 - 2.0955
in.
CAMSHAFT
DESCRIPTION SPECIFICATION
Metric Standard
Hydraulic
Tappet
Clearance
Zero Lash
Bore Diameter 26.02 - 26.04
mm
1.0245 - 1.0252
in.
Bearing Journal
Diameter
No. 1 51.54 - 51.56
mm
2.029 - 2.030 in.
No. 2 51.28 - 51.31
mm
2.019 - 2.020 in.
No. 3 51.03 - 51.05
mm
2.009 - 2.010 in.
No. 4 50.78 - 50.80
mm
1.999 - 2.000 in.
Base Circle
Runout (MAX)
0.033 mm 0.001 in.
Valve Lift
Intake 10.350 mm 0.4075 in.
Exhaust 10.528 mm 0.4145 in.
VALVE TIMING
DESCRIPTION SPECIFICATION
Intake
Opens (BTDC) 12.4°
Closes (ABDC) 60.9°
Duration 253.3°
Exhaust
Opens (BBDC) 49.8°
Closes (ATDC) 29.2°
Duration 259.0°
Valve Overlap 41.6°
TJ ENGINE 4. 0L 9 - 81
ENGINE 4.0L (Continued)
VALVES
DESCRIPTION SPECIFICATION
Face Angle 46.5°
Head Diameter
Intake 48.38 - 48.64 mm
(1.905 - 1.915 in.)
Exhaust 37.97 - 38.22 mm
(1.495 - 1.505 in.)
Length (Overall)
Intake 122.47 - 122.86 mm
(4.822 - 4.837)
Exhaust 122.86 - 123.24 mm
(4.83 - 4.85 in.)
Stem Diameter 7.89 - 7.92 mm
(0.311 - 0.312 in.)
Stem - to - Guide
Clearance
0.025 - 0.076 mm
(0.001 - 0.003 in.)
Tip Refinishing (Max.
Allowable)
0.025 mm (0.010 in.)
VALVE SPRING
DESCRIPTION SPECIFICATION
Free Length (Approx) 47.65 mm (1.876 in.)
Spring Force (Valve
Closed)
Intake and Exhaust 316.0 - 351.0 N @ 41.65
mm
(71.0 - 79.0 lbs. @ 1.64
in.)
Spring Force (Valve
Open)
Intake and Exhaust 898.6 - 969.7 N @ 30.89
mm
(202.0 - 218.0 lbs. @
1.216 in.)
Wire Diameter (Inside) 21.0 - 21.51 mm
Intake and Exhaust (0.827 - 0.847 in.)
Installed Height (Spring
Seat to Bottom of
Retainer)
41.65 mm (1.64 in.)
CYLINDER HEAD
DESCRIPTION SPECIFICATION
Combustion Chamber 55.22 - 58.22 cc
(3.37 - 3.55 cu. in.)
Valve Seat Angle 44.5°
Valve Seat Runout (MAX) 0.064 mm (0.0025 in.)
Valve Seat Width 1.02 - 1.52 mm
(0.040 - 0.060 in.)
Valve Guide I. D
(Integral)
7.95 - 7.97 mm
(0.313 - 0.314 in.)
Valve Stem to Guide
Clearance
0.025 - 0.076 mm
(0.001 - 0.003 in.)
Cylinder Head Warpage
(Flatness)
0.03 mm per 25 mm
(0.001 in. per 1 in.)
0.05 mm per 152 mm
(0.002 in. per 6 in.)
Flatness (MAX) 0.20 mm - max for total
length
OIL PUMP
DESCRIPTION SPECIFICATION
Gear to Body Clearance
(Radial)
0.051 - 0.102 mm
(0.002 - 0.004 in.)
Gear to Body Clearance
(Radial Preferred)
0.051 mm
(0.002 in.)
Gear End Clearance
(Plastigage)
0.051 - 0.152 mm
(0.002 - 0.006 in.)
Gear End Clearance
(Plastigage Preferred)
.051 mm (.002 in.)
Gear End Clearance
(FeelerGauge)
0.1016 - 0.2032 mm
(0.004 - 0.008 in.)
Gear End Clearance
(FeelerGauge Preferred)
0.1778 mm (0.007 in.)
9 - 82 ENGINE 4. 0L TJ
ENGINE 4.0L (Continued)
OIL PRESSURE
SPECIFICATION SPECIFICATION
At Curb Idle Speed* 89.6 kPa (13 psi)
@ 1600 and Higher Rpm 255 - 517 kPa (37 - 75
psi)
Oil Pressure Relief 517 kPa (75 psi.)
* CAUTION: If pressure is zero at curb idle, DO
NOT run engine at 3000 rpm.
TORQUE - 4. 0L ENGINE
DESCRIPTION N·m Ft. In.
Lbs. Lbs.
A/C Compressor—Bolts 28 — 250
Block Heater—Nut 2 — 16
Camshaft Sprocket—Bolt 68 50 —
Camshaft Thrust Plate to
Cylinder Block—Screws 24 18 —
Clutch Cover to Flywheel—
Bolts
54 40 —
Coil Bracket to Block—Bolts 22 — 192
Connecting Rod—Nuts 45 33 —
Cylinder Block—Drain Plugs 34 25 —
Cylinder Head—Bolts 135 100 —
Cylinder Head Cover—Bolts 10 — 85
Distributor Clamp—Bolts 23 — 204
Engine Mounts—Front
Support Bracket Bolts 61 45 —
Support Cushion Bolts/Nuts 41 30 —
Support Cushion Bracket
Bolts
54 40 —
Support Cushion Bracket Stud
Nuts
41 30 —
Support Cushion Thru-Bolt 65 48 —
Engine Mounts—Rear
Crossmember to Sill Bolts—
(Automatic) 41 30 —
Insulator Stud Assembly—Nut 41 30 —
Support Cushion/
Crossmember—
Nuts 22 — 192
Support Cushion/Bracket—
Nuts
(Manual) 75 55 —
DESCRIPTION N·m Ft. In.
Lbs. Lbs.
Transmission Support Bracket
—Bolt (Manual) 46 34 —
Transmission Support Bracket/
Cushion—Bolt (4WD Auto) 75 55 —
Transmission Support Adaptor
Bracket—Bolts (2WD Auto) 75 55 —
Exhaust Manifold/Pipe—Nuts 27 20 —
Intake/Exhaust Manifold
Fasteners #1-5 33 24 —
Fasteners #6 and 7 14 — 126
Fasteners #8-11 33 24 —
Flywheel to Converter
Housing—Bolts
38 28 —
Flywheel to Crankshaft—Bolts 143 105 —
Front Cover to Block—Bolts
1/4-20 7 — 60
5/16-18 22 — 192
Fuel Rail—Bolts/Stud 12 — 108
Generator—Bolts 57 42 —
Generator Bracket to
Engine—Bolts
47 35 —
Idler Pulley to Cylinder
Head—Bolt
47 35 —
Main Bearing Cap—Bolts 108 80 —
Oil Filter 18 — 156
Oil Filter Connector to
Adaptor 47 35 —
Block 68 50 —
Adaptor Bolts 102 50 —
Oil Galley—Plug 41 30 —
Oil Pan—Bolts
1/4-20 9.5 — 84
5/16-18 15 — 132
Oil Pan—Drain Plug 34 25 —
Oil Pump
Mounting Bolts 23 — 204
Cover Bolts 8 — 70
Rocker Arm Assembly to
Cylinder
Head—Capscrews 30 21 —
Spark Plugs 37 27 —
TJ ENGINE 4. 0L 9 - 83
ENGINE 4.0L (Continued)
DESCRIPTION N·m Ft. In.
Lbs. Lbs.
Starter Motor—Mounting Bolts 45 33 —
Thermostat Housing—Bolts 18 — 156
Throttle Body—Bolts 10 — 90
Vibration Damper—Bolt 108 80 —
Water Pump to Block—Bolts 23 17 —
AIR CLEANER ELEMENT
REMOVAL
(1) Loosen ai r tube cl amp at housi ng cover (Fi g. 7).
(2) Di sconnect ai r tube at cover.
(3) Pry back the cl i ps retai ni ng ai r cl eaner cover to
ai r cl eaner housi ng.
(4) Li ft cover up to expose ai r cl eaner el ement.
(5) Remove ai r cl eaner el ement.
(6) Cl ean i nsi de of ai r cl eaner housi ng and i ts
cover before i nstal l i ng new el ement.
INSTALLATION
(1) I nstal l ai r cl eaner el ement i nto housi ng.
(2) I nstal l housi ng cover to housi ng. Be sure cover
i s properl y seated to ai r cl eaner housi ng.
(3) Connect ai r tube at cover.
AIR CLEANER HOUSING
REMOVAL
(1) Loosen ai r tube cl amp at housi ng cover.
(2) Di sconnect ai r tube at cover. (Fi g. 8)
(3) Pry back the cl i ps retai ni ng ai r cl eaner cover to
ai r cl eaner housi ng.
(4) Li ft cover up to expose ai r cl eaner el ement.
(5) Remove ai r cl eaner el ement.
(6) Remove the ai r i nl et duct.
(7) Li ft up and remove the ai r cl eaner housi ng.
(8)
INSTALLATION
(1) Push down on the ai r cl eaner housi ng to l ock i n
pl ace.
(2) I nstal l the ai r i nl et tube.
(3) I nstal l the ai r cl eaner el ement.
(4) Pry back the cl i ps retai ni ng ai r cl eaner cover to
ai r cl eaner housi ng. (Fi g. 8)
(5) I nstal l the ai r cl eaner housi ng cover. Be sure
cover i s properl y seated.
(6) I nstal l the ai r out l et tube.
Fig. 7 AIR CLEANER ELEMENT
1 - COVER
2 - CLAMP
3 - AIR TUBE
4 - HOUSING
5 - FILTER
Fig. 8 AIR CLEANER ELEMENT
1 - COVER
2 - CLAMP
3 - AIR TUBE
4 - HOUSING
5 - FILTER
9 - 84 ENGINE 4. 0L TJ
ENGINE 4.0L (Continued)
CYLINDER HEAD
DESCRIPTION
The cyl i nder head i s made of cast i ron contai ni ng
twel ve val ves made of chrome pl ated heat resi stant
steel , val ve stem seal s, spri ngs, retai ners and keep-
ers. The cyl i nder head and val ve seats can be resur-
faced for servi ce purposes.
The val ve gui des are i ntegral to the cyl i nder head,
They are not repl aceabl e. However, they are servi ce-
abl e.
The cyl i nder head uses dual quench-type desi gn
combusti on chambers whi ch cause turbul ence i n the
cyl i nders al l owi ng faster burni ng of the ai r/fuel mi x-
ture, resul ti ng i n better fuel economy (Fi g. 9).
DIAGNOSIS AND TESTING - ENGINE CYLINDER
HEAD GASKET FAILURE
A l eaki ng engi ne cyl i nder head gasket usual l y
resul ts i n l oss of power, l oss of cool ant and engi ne
mi sfi ri ng.
An engi ne cyl i nder head gasket l eak can be l ocated
between adjacent cyl i nders or between a cyl i nder and
the adjacent water jacket.
• An engi ne cyl i nder head gasket l eaki ng between
adjacent cyl i nders i s i ndi cated by a l oss of power
and/or engi ne mi sfi re.
• An engi ne cyl i nder head gasket l eaki ng between
a cyl i nder and an adjacent water jacket i s i ndi cated
by cool ant foami ng or overheati ng and l oss of cool ant.
CYLINDER-TO-CYLINDER LEAKAGE TEST
To determi ne i f an engi ne cyl i nder head gasket i s
l eaki ng between adjacent cyl i nders; fol l ow the proce-
dures outl i ned . An engi ne cyl i nder head gasket l eak-
i ng between adjacent cyl i nders wi l l resul t i n
approxi matel y a 50-70% reducti on i n compressi on
pressure.
CYLINDER-TO-WATER JACKET LEAKAGE TEST
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR THE FAN.
DO NOT WEAR LOOSE CLOTHING.
Remove the radi ator cap.
Start the engi ne and al l ow i t to warm up unti l the
engi ne thermostat opens.
I f a l arge combusti on/compressi on pressure l eak
exi sts, bubbl es wi l l be vi si bl e i n the cool ant.
I f bubbl es are not vi si bl e, i nstal l a radi ator pres-
sure tester and pressuri ze the cool ant system.
I f a cyl i nder i s l eaki ng combusti on pressure i nto
the water jacket, the tester poi nter wi l l pul sate wi th
every combusti on stroke of the cyl i nder.
REMOVAL
NOTE: This procedure can be done with the engine
in or out of the vehicle.
(1) Di sconnect the battery negati ve cabl e.
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR
DRAIN COCK WITH THE SYSTEM HOT AND PRES-
SURIZED BECAUSE SERIOUS BURNS FROM THE
COOLANT CAN OCCUR.
(2) Drai n the cool ant (Refer to 7 - COOLI NG -
STANDARD PROCEDURE) and di sconnect the hoses
at the engi ne thermostat housi ng and the water
pump i nl et. DO NOT waste reusabl e cool ant. I f the
sol uti on i s cl ean and i s bei ng drai ned onl y to servi ce
the engi ne or cool i ng system, drai n the cool ant i nto a
cl ean contai ner for reuse.
(3) Remove the ai r cl eaner assembl y.
(4) Remove the cyl i nder head cover (Refer to 9 -
ENGI NE/CYLI NDER HEAD/CYLI NDER HEAD
COVER(S) - REMOVAL).
(5) Remove the capscrews, bri dge and pi vot assem-
bl i es and rocker arms (Refer to 9 - ENGI NE/CYLI N-
DER HEAD/ROCKER ARM / ADJUSTER ASSY -
REMOVAL).
(6) Remove the push rods.Retain the push rods,
bridges, pivots and rocker arms in the same
order as removed.
(7) Remove the accessory dri ve bel t (Refer to 7 -
COOLI NG/ACCESSORY DRI VE/DRI VE BELTS -
REMOVAL).
Fig. 9 Cylinder Head 4.0L Engine
1 - CYLINDER HEAD BOLTS
2 - CYLINDER HEAD GASKET
3 - CYLINDER HEAD
TJ ENGINE 4. 0L 9 - 85
(8) Remove the A/C compressor mounti ng bol ts
and secure the compressor to the si de.
(9) Remove the power steeri ng pump and bracket
from the i ntake mani fol d and water pump. Set the
pump and bracket asi de. DO NOT di sconnect the
hoses.
(10) Perform the Fuel System Pressure Rel ease
procedure (Refer to 14 - FUEL SYSTEM/FUEL
DELI VERY - STANDARD PROCEDURE).
(11) Di sconnect the fuel suppl y l i ne at the fuel rai l .
(12) Remove the i ntake and exhaust mani fol ds
from the engi ne cyl i nder head (Refer to 9 - ENGI NE/
MANI FOLDS/I NTAKE MANI FOLD - REMOVAL).
(13) Di sconnect the coi l rai l el ectri cal connectors
and remove the coi l rai l (Refer to 8 - ELECTRI CAL/
I GNI TI ON CONTROL/COI L RAI L - REMOVAL).
(14) Remove spark pl ugs (Refer to 8 - ELECTRI -
CAL/I GNI TI ON CONTROL/SPARK PLUG -
REMOVAL).
(15) Di sconnect the temperature sendi ng uni t wi re
connector.
(16) Remove the engi ne cyl i nder head bol ts. Bol t
No.14 cannot be removed unti l the head i s moved for-
ward (Fi g. 10). Pul l bol t No.14 out as far as i t wi l l go
and then suspend the bol t i n thi s posi ti on (tape
around the bol t).
(17) Remove the engi ne cyl i nder head and gasket
(Fi g. 10).
(18) I f thi s was the fi rst ti me the bol ts were
removed, put a pai nt dab on the top of the bol t. I f the
bol ts have a pai nt dab on the top of the bol t or i t
i sn’t known i f they were used before, di scard the
bol ts.
(19) Stuff cl ean l i nt free shop towel s i nto the cyl -
i nder bores.
NOTE: If the valves, springs, or seals are to be
inspected/replaced at this time, refer to Valves and
Valve Springs in this section for proper inspection
procedures.
CLEANING
Thoroughl y cl ean the engi ne cyl i nder head and cyl -
i nder bl ock mati ng surfaces. Cl ean the i ntake and
engi ne exhaust mani fol d and engi ne cyl i nder head
mati ng surfaces. Remove al l gasket materi al and car-
bon.
Check to ensure that no cool ant or forei gn materi al
has fal l en i nto the tappet bore area.
Remove the carbon deposi ts from the combusti on
chambers and top of the pi stons.
INSPECTION
Use a strai ghtedge and feel er gauge to check the
fl atness of the engi ne cyl i nder head and bl ock mati ng
surfaces.
INSTALLATION
NOTE: This procedure can be done with the engine
in or out of the vehicle.
The engi ne cyl i nder head gasket i s a composi ti on
gasket. The gasket i s to be i nstal l ed DRY. DO NOT
use a gasket sealing compound on the gasket.
I f the engi ne cyl i nder head i s to be repl aced and
the ori gi nal val ves used, measure the val ve stem
di ameter. Onl y standard si ze val ves can be used wi th
a servi ce repl acement engi ne cyl i nder head unl ess
the repl acement head val ve stem gui de bores are
reamed to accommodate oversi ze val ve stems.
Remove al l carbon bui l dup and reface the val ves.
(1) Remove the shop towel s from the cyl i nder
bores. Coat the bores wi th cl ean engi ne oi l .
(2) Posi ti on the engi ne cyl i nder head gasket (wi th
the numbers faci ng up) usi ng the al i gnment dowel s
i n the cyl i nder bl ock, to posi ti on the gasket.
CAUTION: Engine cylinder head bolts should be
reused only once. Replace the head bolts if they
were used before or if they have a paint dab on the
top of the bolt.
(3) Wi th bol t No.14 hel d i n pl ace (tape around
bol t), i nstal l the engi ne cyl i nder head over the same
dowel s used to l ocate the gasket. Remove the tape
from bol t No.14.
(4) Coat the threads of stud bol t No.11 wi th Loc-
ti te 592 seal ant, or equi val ent.
(5) Ti ghten the engi ne cyl i nder head bol ts i n
sequence accordi ng to the fol l owi ng procedure (Fi g.
11).
Fig. 10 Engine Cylinder
1 - CYLINDER HEAD BOLTS
2 - CYLINDER HEAD GASKET
3 - CYLINDER HEAD
9 - 86 ENGINE 4. 0L TJ
CYLINDER HEAD (Continued)
CAUTION: During the final tightening sequence,
bolt No.11 will be tightened to a lower torque than
the rest of the bolts. DO NOT overtighten bolt
No.11.
(a) Ti ghten al l bol ts i n sequence (1 through 14)
to 30 N·m (22 ft. l bs.) torque.
(b) Ti ghten al l bol ts i n sequence (1 through 14)
to 61 N·m (45 ft. l bs.) torque.
(c) Check al l bol ts to veri fy they are set to 61
N·m (45 ft. l bs.) torque.
(d) Ti ghten bol ts i n sequence:
• Bol ts 1 through 10 to 149 N·m (110 ft. l bs.)
torque.
• Bol t 11 to 135 N·m (100 ft. l bs.) torque.
• Bol ts 12 through 14 to 149 N·m (110 ft. l bs.)
torque.
(e) Check al l bol ts i n sequence to veri fy the cor-
rect torque.
(f) I f not al ready done, cl ean and mark each bol t
wi th a dab of pai nt after ti ghteni ng. Shoul d you
encounter bol ts whi ch were pai nted i n an earl i er
servi ce operati on, repl ace them.
(6) I nstal l the spark pl ugs (Refer to 8 - ELECTRI -
CAL/I GNI TI ON CONTROL/SPARK PLUG - I NSTAL-
LATI ON).
(7) Connect the temperature sendi ng uni t wi re
connector.
(8) I nstal l the i gni ti on coi l rai l and coi l rai l el ectri -
cal connectors (Refer to 8 - ELECTRI CAL/I GNI TI ON
CONTROL/COI L RAI L - I NSTALLATI ON).
(9) I nstal l the i ntake and exhaust mani fol ds (Refer
to 9 - ENGI NE/MANI FOLDS/I NTAKE MANI FOLD -
I NSTALLATI ON).
(10) I nstal l the fuel l i ne and the vacuum advance
hose.
(11) Attach the power steeri ng pump and bracket.
(12) I nstal l the push rods, rocker arms, pi vots and
bri dges i n the order they were removed (Refer to 9 -
ENGI NE/CYLI NDER HEAD/ROCKER ARM /
ADJUSTER ASSY - I NSTALLATI ON).
(13) I nstal l the engi ne cyl i nder head cover (Refer
to 9 - ENGI NE/CYLI NDER HEAD/CYLI NDER
HEAD COVER(S) - I NSTALLATI ON).
(14) Attach the ai r condi ti oner compressor mount-
i ng bracket to the engi ne cyl i nder head and bl ock.
Ti ghten the bol ts to 40 N·m (30 ft. l bs.) torque.
(15) Attach the ai r condi ti oni ng compressor to the
bracket. Ti ghten the bol ts to 27 N·m (20 ft. l bs.)
torque.
CAUTION: The serpentine drive belt must be routed
correctly. Incorrect routing can cause the water
pump to turn in the opposite direction causing the
engine to overheat.
(16) I nstal l the serpenti ne dri ve bel t (Refer to 7 -
COOLI NG/ACCESSORY DRI VE/DRI VE BELTS -
I NSTALLATI ON).
(17) I nstal l the ai r cl eaner and ducti ng.
(18) Connect the hoses to the engi ne thermostat
housi ng and fi l l the cool i ng system to the speci fi ed
l evel (Refer to 7 - COOLI NG - STANDARD PROCE-
DURE).
(19) The automati c transmi ssi on throttl e l i nkage
and cabl e must be adjusted after compl eti ng the
engi ne cyl i nder head i nstal l ati on (Refer to 21 -
TRANSMI SSI ON/TRANSAXLE/AUTOMATI C -
30RH/THROTTLE VALVE CABLE - ADJUST-
MENTS) or (Refer to 21 - TRANSMI SSI ON/TRANS-
AXLE/AUTOMATI C - 32RH/THROTTLE VALVE
CABLE - ADJUSTMENTS).
(20) I nstal l the temperature sendi ng uni t and con-
nect the wi re connector.
(21) I f equi pped wi th ai r condi ti oni ng, i nstal l A/C
compressor (Refer to 24 - HEATI NG & AI R CONDI -
TI ONI NG/PLUMBI NG/A/C COMPRESSOR -
I NSTALLATI ON) and charge A/C system (Refer to 24
- HEATI NG & AI R CONDI TI ONI NG/PLUMBI NG -
STANDARD PROCEDURE).
(22) Connect negati ve cabl e to battery.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN DIRECT
LINE WITH THE FAN. DO NOT PUT HANDS NEAR
THE PULLEYS, BELTS OR FAN. DO NOT WEAR
LOOSE CLOTHING.
(23) Operate the engi ne wi th the radi ator cap off.
I nspect for l eaks and conti nue operati ng the engi ne
unti l the engi ne thermostat opens. Add cool ant, i f
requi red.
Fig. 11 Engine Cylinder Head Bolt Tightening
Sequence
TJ ENGINE 4. 0L 9 - 87
CYLINDER HEAD (Continued)
CYLINDER HEAD COVER(S)
DESCRIPTION
The cyl i nder head cover (Fi g. 12) i s made of
stamped steel and i ncorporates the Crankcase Venti -
l ati on (CCV) Hoses and the oi l fi l l openi ng.
REMOVAL
The cyl i nder head cover i s i sol ated from the cyl i n-
der head vi a grommets and a reusabl e mol ded rubber
gasket. The grommet and l i mi ter are retai ned i n the
cyl i nder head cover.
(1) Di sconnect negati ve cabl e from battery.
(2) Di sconnect the Crankcase Venti l ati on (CCV)
vacuum hose from engi ne cyl i nder head cover.
(3) Di sconnect the fresh ai r i nl et hose from the
engi ne cyl i nder head cover.
(4) Di sconnect the accel erator, transmi ssi on, and
speed (i f equi pped) control cabl es from the throttl e
body (Fi g. 13).
(5) Remove the three bol ts that fasten the control
cabl e bracket to the i ntake mani fol d.
(6) Remove control cabl es from cyl i nder head cover
cl i p.
(7) Posi ti on control cabl es and bracket away from
cyl i nder head cover secure wi th ti e straps.
NOTE: The wiring harness loom on the left hand
side of the engine must be disconnected and
moved over to the right hand side of the engine to
gain clearance for cylinder head cover removal.
(8) Di sconnect the l eft hand si de of the wi ri ng har-
ness l oom from al l components.
(9) Remove fasteners from pl asti c wi ri ng l oom
trough on rear of cyl i nder head cover.
NOTE: Before trying to move the Left side of the
harness to the right side, remove the tie strap from
the harness on the right side, just below the cover,
near the coil pack area, if equipped.
(10) Move the l eft hand si de harness l oom and the
pl asti c trough to the ri ght si de.
(11) Remove the engi ne cyl i nder head cover
mounti ng bol ts.
(12) Remove the engi ne cyl i nder head cover and
gasket.
CLEANING
Remove any ori gi nal seal er from the cover seal i ng
surface of the engi ne cyl i nder head and cl ean the
surface usi ng a fabri c cl eaner.
Remove al l resi due from the seal i ng surface usi ng
a cl ean, dry cl oth.
INSPECTION
I nspect the engi ne cyl i nder head cover for cracks.
Repl ace the cover, i f cracked.
The ori gi nal dark grey gasket materi al shoul d
NOT be removed. I f secti ons of the gasket materi al
are mi ssi ng or are compressed, repl ace the engi ne
cyl i nder head cover. However, secti ons wi th mi nor
damage such as smal l cracks, cuts or chi ps may be
repai red wi th a hand hel d appl i cator. The new mate-
ri al must be smoothed over to mai ntai n gasket
hei ght. Al l ow the gasket materi al to cure pri or to
engi ne cyl i nder head cover i nstal l ati on.
INSTALLATION
The cyl i nder head cover i s i sol ated from the cyl i n-
der head vi a grommets and a reusabl e mol ded rubber
gasket. The grommet and l i mi ter are retai ned i n the
cyl i nder head cover.
Fig. 12 Cylinder Head Cover
Fig. 13 Engine Cylinder Head Cover
1 - TRANS CONTROL CABLE
2 - ACCELERATOR CABLE
3 - CONTROL CABLE BRACKET
4 - CYLINDER HEAD COVER
9 - 88 ENGINE 4. 0L TJ
(1) I f a repl acement cover i s i nstal l ed, transfer the
CCV val ve grommet and oi l fi l l er cap from the ori gi -
nal cover to the repl acement cover.
(2) I nstal l cyl i nder head cover and gasket (Fi g. 14).
Ti ghten the mounti ng bol ts to 10 N·m (85 i n. l bs.)
torque.
(3) Rei nstal l the pl asti c wi ri ng l oom trough at the
rear of cyl i nder head cover.
(4) Reconnect the l eft hand si de of the wi ri ng har-
ness l oom to al l components.
(5) Connect the CCV hoses.
(6) I nstal l control cabl es and bracket on i ntake
mani fol d and ti ghten bol ts to 8.7 N·m (77 i n. l bs.)
torque.
(7) Connect control cabl es to throttl e body l i nkage.
(8) Snap control cabl es i nto cyl i nder head cover
cl i p.
(9) Connect negati ve cabl e to battery.
INTAKE/EXHAUST VALVES &
SEATS
DESCRIPTION
The val ves are made of heat resi stant steel and
have chrome pl ated stems to prevent scuffi ng. Al l
val ves use three bead l ocks to promote val ve rotati on
(Fi g. 15).
STANDARD PROCEDURE - VALVE SERVICE
VALVE REFACING
Cl ean al l carbon deposi ts from the combusti on
chambers, val ve ports, val ve stems, val ve stem
gui des and head.
(1) Use a val ve refaci ng machi ne to reface the
i ntake and exhaust val ves to the speci fi ed angl e.
(2) After refaci ng, a margi n of at l east 0.787 mm
(0.031 i nch) must remai n (Fi g. 16). I f the margi n i s
l ess than 0.787 mm (0.031 i nch), the val ve must be
repl aced.
VALVE SEAT REFACING
Cl ean al l carbon deposi ts from the combusti on
chambers, val ve ports, val ve stems, val ve stem
gui des and head.
(1) I nstal l a pi l ot of the correct si ze i n the val ve
gui de bore. Reface the val ve seat to the speci fi ed
Fig. 14 Cylinder Head Cover Gasket Locator Pins at
#8 & #9
Fig. 15 VALVE AND KEEPER CONFIGURATION 4.0L
1 - VALVE LOCKS (3–BEAD)
2 - RETAINER
3 - VALVE STEM OIL SEAL
4 - INTAKE VALVE
5 - EXHAUST VALVE
6 - VALVE SPRING
Fig. 16 Valve Facing
1 - VALVE MARGIN
2 - NO MARGIN
TJ ENGINE 4. 0L 9 - 89
CYLINDER HEAD COVER(S) (Continued)
angl e wi th a good dressi ng stone. Remove onl y
enough metal to provi de a smooth fi ni sh.
(2) Use tapered stones to obtai n the speci fi ed seat
wi dth when requi red.
(3) Control val ve seat runout to a maxi mum of
0.0635 mm (0.0025 i n.) (Fi g. 17).
VALVE STEM-TO-GUIDE CLEARANCE
MEASUREMENT
PREFERRED METHOD
(1) Remove the val ve from the head.
(2) Cl ean the val ve stem gui de bore wi th sol vent
and a bri stl e brush.
(3) I nsert a tel escopi ng gauge i nto the val ve stem
gui de bore approxi matel y 9.525 mm (.375 i nch) from
the val ve spri ng si de of the head (Fi g. 18).
(4) Remove and measure tel escopi ng gauge wi th a
mi crometer.
(5) Repeat the measurement wi th contacts l ength-
wi se to engi ne cyl i nder head.
(6) Compare the crosswi se to l engthwi se measure-
ments to determi ne out-of-roundness. I f the measure-
ments di ffer by more than 0.0635 mm (0.0025 i n.),
ream the gui de bore to accommodate an oversi ze
val ve stem.
(7) Compare the measured val ve gui de bore di am-
eter wi th speci fi cati ons (7.95-7.97 mm or 0.313-0.314
i nch). I f the measurement di ffers from speci fi cati on
by more than 0.076 mm (0.003 i nch), ream the gui de
bore to accommodate an oversi ze val ve stem.
ALTERNATIVE METHOD
(1) Use a di al i ndi cator to measure the l ateral
movement of the val ve stem (stem-to-gui de cl ear-
ance). Thi s must be done wi th the val ve i nstal l ed i n
i ts gui de and just off the val ve seat (Fi g. 19).
(2) Correct cl earance i s 0.025-0.0762 mm
(0.001-0.003 i nch). I f i ndi cated movement exceeds the
speci fi cati on ream the val ve gui de to accommodate
an oversi ze val ve stem.
NOTE: Valve seats must be ground after reaming
the valve guides to ensure that the valve seat is
concentric to the valve guide.
Fig. 17 Measurement of Valve Seat Runout
1 - DIAL INDICATOR
Fig. 18 Measurement of Valve Guide Bore Diameter
1 - GAUGE
2 - 9.525 MM (3/8 INCH)
3 - VALVE STEM GUIDE
4 - CYLINDER HEAD
Fig. 19 Measurement of Lateral Movement Of Valve
Stem
1 - DIAL INDICATOR
9 - 90 ENGINE 4. 0L TJ
INTAKE/EXHAUST VALVES & SEATS (Continued)
REMOVAL
NOTE: This procedure is done with the engine cyl-
inder head removed from the block.
(1) Remove the engi ne cyl i nder head (Refer to 9 -
ENGI NE/CYLI NDER HEAD - REMOVAL) from the
cyl i nder bl ock.
(2) Use Val ve Spri ng Compressor Tool
MD-998772A and compress each val ve spri ng.
(3) Remove the val ve l ocks, retai ners, spri ngs and
val ve stem oi l seal s. Di scard the oi l seal s (Fi g. 20).
(4) Use a smooth stone or a jewel ers fi l e to remove
any burrs on the top of the val ve stem, especi al l y
around the groove for the l ocks.
(5) Remove the val ves, and pl ace them i n a rack i n
the same order as removed.
INSTALLATION
NOTE: This procedure is done with the engine cyl-
inder head removed from the block.
(1) Thoroughl y cl ean the val ve stems and the val ve
gui de bores.
(2) Li ghtl y l ubri cate the stem.
(3) I nstal l the val ve i n the ori gi nal val ve gui de
bore.
(4) I nstal l the repl acement val ve stem oi l seal s on
the val ve stems (Fi g. 21). I f the 0.381 mm (0.015
i nch) oversi ze val ve stems are used, oversi ze oi l seal s
are requi red.
(5) Posi ti on the val ve spri ng and retai ner on the
engi ne cyl i nder head and compress the val ve spri ng
wi th Val ve Spri ng Compressor Tool MD-998772A.
(6) I nstal l the val ve l ocks and rel ease the tool .
(7) Tap the val ve spri ng from si de to si de wi th a
hammer to ensure that the spri ng i s properl y seated
at the engi ne cyl i nder head. Al so tap the top of the
retai ner to seat the val ve l ocks.
(8) I nstal l the engi ne cyl i nder head (Refer to 9 -
ENGI NE/CYLI NDER HEAD - I NSTALLATI ON).
ROCKER ARM / ADJ USTER
ASSEMBLY
DESCRIPTION
The rocker arms are made of stamped steel and
have a operati onal rati o of 1.6:1 (Fi g. 22).
OPERATION
When the push rods are forced upward by the cam-
shaft l obes the push rod presses upward on the
rocker arms, the rocker arms pi vot, forci ng down-
ward pressure on the val ves forci ng the val ves to
move downward and off from thei r seats.
Fig. 20 Valve and Valve Components
1 - VALVE LOCKS (3–BEAD)
2 - RETAINER
3 - VALVE STEM OIL SEAL
4 - INTAKE VALVE
5 - EXHAUST VALVE
6 - VALVE SPRING
Fig. 21 Valve and Valve Components
1 - VALVE LOCKS (3–BEAD)
2 - RETAINER
3 - VALVE STEM OIL SEAL
4 - INTAKE VALVE
5 - EXHAUST VALVE
6 - VALVE SPRING
TJ ENGINE 4. 0L 9 - 91
INTAKE/EXHAUST VALVES & SEATS (Continued)
REMOVAL
NOTE: This procedure can be done with the engine
in or out of the vehicle.
(1) Remove the cyl i nder head cover (Refer to 9 -
ENGI NE/CYLI NDER HEAD/CYLI NDER HEAD
COVER(S) - REMOVAL).
(2) Check for rocker arm bri dges whi ch are caus-
i ng mi sal i gnment of the rocker arm to val ve ti p area.
(3) Remove the capscrews at each bri dge and pi vot
assembl y (Fi g. 23). Al ternatel y l oosen the capscrews
one turn at a ti me to avoi d damagi ng the bri dges.
(4) Remove the bri dges, pi vots and correspondi ng
pai rs of rocker arms (Fi g. 23). Pl ace them on a bench
i n the same order as removed.
(5) Remove the push rods and pl ace them on a
bench i n the same order as removed.
CLEANING
Cl ean al l the components wi th cl eani ng sol vent.
Use compressed ai r to bl ow out the oi l passages i n
the rocker arms and push rods.
INSPECTION
I nspect the pi vot surface area of each rocker arm.
Repl ace any that are scuffed, pi tted, cracked or
excessi vel y worn.
I nspect the val ve stem ti p contact surface of each
rocker arm and repl ace any rocker arm that i s deepl y
pi tted.
I nspect each push rod end for excessi ve wear and
repl ace as requi red. I f any push rod i s excessi vel y
worn because of l ack of oi l , repl ace i t and i nspect the
correspondi ng hydraul i c tappet for excessi ve wear.
I nspect the push rods for strai ghtness by rol l i ng
them on a fl at surface or by shi ni ng a l i ght between
the push rod and the fl at surface.
A wear pattern al ong the l ength of the push rod i s
not normal . I nspect the engi ne cyl i nder head for
obstructi on i f thi s condi ti on exi sts.
INSTALLATION
NOTE: This procedure can be done with the engine
in or out of the vehicle.
(1) Lubri cate the bal l ends of the push rods wi th
Mopar௡ Engi ne Oi l Suppl ement, or equi val ent and
i nstal l push rods i n thei r ori gi nal l ocati ons. Ensure
Fig. 22 Rocker Arms—Typical
1 - CAPSCREWS
2 - BRIDGE
3 - PIVOT ASSEMBLY
4 - PUSH RODS
5 - ROCKER ARMS
Fig. 23 Rocker Arm
1 - CAPSCREWS
2 - BRIDGE
3 - PIVOT ASSEMBLY
4 - PUSH RODS
5 - ROCKER ARMS
9 - 92 ENGINE 4. 0L TJ
ROCKER ARM / ADJ USTER ASSEMBLY (Continued)
that the bottom end of each push rod i s centered i n
the tappet pl unger cap seat.
(2) Usi ng Mopar௡ Engi ne Oi l Suppl ement, or
equi val ent, l ubri cate the area of the rocker arm that
the pi vot contacts. I nstal l rocker arms, pi vots and
bri dge above each cyl i nder i n thei r ori gi nal l y posi ti on
(Fi g. 24).
(3) Loosel y i nstal l the capscrews through each
bri dge.
(4) At each bri dge, ti ghten the capscrews al ter-
natel y, one turn at a ti me, to avoi d damagi ng the
bri dge. Ti ghten the capscrews to 28 N·m (21 ft. l bs.)
torque.
(5) I nstal l the engi ne cyl i nder head cover (Refer to
9 - ENGI NE/CYLI NDER HEAD/CYLI NDER HEAD
COVER(S) - I NSTALLATI ON).
VALVE STEM SEALS
DESCRIPTION
The val ve stem seal s (Fi g. 25) are made of rubber
and i ncorporate a garter spri ng to mai ntai n consi s-
tent l ubri cati on control .
VALVE SPRINGS
DESCRIPTION
The val ve spri ngs (Fi g. 26) are made of hi gh
strength si l i con chrome spri ng steel . The spri ngs are
common for both i ntake and exhaust val ves.
STANDARD PROCEDURE - VALVE SPRING
TENSION TEST
Cl ean al l carbon deposi ts from the combusti on
chambers, val ve ports, val ve stems, val ve stem
gui des and head.
Use a uni versal Val ve Spri ng Tester and a torque
wrench to test each val ve spri ng for the speci fi ed ten-
si on val ue (Fi g. 27).
Repl ace val ve spri ngs that are not wi thi n speci fi ca-
ti ons.
REMOVAL
NOTE: This procedure can be done with the engine
cylinder head installed on the block.
I nspect the val ve stems, especi al l y the grooves. An
Arkansas smooth stone shoul d be used to remove
ni cks and hi gh spots.
Fig. 24 Rocker Arm
1 - CAPSCREWS
2 - BRIDGE
3 - PIVOT ASSEMBLY
4 - PUSH RODS
5 - ROCKER ARMS
Fig. 25 Valve
1 - VALVE LOCKS (3–BEAD)
2 - RETAINER
3 - VALVE STEM OIL SEAL
4 - INTAKE VALVE
5 - EXHAUST VALVE
6 - VALVE SPRING
TJ ENGINE 4. 0L 9 - 93
ROCKER ARM / ADJ USTER ASSEMBLY (Continued)
Each val ve spri ng i s hel d i n pl ace by a retai ner
and a set of coni cal val ve l ocks. The l ocks can be
removed onl y by compressi ng the val ve spri ng.
(1) Remove the engi ne cyl i nder head cover (Refer
to 9 - ENGI NE/CYLI NDER HEAD/CYLI NDER
HEAD COVER(S) - REMOVAL).
(2) Remove cap screws, bri dge and pi vot assem-
bl i es and rocker arms (Refer to 9 - ENGI NE/CYLI N-
DER HEAD/ROCKER ARM / ADJUSTER ASSY -
REMOVAL) for access to each val ve spri ng to be
removed.
(3) Remove push rods. Retain the push rods,
bridges, pivots and rocker arms in the same
order and position as removed.
(4) I nspect the spri ngs and retai ner for cracks and
possi bl e si gns of weakeni ng.
(5) Remove the spark pl ug(s) adjacent to the cyl i n-
der(s) bel ow the val ve spri ngs to be removed.
(6) Connect an ai r hose to the adapter and appl y
ai r pressure sl owl y. Mai ntai n at l east 621 kPa (90
psi ) of ai r pressure i n the cyl i nder to hol d the val ves
agai nst thei r seats. For vehi cl es equi pped wi th an ai r
condi ti oner, use a fl exi bl e ai r adaptor when servi ci ng
the No.1 cyl i nder.
(7) Tap the retai ner or ti p wi th a rawhi de hammer
to l oosen the l ock from the retai ner. Use Val ve Spri ng
Compressor Tool MD-998772A to compress the spri ng
and remove the l ocks (Fi g. 28).
(8) Remove val ve spri ng and retai ner (Fi g. 28).
(9) Remove val ve stem oi l seal s (Fi g. 28). Note the
val ve seal s are di fferent for i ntake and exhaust
val ves. The top of each seal i s marked ei ther I NT
(i ntake/bl ack i n col or) or EXH (exhaust/brown i n
col or). DO NOT mi x the seal s.
Fig. 26 VALVE AND KEEPER CONFIGURATION 4.0L
1 - VALVE LOCKS (3–BEAD)
2 - RETAINER
3 - VALVE STEM OIL SEAL
4 - INTAKE VALVE
5 - EXHAUST VALVE
6 - VALVE SPRING
Fig. 27 Valve Spring Tester
1 - TORQUE WRENCH
2 - VALVE SPRING TESTER
Fig. 28 Valve and Valve Components
1 - VALVE LOCKS (3–BEAD)
2 - RETAINER
3 - VALVE STEM OIL SEAL
4 - INTAKE VALVE
5 - EXHAUST VALVE
6 - VALVE SPRING
9 - 94 ENGINE 4. 0L TJ
VALVE SPRINGS (Continued)
INSTALLATION
NOTE: This procedure can be done with the engine
cylinder head installed on the block.
CAUTION: Install oil seals carefully to prevent dam-
age from the sharp edges of the valve spring lock
grove.
(1) Li ghtl y push the val ve seal over the val ve stem
and val ve gui de boss. Be sure the seal i s compl etel y
seated on the val ve gui de boss.
(2) I nstal l val ve spri ng and retai ner (Fi g. 29).
(3) Compress the val ve spri ng wi th Val ve Spri ng
Compressor Tool MD-998772A and i nsert the val ve
l ocks. Rel ease the spri ng tensi on and remove the
tool . Tap the spri ng from si de-to-si de to ensure that
the spri ng i s seated properl y on the engi ne cyl i nder
head.
(4) Rel ease ai r pressure and di sconnect the ai r
hose. Remove the adaptor from the spark pl ug hol e
and i nstal l the spark pl ug.
(5) Repeat the procedures for each remai ni ng val ve
spri ng to be removed.
(6) I nstal l the push rods. Ensure the bottom end of
each rod i s centered i n the pl unger cap seat of the
hydraul i c val ve tappet.
(7) I nstal l the rocker arms, pi vots and bri dge
(Refer to 9 - ENGI NE/CYLI NDER HEAD/ROCKER
ARM /ADJUSTER ASSY - I NSTALLATI ON) at thei r
ori gi nal l ocati on.
(8) I nstal l the engi ne cyl i nder head cover (Refer to
9 - ENGI NE/CYLI NDER HEAD/CYLI NDER HEAD
COVER(S) - I NSTALLATI ON).
ENGINE BLOCK
CLEANING
Thoroughl y cl ean the oi l pan and engi ne bl ock gas-
ket surfaces.
Use compressed ai r to cl ean out:
• The gal l ey at the oi l fi l ter adaptor hol e.
• The front and rear oi l gal l ey hol es.
• The feed hol es for the crankshaft mai n beari ngs.
Once the bl ock has been compl etel y cl eaned, appl y
Locti te PST pi pe seal ant wi th Tefl on 592 to the
threads of the front and rear oi l gal l ey pl ugs. Ti ghten
the pl ugs to 34 N·m (25 ft. l bs.) torque.
INSPECTION
(1) I t i s mandatory to use a di al bore gauge to
measure each cyl i nder bore di ameter (Fi g. 30). To
correctl y sel ect the proper si ze pi ston, a cyl i nder bore
gauge, capabl e of readi ng i n 0.003 mm (.0001 i n.)
I NCREMENTS i s requi red. I f a bore gauge i s not
avai l abl e, do not use an i nsi de mi crometer.
(2) Measure the i nsi de di ameter of the cyl i nder
bore at three l evel s bel ow top of bore. Start perpen-
Fig. 29 Valve and Valve
1 - VALVE LOCKS (3–BEAD)
2 - RETAINER
3 - VALVE STEM OIL SEAL
4 - INTAKE VALVE
5 - EXHAUST VALVE
6 - VALVE SPRING
Fig. 30 Cylinder Bore Measurement
TJ ENGINE 4. 0L 9 - 95
VALVE SPRINGS (Continued)
di cul ar (across or at 90 degrees) to the axi s of the
crankshaft and then take two addi ti onal readi ng.
(3) Measure the cyl i nder bore di ameter crosswi se
to the cyl i nder bl ock near the top of the bore. Repeat
the measurement near the mi ddl e of the bore, then
repeat the measurement near the bottom of the bore.
(4) Determi ne taper by subtracti ng the smal l er
di ameter from the l arger di ameter.
(5) Rotate measuri ng devi ce 90° and repeat steps
above.
(6) Determi ne out-of-roundness by compari ng the
di fference between each measurement.
(7) I f cyl i nder bore taper does not exceed 0.025
mm (0.001 i nch) and out-of-roundness does not
exceed 0.025 mm (0.001 i nch), the cyl i nder bore can
be honed. I f the cyl i nder bore taper or out- of-round
condi ti on exceeds these maxi mum l i mi ts, the cyl i nder
must be bored and then honed to accept an oversi ze
pi ston. A sl i ght amount of taper al ways exi sts i n the
cyl i nder bore after the engi ne has been i n use for a
peri od of ti me.
CAMSHAFT & BEARINGS (IN
BLOCK)
DESCRIPTION
The camshaft i s made of gray cast i ron wi th twel ve
machi ned l obes and four beari ng journal s (Fi g. 31).
When the camshaft rotates the l obes actuate the tap-
pets and push rods, forci ng upward on the rocker
arms whi ch appl i es downward force on the val ves.
REMOVAL
REMOVAL - CAMSHAFT BEARINGS
The camshaft rotates wi thi n four steel -shel l ed,
babbi tt-l i ned beari ngs that are pressed i nto the cyl -
i nder bl ock and then l i ne reamed. The camshaft
beari ng bores and beari ng di ameters are not the
same si ze. They are stepped down i n 0.254 mm
(0.010 i nch) i ncrements from the front beari ng (l arg-
est) to the rear beari ng (smal l est). Thi s permi ts eas-
i er removal and i nstal l ati on of the camshaft. The
camshaft beari ngs are pressure l ubri cated. Camshaft
end pl ay i s mai ntai ned by the thrust pl ate.
(1) Remove the camshaft (Refer to 9 - ENGI NE/
ENGI NE BLOCK/CAMSHAFT & BEARI NGS (I N
BLOCK) - REMOVAL).
NOTE: It is not advisable to attempt to replace cam-
shaft bearings unless special removal and installa-
tion tools are available, such as recommended tool
8544 Camshaft Bushing Remover Installer.
(2) Usi ng Speci al tool 8544 Camshaft Bushi ng
Remover I nstal l er, remove the camshaft beari ngs.
REMOVAL - CAMSHAFT
WARNING: THE COOLANT IN A RECENTLY OPER-
ATED ENGINE IS HOT AND PRESSURIZED.
RELEASE THE PRESSURE BEFORE REMOVING
THE DRAIN COCK, CAP AND DRAIN PLUGS.
(1) Di sconnect negati ve cabl e from battery.
(2) Drai n the cool i ng system (Refer to 7 - COOL-
I NG - STANDARD PROCEDURE).
(3) Remove the radi ator (Refer to 7 - COOLI NG/
ENGI NE/RADI ATOR - REMOVAL) and condenser
(Refer to 24 - HEATI NG & AI R CONDI TI ONI NG/
PLUMBI NG/A/C CONDENSER - REMOVAL), i f
equi pped wi th A/C.
(4) Remove the engi ne cyl i nder head cover (Refer
to 9 - ENGI NE/CYLI NDER HEAD/CYLI NDER
HEAD COVER(S) - REMOVAL).
(5) Remove the rocker arms, bri dges and pi vots
(Refer to 9 - ENGI NE/CYLI NDER HEAD/ROCKER
ARM /ADJUSTER ASSY - REMOVAL).
(6) Remove the push rods.
(7) Remove the engi ne cyl i nder head and gasket
(Refer to 9 - ENGI NE/CYLI NDER HEAD -
REMOVAL).
(8) Remove the hydraul i c val ve tappets from the
engi ne cyl i nder bl ock (Refer to 9 - ENGI NE/ENGI NE
Fig. 31 Camshaft—Typical
1 - CAMSHAFT
2 - LOBES
3 - BEARING JOURNAL
9 - 96 ENGINE 4. 0L TJ
ENGINE BLOCK (Continued)
BLOCK/HYDRAULI C LI FTERS (CAM I N BLOCK) -
REMOVAL).
(9) Remove the vi brati on damper (Refer to 9 -
ENGI NE/ENGI NE BLOCK/VI BRATI ON DAMPER -
REMOVAL).
(10) Remove the ti mi ng case cover (Refer to 9 -
ENGI NE/VALVE TI MI NG/TI MI NG BELT / CHAI N
COVER(S) - REMOVAL).
(11) Rotate the crankshaft unti l the crankshaft
sprocket ti mi ng mark i s al i gned on centerl i ne wi th
the camshaft sprocket ti mi ng mark (Fi g. 33).
(12) Remove the ti mi ng chai n and sprockets (Refer
to 9 - ENGI NE/VALVE TI MI NG/TI MI NG BELT/
CHAI N AND SPROCKETS - REMOVAL).
(13) Remove the front bumper and/or gri l l e, as
requi red.
(14) Remove the two thrust pl ate retai ni ng screws,
thrust pl ate and camshaft (Fi g. 32).
INSTALLATION
INSTALLATION - CAMSHAFT BEARINGS
CAUTION: Make sure outside diameter of number 1
bearing is clean. Make sure that the bearing is
properly installed in the engine block, align the oil
hole in the bearing with the oil gallery in the bear-
ing bore. Failure to do so will cause inadequate oil
supply for the sprockets and timing chain.
(1) Usi ng recommended speci al tool 8544 Cam-
shaft Beari ng Remover/I nstal l er, i nstal l new cam-
shaft beari ngs.
INSTALLATION - CAMSHAFT
(1) Lubri cate the camshaft wi th Mopar௡ Engi ne
Oi l Suppl ement, or equi val ent.
(2) Careful l y i nstal l the camshaft to prevent dam-
age to the camshaft beari ngs.
(3) Posi ti on thrust pl ate and i nstal l retai ni ng
screws. Ti ghten screws to 24 N·m (18 ft. l bs.).
(4) Lubri cate the camshaft wi th Mopar௡ engi ne oi l
suppl ement, or equi val ent.
(5) I nstal l the camshaft sprocket, crankshaft
sprocket and ti mi ng chai n (Refer to 9 - ENGI NE/
VALVE TI MI NG/TI MI NG BELT/CHAI N AND
SPROCKETS - I NSTALLATI ON).
(6) Ti ghten the camshaft sprocket bol t and washer
to 68 N·m (50 ft. l bs.).
(7) To veri fy correct i nstal l ati on of the ti mi ng
chai n, turn the crankshaft two ful l revol uti ons then
posi ti on the camshaft sprocket ti mi ng mark as shown
i n (Fi g. 34).
(8) I nstal l the ti mi ng case cover wi th a repl ace-
ment oi l seal (Fi g. 35). (Refer to 9 - ENGI NE/VALVE
TI MI NG/TI MI NG BELT / CHAI N COVER(S) -
I NSTALLATI ON).
Fig. 32 Camshaft Removal
1 - CAMSHAFT
2 - CRANKSHAFT
Fig. 33 Crankshaft / Camshaft Sprocket Timing Mark
Alignment
1 - CAMSHAFT SPROCKET
2 - TIMING MARKS
3 - CRANKSHAFT SPROCKET
TJ ENGINE 4. 0L 9 - 97
CAMSHAFT & BEARINGS (IN BLOCK) (Continued)
(9) I nstal l the vi brati on damper (Fi g. 35) (Refer to
9 - ENGI NE/ENGI NE BLOCK/VI BRATI ON
DAMPER - I NSTALLATI ON).
(10) I nstal l the hydraul i c val ve tappets (Refer to 9
- ENGI NE/ENGI NE BLOCK/HYDRAULI C LI FTERS
(CAM I N BLOCK) - I NSTALLATI ON).
(11) I nstal l the cyl i nder head gasket wi th the
numbers faci ng up.
(12) I nstal l the cyl i nder head (Refer to 9 -
ENGI NE/CYLI NDER HEAD - I NSTALLATI ON).
(13) I nstal l the push rods.
(14) I nstal l the rocker arms and pi vot and bri dge
assembl i es (Refer to 9 - ENGI NE/CYLI NDER HEAD/
ROCKER ARM / ADJUSTER ASSY - I NSTALLA-
TI ON).
(15) I nstal l the engi ne cyl i nder head cover (Refer
to 9 - ENGI NE/CYLI NDER HEAD/CYLI NDER
HEAD COVER(S) - I NSTALLATI ON).
(16) I nstal l the serpenti ne dri ve bel t (Refer to 7 -
COOLI NG/ACCESSORY DRI VE/DRI VE BELTS -
I NSTALLATI ON).
NOTE: During installation, lubricate the hydraulic
valve tappets and all valve components with
Moparா Engine Oil Supplement, or equivalent. The
Moparா Engine Oil Supplement, or equivalent must
remain with the engine oil for at least 1609 km
(1,000 miles). The oil supplement need not be
drained until the next scheduled oil change.
(17) I nstal l the radi ator (Refer to 7 - COOLI NG/
ENGI NE/RADI ATOR - I NSTALLATI ON).
(18) Check the i gni ti on ti mi ng and adjust as nec-
essary.
(19) I nstal l the gri l l e and bumper, i f removed.
(20) Connect negati ve cabl e to battery.
CONNECTING ROD BEARINGS
STANDARD PROCEDURE - FITTING
CONNECTING ROD BEARINGS
I nspect the connecti ng rod beari ngs for scori ng and
bent al i gnment tabs (Fi g. 36) (Fi g. 37). Check the
beari ngs for normal wear patterns, scori ng, groovi ng,
fati gue and pi tti ng (Fi g. 38). Repl ace any beari ng
that shows abnormal wear.
I nspect the connecti ng rod journal s for si gns of
scori ng, ni cks and burrs.
Mi sal i gned or bent connecti ng rods can cause
abnormal wear on pi stons, pi ston ri ngs, cyl i nder
wal l s, connecti ng rod beari ngs and crankshaft con-
necti ng rod journal s. I f wear patterns or damage to
any of these components i ndi cate the probabi l i ty of a
mi sal i gned connecti ng rod, i nspect i t for correct rod
al i gnment. Repl ace mi sal i gned, bent or twi sted con-
necti ng rods.
BEARING-TO-JOURNAL CLEARANCE
(1) Wi pe the oi l from the connecti ng rod journal .
(2) Use short rubber hose secti ons over rod bol ts
duri ng i nstal l ati on.
(3) Lubri cate the upper beari ng i nsert and i nstal l
i n connecti ng rod.
Fig. 34 Crankshaft / Camshaft Chain Drive
Installation—Typical
1 - CAMSHAFT SPROCKET
2 - TIMING MARKS
3 - CRANKSHAFT SPROCKET
Fig. 35 Timing Case Cover Components
1 - TIMING CASE COVER
2 - OIL SLINGER
3 - CRANKSHAFT OIL SEAL
4 - VIBRATION DAMPER PULLEY
9 - 98 ENGINE 4. 0L TJ
CAMSHAFT & BEARINGS (IN BLOCK) (Continued)
(4) Use pi ston ri ng compressor to i nstal l the rod
and pi ston assembl i es. The oi l squi rt hol es i n the
rods must face the camshaft. The arrow on the pi ston
crown shoul d poi nt to the front of the engi ne (Fi g.
39). Veri fy that the oi l squi rt hol es i n the rods face
the camshaft and that the arrows on the pi stons face
the front of the engi ne.
(5) I nstal l the l ower beari ng i nsert i n the beari ng
cap. The l ower i nsert must be dry. Pl ace stri p of Pl as-
ti gage across ful l wi dth of the l ower i nsert at the cen-
ter of beari ng cap. Pl asti gage must not crumbl e i n
use. I f bri ttl e, obtai n fresh stock.
(6) I nstal l beari ng cap and connecti ng rod on the
journal and ti ghten nuts to 45 N·m (33 ft. l bs.)
torque. DO NOT rotate crankshaft. Pl asti gage wi l l
smear, resul ti ng i n i naccurate i ndi cati on.
(7) Remove the beari ng cap and determi ne amount
of beari ng-to- journal cl earance by measuri ng the
wi dth of compressed Pl asti gage (Fi g. 40). Plastigage
should indicate the same clearance across the
entire width of the insert. If the clearance var-
ies, it may be caused by either a tapered jour-
nal, bent connecting rod or foreign material
trapped between the insert and cap or rod.
Fig. 36 Connecting Rod Bearing Inspection
1 - UPPER BEARING HALF
2 - MATING EDGES
3 - GROOVES CAUSED BY ROD BOLTS SCRATCHING JOURNAL
DURING INSTALLATION
4 - WEAR PATTERN - ALWAYS GREATER ON UPPER BEARING
5 - LOWER BEARING HALF
Fig. 37 Locking Tab Inspection
1 - ABNORMAL CONTACT AREA CAUSED BY LOCKING TABS
NOT FULLY SEATED OR BEING BENT
Fig. 38 Scoring Caused by Insufficient Lubrication
or Damaged Crankshaft Journal
Fig. 39 Rod and Piston Assembly Installation
Fig. 40 Measuring Bearing Clearance with
Plastigage
1 - PLASTIGAGE SCALE
2 - COMPRESSED PLASTIGAGE
TJ ENGINE 4. 0L 9 - 99
CONNECTING ROD BEARINGS (Continued)
(8) I f the correct cl earance i s i ndi cated, repl ace-
ment of the beari ng i nserts i s not necessary. Remove
the Pl asti gage from crankshaft journal and beari ng
i nsert. Proceed wi th i nstal l ati on.
(9) I f beari ng-to-journal cl earance exceeds the
speci fi cati on, i nstal l a pai r of 0.0254 mm (0.001 i nch)
undersi ze beari ng i nserts. Al l the odd si ze i nserts
must be on the bottom. The si zes of the servi ce
repl acement beari ng i nserts are stamped on the
backs of the i nserts. Measure the cl earance as
descri bed i n the previ ous steps.
(10) The cl earance i s measured wi th a pai r of
0.0254 mm (0.001 i nch) undersi ze beari ng i nserts
i nstal l ed. Thi s wi l l determi ne i f two 0.0254 mm
(0.001 i nch) undersi ze i nserts or another combi nati on
i s needed to provi de the correct cl earance. Refer to
CONNECTI NG ROD BEARI NG FI TTI NG CHART.
CONNECTING ROD BEARING FITTING CHART
CRANKSHAFT JOURNAL CORRESPONDING ROD BEARING INSERT
Color Code Diameter Upper Insert Size Lower Insert Size
Yellow
53.2257 - 53.2079 mm
Yellow - Standard Yellow - Standard
(2.0955 - 2.0948 in.)
Orange
53.2079 - 53.1901 mm
Yellow - Standard
Blue - Undersize (2.0948 - 2.0941 in.)
0.0178 mm (0.0007 in.) 0.025 mm (0.001 in.)
Undersize
Blue
53.1901 - 53.1724 mm
Blue - Undersize Blue - Undersize (2.0941 - 2.0934 in.)
0.0356 mm (0.0014 in.) 0.025 mm (0.001 in.) 0.025 mm (0.001 in.)
Undersize
Red
52.9717 - 52.9539 mm
Red - Undersize Red - Undersize (2.0855 - 2.0848 in.)
0.254 mm (0.010 in.) 0.254 mm (0.010 in.) 0.254 mm (0.010 in.)
Undersize
(11) FOR EXAMPLE: I f the i ni ti al cl earance was
0.0762 mm (0.003 i nch), 0.025 mm (0.001 i nch)
undersi ze i nserts woul d reduce the cl earance by
0.025 mm (0.001 i nch). The cl earance woul d be 0.002
i nch and wi thi n speci fi cati on. A 0.051 mm (0.002
i nch) undersi ze i nsert woul d reduce the i ni ti al cl ear-
ance an addi ti onal 0.013 mm (0.0005 i nch). The
cl earance woul d then be 0.038 mm (0.0015 i nch).
(12) Repeat the Pl asti gage measurement to veri fy
your beari ng sel ecti on pri or to fi nal assembl y.
(13) Once you have sel ected the proper i nsert,
i nstal l the i nsert and cap. Ti ghten the connecti ng rod
bol ts to 45 N·m (33 ft. l bs.) torque.
SIDE CLEARANCE MEASUREMENT
Sl i de snug-fi tti ng feel er gauge between the con-
necti ng rod and crankshaft journal fl ange (Fi g. 41).
(Refer to 9 - ENGI NE - SPECI FI CATI ONS). Repl ace
the connecti ng rod i f the si de cl earance i s not wi thi n
speci fi cati on.
Fig. 41 Checking Connecting Rod Side Clearance -
Typical
9 - 100 ENGINE 4. 0L TJ
CONNECTING ROD BEARINGS (Continued)
CRANKSHAFT
DESCRIPTION
The crankshaft i s constructed of nodul ar cast i ron.
The crankshaft i s a crosshaped four throw desi gn
wi th ei ght counterwei ghts for bal anci ng purposes.
The crankshaft i s supported by seven sel ect mai n
beari ngs wi th the number three servi ng as the thrust
washer l ocati on. The mai n journal s of the crankshaft
are cross dri l l ed to i mprove rod beari ng l ubri cati on.
The sel ect fi t mai n beari ng marki ngs are l ocated on
the crankshaft counter wei ghts. The crankshaft rear
oi l seal i s a two pi ece desi gn. The front oi l seal i s a
one pi ece desi gn retai ned i n the ti mi ng chai n cover
(Fi g. 42).
CRANKSHAFT MAIN
BEARINGS
STANDARD PROCEDURE - FITTING
CRANKSHAFT MAIN BEARINGS
FITTING BEARINGS (CRANKSHAFT INSTALLED)
The mai n beari ng caps, numbered (front to rear)
from 1 through 7 have an arrow to i ndi cate the for-
ward posi ti on. The upper mai n beari ng i nserts are
grooved to provi de oi l channel s whi l e the l ower
i nserts are smooth.
Each beari ng i nsert pai r i s sel ecti vel y fi tted to i ts
respecti ve journal to obtai n the speci fi ed operati ng
cl earance. I n producti on, the sel ect fi t i s obtai ned by
usi ng vari ous-si zed col or-coded beari ng i nsert pai rs
as l i sted i n the Mai n Beari ng Fi tti ng Chart. The
beari ng col or code appears on the edge of the i nsert.
The size is not stamped on bearing inserts used
for engine production.
The mai n beari ng journal si ze (di ameter) i s i denti -
fi ed by a col or-coded pai nt mark (Fi g. 43)on the adja-
cent cheek or counterwei ght towards the rear of the
crankshaft (fl ange end). The rear mai n journal , i s
i denti fi ed by a col or-coded pai nt mark on the crank-
shaft rear fl ange.
When requi red, upper and l ower beari ng i nserts of
di fferent si zes may be used as a pai r. A standard si ze
i nsert i s someti mes used i n combi nati on wi th a 0.025
mm (0.001 i nch) undersi ze i nsert to reduce the cl ear-
ance by 0.013 mm (0.0005 i nch). Never use a pair
of bearing inserts with greater than a 0.025 mm
(0.001 inch) difference in size. Refer to the
Bearing Insert Pair Chart.
NOTE: When replacing inserts, the odd size inserts
must be either all on the top (in cylinder block) or
all on the bottom (in main bearing cap).
Once the beari ngs have been properl y fi tted, (Refer
to 9 - ENGI NE/ENGI NE BLOCK/CRANKSHAFT
MAI N BEARI NGS - I NSTALLATI ON).
BEARING-TO-JOURNAL CLEARANCE (CRANKSHAFT
INSTALLED)
When usi ng Pl asti gage, check onl y one beari ng
cl earance at a ti me.
I nstal l the grooved mai n beari ngs i nto the cyl i nder
bl ock and the non-grooved beari ngs i nto the beari ng
caps.
I nstal l the crankshaft i nto the upper beari ngs dry.
Pl ace a stri p of Pl asti gage across ful l wi dth of the
crankshaft journal to be checked.
I nstal l the beari ng cap and ti ghten the bol ts to 108
N·m (80 ft. l bs.) torque.
NOTE: DO NOT rotate the crankshaft. This will
cause the Plastigage to shift, resulting in an inaccu-
rate reading. Plastigage must not be permitted to
crumble. If brittle, obtain fresh stock.
Remove the beari ng cap. Determi ne the amount of
cl earance by measuri ng the wi dth of the compressed
Pl asti gage wi th the scal e on the Pl asti gage envel ope
(Fi g. 44). (Refer to 9 - ENGI NE - SPECI FI CATI ONS)
for the proper cl earance.
Pl asti gage shoul d i ndi cate the same cl earance
across the enti re wi dth of the i nsert. I f cl earance var-
i es, i t may i ndi cate a tapered journal or forei gn
materi al trapped behi nd the i nsert.
I f the speci fi ed cl earance i s i ndi cated and there are
no abnormal wear patterns, repl acement of the bear-
i ng i nserts i s not necessary. Remove the Pl asti gage
from the crankshaft journal and beari ng i nsert. Pro-
ceed to (Refer to 9 - ENGI NE/ENGI NE BLOCK/
CRANKSHAFT MAI N BEARI NGS -
I NSTALLATI ON).
Fig. 42 Crankshaft with Select Fit Marking Location
1 - 1/4” LETTERS
2 - (ROD)
3 - (MAIN)
TJ ENGINE 4. 0L 9 - 101
I f the cl earance exceeds speci fi cati on, i nstal l a pai r
of 0.025 mm (0.001 i nch) undersi ze beari ng i nserts
and measure the cl earance as descri bed i n the previ -
ous steps.
The cl earance i ndi cate wi th the 0.025 mm (0.001
i nch) undersi ze i nsert pai r i nstal l ed wi l l determi ne i f
thi s i nsert si ze or some other combi nati on wi l l pro-
vi de the speci fi ed cl earance. FOR EXAMPLE: I f the
cl earance was 0.0762 mm (0.003 i nch) ori gi nal l y, a
pai r of 0.0254 mm (0.001 i nch) undersi ze i nserts
woul d reduce the cl earance by 0.0254 mm (0.001
i nch). The cl earance woul d then be 0.0508 mm (0.002
i nch) and wi thi n the speci fi cati on. A 0.051 mm (0.002
i nch) undersi ze beari ng i nsert and a 0.0254 mm
(0.001 i nch) undersi ze i nsert woul d reduce the ori gi -
nal cl earance an addi ti onal 0.0127 mm (0.0005 i nch).
The cl earance woul d then be 0.0381 mm (0.0015
i nch).
CAUTION: Never use a pair of inserts that differ
more than one bearing size as a pair.
FOR EXAMPLE: DO NOT use a standard si ze
upper i nsert and a 0.051 mm (0.002 i nch) undersi ze
l ower i nsert.
I f the cl earance exceeds speci fi cati on usi ng a pai r
of 0.051 mm (0.002 i nch) undersi ze beari ng i nserts,
measure crankshaft journal di ameter wi th a
mi crometer. I f the journal di ameter i s correct, the
crankshaft bore i n the cyl i nder bl ock may be mi s-
al i gned, whi ch requi res cyl i nder bl ock repl acement or
machi ni ng to true bore.
Repl ace the crankshaft or gri nd to accept the
appropri ate undersi ze beari ng i nserts i f:
• Journal di ameters 1 through 6 are l ess than
63.4517 mm (2.4981 i nches)
• Journal 7 di ameter i s l ess than 63.4365 mm
(2.4975 i nches).
Once the proper cl earances have been obtai ned,
proceed to (Refer to 9 - ENGI NE/ENGI NE BLOCK/
CRANKSHAFT MAI N BEARI NGS - I NSTALLA-
TI ON).
JOURNAL DIAMETER (CRANKSHAFT REMOVED)
Remove the crankshaft from the cyl i nder bl ock.
Cl ean the oi l off the mai n beari ng journal .
Determi ne the maxi mum di ameter of the journal
wi th a mi crometer. Measure at two l ocati ons 90°
apart at each end of the journal .
Fig. 43 Crankshaft Journal Size Paint I.D. Location
1 - NO. 7 MAIN JOURNAL SIZE PAINT MARK
2 - NO. 6 CONNECTING ROD JOURNAL SIZE PAINT MARK
3 - NO. 1 CONNECTING ROD JOURNAL SIZE PAINT MARK
4 - NO. 1 MAIN JOURNAL SIZE PAINT MARK
Fig. 44 Measuring Bearing Clearance with
Plastigage
1 - PLASTIGAGE SCALE
2 - COMPRESSED PLASTIGAGE
9 - 102 ENGINE 4. 0L TJ
CRANKSHAFT MAIN BEARINGS (Continued)
The maxi mum al l owabl e taper and out of round i s
0.013 mm (0.0005 i nch). Compare the measured
di ameter wi th the journal di ameter speci fi cati on
MAI N BEARI NG FI TTI NG CHART. Sel ect i nserts
requi red to obtai n the speci fi ed beari ng-to-journal
cl earance.
I nstal l the crankshaft i nto the cyl i nder bl ock.
MAIN BEARING FITTING CHART
Crankshaft Journals #1-6
Corresponding
Crankshaft Bearing
Insert
Color
Code
Diameter
Upper
Insert
Size
Lower
Insert
Size
Yellow
63.5025
-63.4898 mm
Yellow -
Standard
Yellow -
Standard
(2.5001 - 2.4996
in.)
Orange
63.4898 -
63.4771 mm
Yellow -
Standard
Blue -
Undersize
0.025
mm
(0.001
in.)
(2.4996 - 2.4991
in.)
0.0127 mm
(0.0005 in.)
Undersize
Blue
63.4771 -
63.4644 mm Blue -
Undersize
0.025
mm
(0.001
in.)
Blue -
Undersize
0.025
mm
(0.001
in.)
(2.4991 - 2.4986
in.)
0.0254 mm
(0.001 in.)
Undersize
Green
63.4644 -
63.4517 mm Blue -
Undersize
0.025
mm
(0.001
in.)
Green -
Undersize
0.051
mm
(0.002
in.)
(2.4986 - 2.4981
in.)
0.0381 mm
(0.0015 in.)
Undersize
Red
63.2485 -
63.2358 mm Red -
Undersize
0.254
mm
(0.010
in.)
Red -
Undersize
0.254
mm
(0.010
in.)
(2.4901 - 2.4896
in.)
0.254 mm
(0.010 in.)
Undersize
Crankshaft Journal #7 Only
Corresponding
Bearing Insert
Color
Code
Diameter
Upper
Insert
Size
Lower
Insert
Size
Yellow
63.4873 -
63.4746 mm
Yellow -
Standard
Yellow -
Standard
(2.4995 - 2.4990
in.)
Orange
63.4746 -
63.4619 mm
Yellow -
Standard
Blue -
Undersize
0.025
mm
(0.001
in.)
(2.4990 - 2.4985
in.)
0.0127 mm
(0.0005 in.)
Undersize
Blue
63.4619 -
63.4492 mm Blue -
Undersize
0.025
mm
(0.001
in.)
Blue -
Undersize
0.025
mm
(0.001
in.)
(2.4985 - 2.4980
in.)
0.0254 mm
(0.001 in.)
Undersize
Green
63.4492 -
63.4365 mm Blue -
Undersize
0.025
mm
(0.001
in.)
Green -
Undersize
0.051
mm
(0.002
in.)
(2.4980 - 2.4975
in.)
0.0381 mm
(0.0015 in.)
Undersize
Red
63.2333 -
63.2206 mm Red -
Undersize
0.254
mm
(0.010
in.)
Red -
Undersize
0.254
mm
(0.010
in.)
(2.4895 - 2.4890
in.)
0.254 mm
(0.010 in.)
Undersize
REMOVAL
(1) Di sconnect negati ve cabl e from battery.
(2) Remove the spark pl ugs (Refer to 8 - ELEC-
TRI CAL/I GNI TI ON CONTROL/SPARK PLUG -
REMOVAL).
(3) Rai se the vehi cl e.
(4) Remove the oi l pan (Refer to 9 - ENGI NE/LU-
BRI CATI ON/OI L PAN - REMOVAL) and oi l pump
(Refer to 9 - ENGI NE/LUBRI CATI ON/OI L PUMP -
REMOVAL).
(5) Remove mai n beari ng cap brace (Fi g. 45).
TJ ENGINE 4. 0L 9 - 103
CRANKSHAFT MAIN BEARINGS (Continued)
(6) Remove onl y one mai n beari ng cap and l ower
i nsert at a ti me (Fi g. 46).
(7) Remove the l ower i nsert from the beari ng cap.
(8) Remove the upper i nsert by LOOSENI NG (DO
NOT REMOVE) al l of the other beari ng caps. Now
i nsert a smal l cotter pi n tool i n the crankshaft jour-
nal oi l hol e. Bend the cotter pi n as i l l ustrated to fab-
ri cate the tool (Fi g. 47). Wi th the cotter pi n tool i n
pl ace, rotate the crankshaft so that the upper bear-
i ng i nsert wi l l rotate i n the di recti on of i ts l ocki ng
tab. Because there i s no hol e i n the No.3 mai n jour-
nal , use a tongue depressor or si mi l ar soft-faced tool
to remove the beari ng i nsert (Fi g. 47). After movi ng
the i nsert approxi matel y 25 mm (1 i nch), i t can be
removed by appl yi ng pressure under the tab.
(9) Usi ng the same procedure descri bed above,
remove the remai ni ng beari ng i nserts one at a ti me
for i nspecti on.
INSPECTION
Wi pe the i nserts cl ean and i nspect for abnormal
wear patterns and for metal or other forei gn materi al
i mbedded i n the l i ni ng. Normal mai n beari ng i nsert
wear patterns are i l l ustrated (Fi g. 48). I n general the
l ower beari ng hal f wi l l have a heaver wear pattern.
NOTE: If any of the crankshaft journals are scored,
remove the engine for crankshaft repair.
I nspect the back of the i nserts for fractures, scrap-
i ngs or i rregul ar wear patterns.
I nspect the upper i nsert l ocki ng tabs for damage.
Repl ace al l damaged or worn beari ng i nserts.
Fig. 45 Main Bearing Caps and Brace.
1 - BLOCK
2 - MAIN BEARING CAP BRACE
Fig. 46 Removing Main Bearing Caps and Lower
Inserts
1 - CONNECTING ROD JOURNAL
2 - MAIN BEARING CAPS
Fig. 47 Removing Upper Inserts
1 - COTTER PIN
2 - BEARING INSERT
3 - TONGUE DEPRESSOR
9 - 104 ENGINE 4. 0L TJ
CRANKSHAFT MAIN BEARINGS (Continued)
INSTALLATION
(1) Lubri cate the beari ng surface of each i nsert
wi th engi ne oi l .
(2) Loosen al l the mai n beari ng caps. I nstal l the
mai n beari ng upper i nserts.
(3) I nstal l the l ower beari ng i nserts i nto the mai n
beari ng caps.
(4) On the rear mai n cap, appl y Mopar௡ Gasket
Maker seal er on both si des of cyl i nder bl ock as
shown i n (Fi g. 49). The dab of seal er shoul d be 3 mm
(0.125 i n.) i n di ameter.
(5) Appl y Mopar௡ Gasket Maker on the rear bear-
i ng cap. The bead shoul d be 2.3 mm (0.09 i n.) i n
di ameter. DO NOT appl y seal er to the l i p of the seal .
(6) I nstal l the mai n beari ng cap(s) and l ower
i nsert(s).
(7) Ti ghten the bol ts of caps 1, 2, 4, 5, 6, and 7 to
54 N·m (40 ft. l bs.) torque. Now ti ghten these bol ts to
95 N·m (70 ft. l bs.) torque. Fi nal l y, ti ghten these
bol ts to 108 N·m (80 ft. l bs.) torque.
(8) Push the crankshaft forward and backward.
Load the crankshaft front or rear and ti ghten cap
bol t No.3 to 54 N·m (40 ft. l bs.) torque. Then ti ghten
to 95 N·m (70 ft. l bs.) torque and fi nal l y ti ghten to
108 N·m (80 ft. l bs.) torque.
(9) Rotate the crankshaft after ti ghteni ng each
mai n beari ng cap to ensure the crankshaft rotates
freel y.
(10) Check crankshaft end pl ay. Crankshaft end
pl ay i s control l ed by the thrust beari ng whi ch i s
fl ange and i nstal l ed at the No.2 mai n beari ng posi -
ti on.
(a) Attach a magneti c base di al i ndi cator to the
cyl i nder bl ock at ei ther the front or rear of the
engi ne.
(b) Posi ti on the di al i ndi cator rod so that i t i s
paral l el to the center l i ne of the crankshaft.
(c) Pry the crankshaft forward, posi ti on the di al
i ndi cator to zero.
(d) Pry the crankshaft forward and backward.
Note the di al i ndi cator readi ngs. End pl ay i s the
di fference between the hi gh and l ow measurements
(Fi g. 50). Correct end pl ay i s 0.038-0.165 mm
(0.0015-0.0065 i nch). The desi red speci fi cati ons are
0.051-0.064 mm (0.002-0.0025 i nch).
(e) I f end pl ay i s not wi thi n speci fi cati on, i nspect
crankshaft thrust faces for wear. I f no wear i s
apparent, repl ace the thrust beari ng and measure
end pl ay. I f end pl ay i s sti l l not wi thi n speci fi ca-
ti on, repl ace the crankshaft.
(11) I f the crankshaft was removed, i nstal l the
crankshaft i nto the cyl i nder bl ock.
(12) I nstal l mai n beari ng cap brace ti ghten nuts to
47 N·m (35 ft. l bs.) torque.
(13) I nstal l oi l pump assy. and ti ghten attachi ng
bol ts to 23 N·m (17 ft. l bs.)
(14) I nstal l the oi l pan (Refer to 9 - ENGI NE/LU-
BRI CATI ON/OI L PAN - I NSTALLATI ON).
(15) I nstal l the drai n pl ug. Ti ghten the pl ug to 34
N·m (25 ft. l bs.) torque.
(16) Lower the vehi cl e.
Fig. 48 Main Bearing Wear Patterns
1 - UPPER INSERT
2 - NO WEAR IN THIS AREA
3 - LOW AREA IN BEARING LINING
4 - LOWER INSERT
Fig. 49 Location of Sealer
1 - DOWEL
2 - SEALER LOCATIONS
3 - CYLINDER BLOCK
4 - HALFWAY BETWEEN
5 - REAR FACE OF CYLINDER BLOCK
6 - 3mm (0.125 in.)
TJ ENGINE 4. 0L 9 - 105
CRANKSHAFT MAIN BEARINGS (Continued)
(17) I nstal l the spark pl ugs. Ti ghten the pl ugs to
37 N·m (27 ft. l bs.) torque.
(18) Fi l l the oi l pan wi th engi ne oi l to the ful l
mark on the di psti ck l evel .
(19) Connect negati ve cabl e to battery.
CRANKSHAFT OIL SEAL -
FRONT
REMOVAL
Thi s procedure i s done wi th the ti mi ng case cover
i nstal l ed.
(1) Di sconnect negati ve cabl e from battery.
(2) Remove the serpenti ne dri ve bel t (Refer to 7 -
COOLI NG/ACCESSORY DRI VE/DRI VE BELTS -
REMOVAL).
(3) Remove the vi brati on damper (Refer to 9 -
ENGI NE/ENGI NE BLOCK/VI BRATI ON DAMPER -
REMOVAL).
(4) Remove the radi ator shroud.
(5) Careful l y remove the oi l seal . Make sure seal
bore i s cl ean.
INSTALLATION
Thi s procedure i s done wi th the ti mi ng case cover
i nstal l ed.
(1) Posi ti on the repl acement oi l seal on Ti mi ng
Case Cover Al i gnment and Seal I nstal l ati on Tool
6139 wi th seal open end faci ng i nward. Appl y a l i ght
fi l m of Perfect Seal , or equi val ent, on the outsi de
di ameter of the seal . Li ghtl y coat the crankshaft wi th
engi ne oi l .
(2) Posi ti on the tool and seal over the end of the
crankshaft and i nsert a draw screw tool i nto Seal
I nstal l ati on Tool 6139 (Fi g. 51). Ti ghten the nut
agai nst the tool unti l i t contacts the cover.
(3) Remove the tool s. Appl y a l i ght fi l m of engi ne
oi l on the vi brati on damper hub contact surface of
the seal .
(4) Appl y Mopar௡ Si l i cone Rubber Adhesi ve Seal -
ant to the keyway i n the crankshaft and i nsert the
key. Wi th the key i nserted i n the keyway i n the
crankshaft, i nstal l the vi brati on damper (Refer to 9 -
ENGI NE/ENGI NE BLOCK/VI BRATI ON DAMPER -
I NSTALLATI ON).
(5) I nstal l the serpenti ne bel t (Refer to 7 - COOL-
I NG/ACCESSORY DRI VE/DRI VE BELTS - I NSTAL-
LATI ON).
(6) I nstal l the radi ator shroud.
(7) Connect negati ve cabl e to battery.
CRANKSHAFT OIL SEAL -
REAR
REMOVAL
The crankshaft rear mai n beari ng oi l seal consi sts
of two hal f pi eces of vi ton wi th a si ngl e l i p that effec-
ti vel y seal s the rear of the crankshaft. Repl ace the
upper and l ower seal hal ves as a uni t to ensure l eak-
free operati on.
(1) Remove transmi ssi on i nspecti on cover.
(2) Remove oi l pan. (Refer to 9 - ENGI NE/LUBRI -
CATI ON/OI L PAN - REMOVAL)
(3) Remove mai n beari ng cap brace.
(4) Remove rear mai n beari ng cap (No.7).
(5) Push upper seal out of the groove. Ensure that
the crankshaft and seal groove are not damaged.
Fig. 50 Crankshaft End Play Measurement
1 - DIAL INDICATOR
2 - CRANKSHAFT
Fig. 51 Timing Case Cover Oil Seal Installation
1 - SEAL INSTALLATION TOOL
2 - DRAW SCREW TOOL
9 - 106 ENGINE 4. 0L TJ
CRANKSHAFT MAIN BEARINGS (Continued)
(6) Remove l ower hal f of the seal from the beari ng
cap.
INSTALLATION
The crankshaft rear mai n beari ng oi l seal consi sts
of two hal f pi eces of vi ton wi th a si ngl e l i p that effec-
ti vel y seal s the rear of the crankshaft. Repl ace the
upper and l ower seal hal ves as a uni t to ensure l eak-
free operati on.
(1) Wi pe the seal surface area of the crankshaft
unti l i t i s cl ean.
(2) Appl y a thi n coat of engi ne oi l .
(3) Coat l i p of the seal wi th engi ne oi l .
(4) Careful l y posi ti on the upper seal i nto the
groove i n the cyl i nder bl ock. The l i p of the seal faces
toward the front of the engi ne.
(5) Appl y Mopar௡ Gasket Maker seal er on both
si des of cyl i nder bl ock as shown i n (Fi g. 52). The dab
of seal er shoul d be 3 mm (0.125 i n.) i n di ameter.
(6) Appl y Mopar௡ Gasket Maker on the rear bear-
i ng cap (Fi g. 52). The bead shoul d be 2.3 mm (0.09
i n.) i n di ameter. DO NOT appl y seal er to the l i p of
the seal .
(7) Posi ti on the l ower seal i nto the beari ng cap
recess and seat i t fi rml y. Be sure the seal i s fl ush
wi th the cyl i nder bl ock pan rai l .
(8) Coat the outer curved surface of the l ower seal
wi th soap and the l i p of the seal wi th engi ne oi l .
(9) I nstal l the rear mai n beari ng cap. DO NOT
stri ke the cap more than twi ce for proper engage-
ment.
(10) Ti ghten al l mai n beari ng bol ts to 108 N·m (80
ft. l bs.) torque.
(11) I nstal l the mai n beari ng cap brace. Ti ghten
nuts to 47 N·m (35 ft. l bs.).
(12) I nstal l the oi l pan gasket and oi l pan (Refer to
9 - ENGI NE/LUBRI CATI ON/OI L PAN - I NSTALLA-
TI ON).
(13) Appl y Mopar௡ Si l i cone Rubber Adhesi ve Seal -
ant on cyl i nder bl ock to rear mai n beari ng cap cor-
ners and cyl i nder bl ock to front cover joi nts (four
pl aces) (Fi g. 53)
(14) I nstal l transmi ssi on i nspecti on cover.
HYDRAULIC LIFTERS
DESCRIPTION
Val ve l ash i s control l ed by hydraul i c tappets
l ocated i nsi de the cyl i nder bl ock, i n tappet bores
above the camshaft.
REMOVAL
NOTE: Retain all the components in the same order
as removed.
(1) Remove the engi ne cyl i nder head(Refer to 9 -
ENGI NE/CYLI NDER HEAD - REMOVAL).
(2) Remove the push rods.
(3) Remove the tappets through the push rod open-
i ngs i n the cyl i nder bl ock wi th a Hydraul i c Val ve
Tappet Removal /I nstal l ati on Tool (Fi g. 54).
CLEANING
Cl ean each tappet assembl y i n cl eani ng sol vent to
remove al l varni sh, gum and sl udge deposi ts.
Fig. 52 Location of Sealer
1 - DOWEL
2 - SEALER LOCATIONS
3 - CYLINDER BLOCK
4 - HALFWAY BETWEEN
5 - REAR FACE OF CYLINDER BLOCK
6 - 3mm (0.125 in.)
Fig. 53 Oil Pan
1 - SEALER LOCATIONS
TJ ENGINE 4. 0L 9 - 107
CRANKSHAFT OIL SEAL - REAR (Continued)
INSPECTION
I nspect for i ndi cati ons of scuffi ng on the si de and
base of each tappet body.
I nspect each tappet base for concave wear wi th a
strai ghtedge posi ti oned across the base. I f the base i s
concave, the correspondi ng l obe on the camshaft i s
al so worn. Repl ace the camshaft and tappets.
After cl eani ng and i nspecti on, test each tappet for
speci fi ed l eak-down rate tol erance to ensure zero-l ash
operati on (Fi g. 55).
Swi ng the wei ghted arm of the hydraul i c val ve tap-
pet tester away from the ram of the Leak-Down
Tester.
(1) Pl ace a 7.925-7.950 mm (0.312-0.313 i nch)
di ameter bal l beari ng on the pl unger cap of the tap-
pet.
(2) Li ft the ram and posi ti on the tappet (wi th the
bal l beari ng) i nsi de the tester cup.
(3) Lower the ram, then adjust the nose of the ram
unti l i t contacts the bal l beari ng. DO NOT ti ghten
the hex nut on the ram.
(4) Fi l l the tester cup wi th hydraul i c val ve tappet
test oi l unti l the tappet i s compl etel y submerged.
(5) Swi ng the wei ghted arm onto the push rod and
pump the tappet pl unger up and down to remove ai r.
When the ai r bubbl es cease, swi ng the wei ghted arm
away and al l ow the pl unger to ri se to the normal
posi ti on.
(6) Adjust the nose of the ram to al i gn the poi nter
wi th the SET mark on the scal e of the tester and
ti ghten the hex nut.
(7) Sl owl y swi ng the wei ghted arm onto the push
rod.
(8) Rotate the cup by turni ng the handl e at the
base of the tester cl ockwi se one revol uti on every 2
seconds.
(9) Observe the l eak-down ti me i nterval from the
i nstant the poi nter al i gns wi th the START mark on
the scal e unti l the poi nter al i gns wi th the 0.125
mark. A normal l y functi oni ng tappet wi l l requi re
20-110 seconds to l eak-down. Di scard tappets wi th
l eak-down ti me i nterval not wi thi n thi s speci fi cati on.
INSTALLATION
Retai n al l the components i n the same order as
removed.
I t i s not necessary to charge the tappets wi th
engi ne oi l . They wi l l charge themsel ves wi thi n a very
short peri od of engi ne operati on.
(1) Di p each tappet i n Mopar௡ Engi ne Oi l Suppl e-
ment, or equi val ent.
(2) Use Hydraul i c Val ve Tappet Removal /I nstal l a-
ti on Tool to i nstal l each tappet i n the same bore from
where i t was ori gi nal l y removed.
(3) I nstal l the cyl i nder head (Refer to 9 - ENGI NE/
CYLI NDER HEAD - I NSTALLATI ON).
(4) I nstal l the push rods i n thei r ori gi nal l ocati ons.
(5) I nstal l the rocker arms and bri dge and pi vot
assembl i es at thei r ori gi nal l ocati ons. Loosel y i nstal l
the capscrews at each bri dge.
(6) Ti ghten the capscrews al ternatel y, one turn at
a ti me, to avoi d damagi ng the bri dges. Ti ghten the
capscrews to 28 N·m (21 ft. l bs.) torque.
(7) Pour the remai ni ng Mopar௡ Engi ne Oi l Suppl e-
ment, or equi val ent over the enti re val ve actuati ng
assembl y. The Mopar௡ Engi ne Oi l Suppl ement, or
equi val ent must remai n wi th the engi ne oi l for at
l east 1 609 km (1,000 mi l es). The oi l suppl ement
need not be drai ned unti l the next schedul ed oi l
change.
Fig. 54 HYDRAULIC VALVE TAPPET REMOVAL -
4.0L
1 - HYDRAULIC TAPPET REMOVAL TOOL
2 - CYLINDER BLOCK
Fig. 55 Leak-Down Tester
1 - POINTER
2 - WEIGHTED ARM
3 - RAM
4 - CUP
5 - HANDLE
6 - PUSH ROD
9 - 108 ENGINE 4. 0L TJ
HYDRAULIC LIFTERS (Continued)
(8) I nstal l the cyl i nder head cover (Refer to 9 -
ENGI NE/CYLI NDER HEAD/CYLI NDER HEAD
COVER(S) - I NSTALLATI ON).
PISTON & CONNECTING ROD
DESCRIPTION
The pi stons (Fi g. 56) are made of a hi gh strength
al umi num al l oy, the pi ston ski rts are coated wi th a
sol i d l ubri cant (Mol ykote) to reduce fri cti on and pro-
vi de scuff resi stance. The connecti ng rods are made
of cast i ron.
STANDARD PROCEDURE - PISTON FITTING
(1) To correctl y sel ect the proper si ze pi ston, a cyl -
i nder bore gauge, capabl e of readi ng i n 0.003 mm
(.0001 i n.) I NCREMENTS i s requi red. I f a bore
gauge i s not avai l abl e, do not use an i nsi de mi crome-
ter.
(2) Measure the i nsi de di ameter of the cyl i nder
bore at a poi nt 49.5 mm (1-15/16 i nches) bel ow top of
bore. Start perpendi cul ar (across or at 90 degrees) to
the axi s of the crankshaft at poi nt A and then take
an addi ti onal bore readi ng 90 degrees to that at poi nt
B (Fi g. 58).
(3) The coated pi stons wi l l be servi ced wi th the
pi ston pi n and connecti ng rod pre-assembl ed. The
coated piston connecting rod assembly can be
used to service previous built engines and
MUST be replaced as complete sets. Ti n coated
pi stons shoul d not be used as repl acements for coated
pi stons.
(4) The coati ng materi al i s appl i ed to the pi ston
after the fi nal pi ston machi ni ng process. Measuri ng
the outsi de di ameter of a coated pi ston wi l l not pro-
vi de accurate resul ts (Fi g. 57). Therefore measuri ng
the i nsi de di ameter of the cyl i nder bore wi th a di al
Bore Gauge i s MANDATORY. To correctl y sel ect the
proper si ze pi ston, a cyl i nder bore gauge capabl e of
readi ng i n 0.003 mm (.0001 i n.) i ncrements i s
requi red.
(5) Pi ston i nstal l ati on i nto the cyl i nder bore
requi res sl i ghtl y more pressure than that requi red
for non-coated pi stons. The bonded coati ng on the
pi ston wi l l gi ve the appearance of a l i ne-to-l i ne fi t
wi th the cyl i nder bore.
Fig. 56 Piston and Connecting Rod Assembly
Fig. 57 Moly Coated Piston
1 - MOLY COATED
2 - MOLY COATED
TJ ENGINE 4. 0L 9 - 109
HYDRAULIC LIFTERS (Continued)
PISTON SIZE CHART
CYLINDER BORE SIZE PISTON LETTER SIZE
98.438 - 98.448 mm
(3.8755 - 3.8759 in.)
A
98.448 - 98.458 mm
(3.8759 - 3.8763 in.)
B
98.458 - 98.468 mm
(3.8763 - 3.8767 in.)
C
98.468 - 98.478 mm
(3.8767 - 3.8771 in.)
D
98.478 - 98.488 mm
(3.8771 - 3.8775 in.)
E
98.488 - 98.498 mm
(3.8775 - 3.8779 in.)
F
REMOVAL
(1) Remove the engi ne cyl i nder head cover. (Refer
to 9 - ENGI NE/CYLI NDER HEAD/CYLI NDER
HEAD COVER(S) - REMOVAL).
(2) Remove the rocker arms, bri dges and pi vots.
(3) Remove the push rods.
(4) Remove the engi ne cyl i nder head. (Refer to 9 -
ENGI NE/CYLI NDER HEAD - REMOVAL).
(5) Posi ti on the pi stons one at a ti me near the bot-
tom of the stroke. Use a ri dge reamer to remove the
ri dge from the top end of the cyl i nder wal l s. Use a
protecti ve cl oth to col l ect the cutti ngs.
(6) Rai se the vehi cl e.
(7) Drai n the engi ne oi l .
(8) Remove the oi l pan and gasket. (Refer to 9 -
ENGI NE/LUBRI CATI ON/OI L PAN - REMOVAL).
(9) Remove mai n beari ng cap brace (Fi g. 59).
(10) Remove the connecti ng rod beari ng caps and
i nserts. Mark the caps and rods wi th the cyl i nder
bore l ocati on. The connecti ng rods and caps are
stamped wi th a two l etter combi nati on (Fi g. 60).
(11) Lower the vehi cl e unti l i t i s about 2 feet from
the fl oor.
Fig. 58 Bore Gauge
1 - FRONT
2 - BORE GAUGE
3 - CYLINDER BORE
4 - 49.5 MM (1-15/16 in.)
Fig. 59 Main Bearings Caps and Brace
1 - BLOCK
2 - MAIN BEARING CAP BRACE
Fig. 60 Stamped Connecting Rods and Caps
1 - CONNECTING ROD CAP
2 - CONNECTING ROD
9 - 110 ENGINE 4. 0L TJ
PISTON & CONNECTING ROD (Continued)
CAUTION: Ensure that the connecting rod bolts DO
NOT scratch the crankshaft journals or cylinder
walls. Short pieces of rubber hose, slipped over the
rod bolts will provide protection during removal.
(12) Have an assi stant push the pi ston and con-
necti ng rod assembl i es up and through the top of the
cyl i nder bores (Fi g. 61).
INSTALLATION
(1) Cl ean the cyl i nder bores thoroughl y. Appl y a
l i ght fi l m of cl ean engi ne oi l to the bores wi th a cl ean
l i nt-free cl oth.
(2) I nstal l the pi ston ri ngs on the pi stons i f
removed (Refer to 9 - ENGI NE/ENGI NE BLOCK/
PI STON RI NGS - STANDARD PROCEDURE).
(3) Lubri cate the pi ston and ri ngs wi th cl ean
engi ne oi l .
CAUTION: Ensure that connecting rod bolts DO
NOT scratch the crankshaft journals or cylinder
walls. Short pieces of rubber hose slipped over the
connecting rod bolts will provide protection during
installation.
(4) Use a pi ston ri ng compressor to i nstal l the con-
necti ng rod and pi ston assembl i es through the top of
the cyl i nder bores (Fi g. 62).
(5) Ensure the arrow on the pi ston top poi nts to
the front of the engi ne (Fi g. 62).
(6) Rai se the vehi cl e.
(7) Each beari ng i nsert i s fi tted to i ts respecti ve
journal to obtai n the speci fi ed cl earance between the
beari ng and the journal . I n producti on, the sel ect fi t
i s obtai ned by usi ng vari ous-si zed, col or-coded bear-
i ng i nserts as l i sted i n the Connecti ng Rod Beari ng
Fi tti ng Chart. The col or code appears on the edge of
the beari ng i nsert. The si ze i s not stamped on i nserts
used for producti on of engi nes.
(8) The rod journal i s i denti fi ed duri ng the engi ne
producti on by a col or-coded pai nt mark on the adja-
cent cheek or counterwei ght toward the fl ange (rear)
end of the crankshaft. The col or codes used to i ndi -
cate journal si zes are l i sted i n the Connecti ng Rod
Beari ng Fi tti ng Chart.
(9) When requi red, upper and l ower beari ng
i nserts of di fferent si zes may be used as a pai r (refer
to Connecti ng Rod Beari ng Fi tti ng Chart). A stan-
dard si ze i nsert i s someti mes used i n combi nati on
wi th a 0.025 mm (0.001 i nch) undersi ze i nsert to
reduce cl earance 0.013 mm (0.0005 i nch).
CAUTION: DO NOT intermix bearing caps. Each
connecting rod and bearing cap are stamped with
the cylinder number. The stamp is located on a
machined surface adjacent to the oil squirt hole
that faces the camshaft side of the cylinder block.
(10) I nstal l the connecti ng rod beari ng caps and
i nserts i n the same posi ti ons as removed.
CAUTION: Verify that the oil squirt holes in the rods
face the camshaft and that the arrows on the pis-
tons face the front of the engine.
(11) I nstal l mai n beari ng cap brace (Fi g. 59).
Ti ghten nuts to 47 N·m (35 ft. l bs.).
(12) I nstal l the oi l pan and gasket (Refer to 9 -
ENGI NE/LUBRI CATI ON/OI L PAN - I NSTALLA-
TI ON).
(13) Lower the vehi cl e.
Fig. 61 Removal of Connecting Rod and Piston
Assembly
1 - PISTON
2 - CONNECTING ROD
3 - BLOCK
Fig. 62 Rod and Piston Assembly Installation
TJ ENGINE 4. 0L 9 - 111
PISTON & CONNECTING ROD (Continued)
(14) I nstal l the engi ne cyl i nder head (Refer to 9 -
ENGI NE/CYLI NDER HEAD - I NSTALLATI ON),
push rods, rocker arms, bri dges, pi vots and engi ne
cyl i nder head cover(Refer to 9 - ENGI NE/CYLI NDER
HEAD/CYLI NDER HEAD COVER(S) - I NSTALLA-
TI ON).
(15) Fi l l the crankcase wi th engi ne oi l .
PISTON RINGS
STANDARD PROCEDURE - PISTON RING
FITTING
(1) Careful l y cl ean the carbon from al l ri ng
grooves. Oi l drai n openi ngs i n the oi l ri ng groove and
pi n boss must be cl ear. DO NOT remove metal from
the grooves or l ands. Thi s wi l l change ri ng-to-groove
cl earances and wi l l damage the ri ng-to-l and seati ng.
(2) Be sure the pi ston ri ng grooves are free of
ni cks and burrs.
(3) Measure the ri ng si de cl earance wi th a feel er
gauge fi tted snugl y between the ri ng l and and ri ng
(Fi g. 63) (Fi g. 64). Rotate the ri ng i n the groove. I t
must move freel y around ci rcumference of the groove.
RING SIDE CLEARANCE CHART
ITEM SPECIFICATION
Top Compression Ring 0.042 - 0.084 mm
(0.0017 - 0.0033 in.)
Second Compression
Ring
0.042 - 0.084 mm
(0.0017 - 0.0033 in.)
Oil Control Ring 0.06 - 0.21 mm
(0.0024 - 0.0083 in.)
(4) Pl ace ri ng i n the cyl i nder bore and push down
wi th i nverted pi ston to posi ti on near l ower end of the
ri ng travel . Measure ri ng gap wi th a feel er gauge fi t-
ti ng snugl y between ri ng ends (Fi g. 65).
RING GAP MEASUREMENT CHART
ITEM SPECIFICATION
Top Compression Ring 0.229 - 0.610 mm
(0.0090 - 0.0240 in.)
Second Compression
Ring
0.483 - 0.965 mm
(0.0190 - 0.080 in.)
Oil Control Ring 0.254 - 1.500 mm
(0.010 - 0.060 in.)
Fig. 63 Piston Dimensions
Fig. 64 Ring Side Clearance Measurement
1 - FEELER GAUGE
9 - 112 ENGINE 4. 0L TJ
PISTON & CONNECTING ROD (Continued)
(5) The oi l control ri ngs are symmetri cal , and can
be i nstal l ed wi th ei ther si de up. I t i s not necessary to
use a tool to i nstal l the upper and l ower rai l s. I nsert
oi l rai l spacer fi rst, then si de rai l s.
(6) The two compressi on ri ngs are di fferent and
cannot be i nterchanged. The top compressi on ri ng
can be i denti fi ed by the shi ny coati ng on the outer
seal i ng surface and can be i nstal l ed wi th ei ther si de
up. (Fi g. 66).
(7) The second compressi on ri ng has a sl i ght
chamfer on the bottom of the i nsi de edge and a dot
on the top for correct i nstal l ati on (Fi g. 67) and (Fi g.
68).
(8) Usi ng a ri ng i nstal l er, i nstal l the second com-
pressi on ri ng wi th the dot faci ng up (Fi g. 67) (Fi g.
69).
(9) Usi ng a ri ng i nstal l er, i nstal l the top compres-
si on ri ng (ei ther si de up).
Fig. 65 Gap Measurement
1 - FEELER GAUGE
Fig. 66 Top Compression ring identification
1 - TOP COMPRESSION RING
Fig. 67 Second Compression Ring Identification
1 - SECOND COMPRESSION RING
2 - CHAMFER
3 - ONE DOT
Fig. 68 Compression Ring Chamfer Location
1 - TOP COMPRESSION RING
2 - SECOND COMPRESSION RING
3 - PISTON
4 - CHAMFER
Fig. 69 Compression Ring Installation
1 - COMPRESSION RING
2 - RING EXPANDER RECOMMENDED
TJ ENGINE 4. 0L 9 - 113
PISTON RINGS (Continued)
Ring Gap Orientation
• Posi ti on the gaps on the pi ston as shown (Fi g.
70).
• Oi l spacer - Gap on center l i ne of pi ston ski rt.
• Oi l rai l s - gap 180° apart on centerl i ne of pi ston
pi n bore.
• No. 2 Compressi on ri ng - Gap 180° from top oi l
rai l gap.
• No. 1 Compressi on ri ng - Gap 180° from No. 2
compressi on ri ng gap.
VIBRATION DAMPER
REMOVAL
(1) Di sconnect negati ve cabl e from battery.
(2) Remove the serpenti ne dri ve bel t (Refer to 7 -
COOLI NG/ACCESSORY DRI VE/DRI VE BELTS -
REMOVAL) and fan shroud.
(3) Remove the vi brati on damper retai ni ng bol t
and washer.
(4) Use Vi brati on Damper Removal Tool 7697 to
remove the damper from the crankshaft (Fi g. 71).
INSTALLATION
(1) Appl y Mopar௡ Si l i cone Rubber Adhesi ve Seal -
ant to the keyway i n the crankshaft and i nsert the
key. Wi th the key i n posi ti on, al i gn the keyway on
the vi brati on damper hub wi th the crankshaft key
and tap the damper onto the crankshaft.
(2) I nstal l the vi brati on damper retai ni ng bol t and
washer.
(3) Ti ghten the damper retai ni ng bol t to 108 N·m
(80 ft. l bs.) torque.
(4) I nstal l the serpenti ne dri ve bel t (Refer to 7 -
COOLI NG/ACCESSORY DRI VE/DRI VE BELTS -
I NSTALLATI ON) and fan shroud.
(5) Connect negati ve cabl e to battery.
STRUCTURAL SUPPORT
REMOVAL
The engi ne bendi ng braces are used to add
strength to the powertrai n and to address some
mi nor NVH concerns.
NOTE: Before the engine or the transmission can
be removed the engine bending braces must be
removed.
(1) Rai se and support vehi cl e.
NOTE: Both left and right side bending braces are
removed the sameway. Only the right side is
shown.
NOTE: The exhaust does not require removal to
preform this procedure.
Fig. 70 Ring Gap Orientation
1 - TOP COMPRESSION RING
2 - BOTTOM COMPRESSION RING
3 - TOP OIL CONTROL RAIL
4 - OIL RAIL SPACER
5 - BOTTOM OIL CONTROL RAIL
6 - IMAGINARY LINE PARALLEL TO PISTON PIN
7 - IMAGINARY LINE THROUGH CENTER OF PISTON SKIRT
Fig. 71 Vibration Damper Removal Tool 7697
1 - VIBRATION DAMPER REMOVAL TOOL
2 - WRENCH
9 - 114 ENGINE 4. 0L TJ
PISTON RINGS (Continued)
(2) Remove the exhaust hanger bracket retai ni ng
bol t.
(3) Remove l ocknut and transmi ssi on bendi ng
brace bar.
(4) Remove engi ne-to-bendi ng brace retai ni ng bol t,
bendi ng brace bar and cross bar.
INSTALLATION
NOTE: DO NOT tighten the retaining hardware until
all bending braces are in place.
(1) Posi ti on the cross brace i nto the engi ne-to-
transmi ssi on brace, then posi ti on the engi ne-to-trans-
mi ssi on brace and i nstal l retai ni ng bol t.
(2) Posi ti on the transmi ssi on bendi ng brace onto
through brace and i nstal l new l ocknut.
(3) Posi ti on exhaust hanger and transmi ssi on
brace, i nstal l retai ni ng bol t (Fi g. 73).
(4) Ti ghten engi ne-to-transmi ssi on brace retai ni ng
bol t (Fi g. 72)to 40 N·m (30 ft. l bs.).
(5) Ti ghten transmi ssi on brace retai ni ng bol ts (Fi g.
73)to 40 N·m (30 ft. l bs.), then ti ghten transmi ssi on
brace retai ni ng l ock nuts (Fi g. 73) to 108 N·m (80 ft.
l bs.).
FRONT MOUNT
REMOVAL
The front mounts support the engi ne at each si de.
These supports are made of resi l i ent rubber.
(1) Di sconnect negati ve cabl e from battery.
(2) Rai se the vehi cl e.
(3) Support the engi ne.
(4) Remove the nut from the through bol t (Fi g. 74)
(Fi g. 75). DO NOT remove the through bol t.
(5) Remove the retai ni ng bol ts and nuts from the
i nsul ator.
(6) Remove the through bol t.
(7) Remove the i nsul ator.
INSTALLATION
The front mounts support the engi ne at each si de.
These supports are made of resi l i ent rubber.
(1) I f the engi ne support bracket was removed,
posi ti on the bracket onto the bl ock and i nstal l the
attachi ng bol ts (Fi g. 74) (Fi g. 75). Ti ghten the bol ts
to 50 N·m (37 ft. l bs.) torque.
(2) Pl ace the i nsul ator on the support bracket.
I nstal l the i nsul ator retai ni ng bol ts and nuts.
Ti ghten the bol ts and nuts to 40 N·m (30 ft. l bs)
torque.
(3) I nstal l the through bol t and the retai ni ng nut.
Ti ghten the through bol t nut to 48 N·m (35 ft. l bs.)
torque.
(4) Remove the engi ne support.
(5) Lower the vehi cl e.
(6) Connect negati ve cabl e to battery.
Fig. 72 Engine-to-Transmission Bending Braces
1 - ENGINE-TO-TRANSMISSION BENDING BRACE
2 - CROSS BRACE
3 - ENGINE-TO-TRANSMISSION BENDING BRACE RETAINING
BOLT
Fig. 73 Transmission Bending Braces and Exhaust
Hanger
1 - TRANSMISSION BENDING BRACE RETAINING BOLT
2 - ENGINE-TO-TRANSMISSION BENDING BRACE
3 - LOCKNUT
4 - TRANSMISSION BRACE
5 - EXHAUST HANGER
TJ ENGINE 4. 0L 9 - 115
STRUCTURAL SUPPORT (Continued)
REAR MOUNT
REMOVAL
A resi l i ent rubber cushi on supports the transmi s-
si on at the rear between the transmi ssi on extensi on
housi ng and the rear support crossmember or ski d
pl ate.
ALL TRANSMISSIONS
(1) Di sconnect negati ve cabl e from battery.
(2) Rai se the vehi cl e and support the transmi ssi on.
(3) Remove the nuts hol di ng the support cushi on
to the ski d pl ate (Fi g. 76) (Fi g. 77).
MANUAL TRANSMISSIONS
(1) Remove nuts hol di ng support cushi on to trans-
mi ssi on support bracket.
(2) Remove the support cushi on.
(3) Remove bol ts hol di ng transmi ssi on support
bracket to transmi ssi on.
(4) Remove the transmi ssi on support bracket.
AUTOMATIC TRANSMISSIONS
(1) Remove nuts hol di ng support cushi on to trans-
mi ssi on support bracket (Fi g. 77). Remove the sup-
port cushi on.
(2) Remove the bol ts hol di ng the transmi ssi on sup-
port bracket to transmi ssi on.
Fig. 74 Left Front Engine Mount
1 - BOLT (2)
2 - THROUGH BOLT
3 - NUT (2)
4 - BOLT (3)
5 - LEFT HAND ENGINE MOUNT ASSEMBLY
Fig. 75 Right Front Engine Mount
1 - RIGHT HAND ENGINE MOUNT ASSEMBLY
2 - THROUGH BOLT
3 - BOLT (3)
Fig. 76 Rear Mount (Manual Transmission)
1 - CUSHION
2 - BRACKET
3 - SKID PLATE
9 - 116 ENGINE 4. 0L TJ
FRONT MOUNT (Continued)
(3) Remove the transmi ssi on support bracket.
INSTALLATION
MANUAL TRANSMISSION
(1) Posi ti on the transmi ssi on mount bracket to the
transmi ssi on and i nstal l the bol ts (Fi g. 76).
(2) Ti ghten the bol ts to 54 N·m (40 ft. l bs.) torque.
(3) Posi ti on the support cushi on to the transmi s-
si on mount bracket and i nstal l nuts (Fi g. 76).
AUTOMATIC TRANSMISSION
(1) Posi ti on the transmi ssi on mount bracket to the
transmi ssi on and i nstal l the bol ts. Ti ghten the bol ts
to 54 N·m (40 ft. l bs.) torque.
(2) Posi ti on the support cushi on to the transmi s-
si on mount bracket and i nstal l nuts. Ti ghten the
nuts to 41 N·m (30 ft. l bs.) torque (Fi g. 77).
(3) I f the support cushi on bracket was removed
from the ski d pl ate, posi ti on the bracket on the ski d
pl ate and i nstal l the nuts and bol ts. Ti ghten the nuts
to 28 N·m (21 ft. l bs.) torque.
ALL TRANSMISSIONS
(1) Posi ti on the ski d pl ate to the studs of the sup-
port cushi on and i nstal l the nuts (Fi g. 76) (Fi g. 77).
Ti ghten the nuts to 28 N·m (21 ft. l bs.) torque.
(2) I nstal l the ski d pl ate bol ts to the si l l and
ti ghten to 75 N·m (55 ft. l bs.) torque.
(3) Remove the transmi ssi on support.
(4) Lower the vehi cl e.
(5) Connect negati ve cabl e to battery.
LUBRICATION
DESCRIPTION
A gear—type posi ti ve di spl acement pump i s
mounted at the undersi de of the bl ock opposi te the
No. 4 mai n beari ng.
OPERATION
The pump draws oi l through the screen and i nl et
tube from the sump at the rear of the oi l pan. The oi l
i s dri ven between the dri ve and i dl er gears and
pump body, then forced through the outl et to the
bl ock. An oi l gal l ery i n the bl ock channel s the oi l to
the i nl et si de of the ful l fl ow oi l fi l ter. After passi ng
through the fi l ter el ement, the oi l passes from the
center outl et of the fi l ter through an oi l gal l ery that
channel s the oi l up to the mai n gal l ery whi ch
extends the enti re l ength of the bl ock.
Gal l eri es extend downward from the mai n oi l gal -
l ery to the upper shel l of each mai n beari ng. The
crankshaft i s dri l l ed i nternal l y to pass oi l from the
mai n beari ng journal s (except number 4 mai n bear-
i ng journal ) to the connecti ng rod journal s. Each con-
necti ng rod beari ng cap has a smal l squi rt hol e, oi l
passes through the squi rt hol e and i s thrown off as
the rod rotates. Thi s oi l throwoff l ubri cates the cam-
shaft l obes, di stri butor dri ve gear, cyl i nder wal l s, and
pi ston pi ns.
The hydraul i c val ve tappets recei ve oi l di rectl y
from the mai n oi l gal l ery. Oi l i s provi ded to the cam-
shaft beari ng through gal l eri es. The front camshaft
beari ng journal passes oi l through the camshaft
sprocket to the ti mi ng chai n. Oi l drai ns back to the
oi l pan under the number one mai n beari ng cap.
The oi l suppl y for the rocker arms and bri dged
pi vot assembl i es i s provi ded by the hydraul i c val ve
tappets whi ch pass oi l through hol l ow push rods to a
hol e i n the correspondi ng rocker arm. Oi l from the
rocker arm l ubri cates the val ve trai n components,
then passes down through the push rod gui de hol es
i n the cyl i nder head past the val ve tappet area, and
returns to the oi l pan (Fi g. 78).
Fig. 77 Rear Mount (AutomaticTransmission)
1 - BRACKET
2 - CUSHION
3 - BRACKET
TJ ENGINE 4. 0L 9 - 117
REAR MOUNT (Continued)
Fig. 78 Oil Lubrication System—4.0L Engine
1 - CAM/CRANK MAIN GALLERY (7)
2 - TAPPET GALLERY
3 - TAPPET GALLERY
4 - CAMSHAFT BEARING
5 - NUMBER 1 CAMSHFT BEARING JOURNAL
6 - CAMSHAFT SPROCKET
7 - TAPPET GALLERY
9 - 118 ENGINE 4. 0L TJ
LUBRICATION (Continued)
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ENGINE OIL
PRESSURE
(1) Di sconnect connector and remove oi l pressure
sendi ng uni t.
(2) I nstal l Oi l Pressure Li ne and Gauge Tool
C-3292 or equi val ent. Start engi ne and record pres-
sure. (Refer to 9 - ENGI NE - SPECI FI CATI ONS) for
the correct pressures.
DIAGNOSIS AND TESTING - ENGINE OIL LEAK
Begi n wi th a thorough vi sual i nspecti on of the
engi ne, parti cul arl y at the area of the suspected l eak.
I f an oi l l eak source i s not readi l y i denti fi abl e, the
fol l owi ng steps shoul d be fol l owed:
(1) Do not cl ean or degrease the engi ne at thi s
ti me because some sol vents may cause rubber to
swel l , temporari l y stoppi ng the l eak.
(2) Add an oi l sol ubl e dye (use as recommended by
manufacturer). Start the engi ne and l et i dl e for
approxi matel y 15 mi nutes. Check the oi l di psti ck to
make sure the dye i s thoroughl y mi xed as i ndi cated
wi th a bri ght yel l ow col or under a bl ack l i ght.
(3) Usi ng a bl ack l i ght, i nspect the enti re engi ne
for fl uorescent dye, parti cul arl y at the suspected area
of oi l l eak. I f the oi l l eak i s found and i denti fi ed,
repai r per servi ce manual i nstructi ons.
(4) I f dye i s not observed, dri ve the vehi cl e at var-
i ous speeds for approxi matel y 24km (15 mi l es), and
repeat i nspecti on.If the oil leak source is not pos-
itively identified at this time, proceed wi th the ai r
l eak detecti on test method.
Air Leak Detection Test Method
(1) Di sconnect the breather cap to ai r cl eaner hose
at the breather cap end. Cap or pl ug breather cap
ni ppl e.
(2) Remove the CCV val ve from the cyl i nder head
cover. Cap or pl ug the CCV val ve grommet.
(3) Attach an ai r hose wi th pressure gauge and
regul ator to the di psti ck tube.
CAUTION: Do not subject the engine assembly to
more than 20.6 kpa (3 PSI) of test pressure.
(4) Gradual l y appl y ai r pressure from 1 psi to 2.5
psi maxi mum whi l e appl yi ng soapy water at the sus-
pected source. Adjust the regul ator to the sui tabl e
test pressure that provi de the best bubbl es whi ch
wi l l pi npoi nt the l eak source. I f the oi l l eak i s
detected and i denti fi ed, repai r per servi ce i nforma-
ti on procedures.
(5) I f the l eakage occurs at the rear oi l seal area,
I NSPECTI ON FOR REAR SEAL AREA LEAKS.
(6) I f no l eaks are detected, turn off the ai r suppl y
and remove the ai r hose and al l pl ugs and caps.
I nstal l the CCV val ve and breather cap hose.
(7) Cl ean the oi l off the suspect oi l l eak area usi ng
a sui tabl e sol vent. Dri ve the vehi cl e at vari ous
speeds approxi matel y 24 km (15 mi l es). I nspect the
engi ne for si gns of an oi l l eak by usi ng a bl ack l i ght.
INSPECTION FOR REAR SEAL AREA LEAKS
Si nce i t i s someti mes di ffi cul t to determi ne the
source of an oi l l eak i n the rear seal area of the
engi ne, a more i nvol ved i nspecti on i s necessary. The
fol l owi ng steps shoul d be fol l owed to hel p pi npoi nt
the source of the l eak.
I f the l eakage occurs at the crankshaft rear oi l seal
area:
(1) Di sconnect the battery.
(2) Rai se the vehi cl e.
(3) Remove torque converter or cl utch housi ng
cover and i nspect rear of bl ock for evi dence of oi l .
Use a bl ack l i ght to check for the oi l l eak:
(a) Ci rcul ar spray pattern general l y i ndi cates
seal l eakage or crankshaft damage.
(b) Where l eakage tends to run strai ght down,
possi bl e causes are a porous bl ock, di stri butor seal ,
camshaft bore cup pl ugs oi l gal l ey pi pe pl ugs, oi l
fi l ter runoff, and mai n beari ng cap to cyl i nder
bl ock mati ng surfaces.
(4) I f no l eaks are detected, pressuri ze the crank-
case as outl i ned i n the, I nspecti on (Engi ne oi l Leaks
i n general )
CAUTION: Do not exceed 20.6 kPa (3 psi).
(5) I f the l eak i s not detected, very sl owl y turn the
crankshaft and watch for l eakage. I f a l eak i s
detected between the crankshaft and seal whi l e
sl owl y turni ng the crankshaft, i t i s possi bl e the
crankshaft seal surface i s damaged. The seal area on
the crankshaft coul d have mi nor ni cks or scratches
that can be pol i shed out wi th emery cl oth.
CAUTION: Use extreme caution when crankshaft
polishing is necessary to remove minor nicks and
scratches. The crankshaft seal flange is especially
machined to complement the function of the rear oil
seal.
(6) For bubbl es that remai n steady wi th shaft
rotati on, no further i nspecti on can be done unti l di s-
assembl ed.
TJ ENGINE 4. 0L 9 - 119
LUBRICATION (Continued)
OIL
STANDARD PROCEDURE - ENGINE OIL
SERVICE
ENGINE OIL CHANGE
WARNING: NEW OR USED ENGINE OIL CAN BE
IRRITATING TO THE SKIN. AVOID PROLONGED OR
REPEATED SKIN CONTACT WITH ENGINE OIL.
CONTAMINANTS IN USED ENGINE OIL, CAUSED BY
INTERNAL COMBUSTION, CAN BE HAZARDOUS TO
YOUR HEALTH. THOROUGHLY WASH EXPOSED
SKIN WITH SOAP AND WATER. DO NOT WASH
SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR
SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO
NOT POLLUTE, DISPOSE OF USED ENGINE OIL
PROPERLY. CONTACT YOUR DEALER OR GOVERN-
MENT AGENCY FOR LOCATION OF COLLECTION
CENTER IN YOUR AREA.
CAUTION: Do not use oil filter with metric threads.
The proper oil filter has SAE type 3/4 X 16 threads.
An oil filter with metric threads can result in oil
leaks and engine failure.
Al l Jeep engi nes are equi pped wi th a hi gh qual i ty
ful l -fl ow, throw-away type oi l fi l ter. Dai ml erChrysl er
Corporati on recommends a Mopar௡ or equi val ent oi l
fi l ter be used.
Change engi ne oi l at mi l eage and ti me i nterval s
descri bed i n Mai ntenance Schedul es.
Run engi ne unti l achi evi ng normal operati ng tem-
perature.
(1) Posi ti on the vehi cl e on a l evel surface and turn
engi ne off.
(2) Hoi st and support vehi cl e on safety stands.
(3) Remove oi l fi l l cap.
(4) Pl ace a sui tabl e drai n pan under crankcase
drai n.
(5) Remove drai n pl ug from crankcase and al l ow
oi l to drai n i nto pan. I nspect drai n pl ug threads for
stretchi ng or other damage. Repl ace drai n pl ug i f
damaged.
(6) I nstal l drai n pl ug i n crankcase.
(7) Posi ti on a drai n pan under the oi l fi l ter.
(8) Usi ng a sui tabl e oi l fi l ter wrench l oosen fi l ter.
(9) Rotate the oi l fi l ter countercl ockwi se to remove
i t from the cyl i nder bl ock oi l fi l ter boss or fi l ter
adapter housi ng.
(10) When fi l ter separates from adapter ni ppl e, ti p
gasket end upward to mi ni mi ze oi l spi l l . Remove fi l -
ter from vehi cl e.
(11) Make sure ol d gasket comes off wi th oi l fi l ter.
Wi th a wi pi ng cl oth, cl ean the gasket seal i ng surface
(Fi g. 79) of oi l and gri me.
(12) Li ghtl y l ubri cate oi l fi l ter gasket wi th engi ne
oi l or chassi s grease.
(13) Thread fi l ter onto adapter ni ppl e. When gas-
ket makes contact wi th seal i ng surface, (Fi g. 79)hand
ti ghten fi l ter one ful l turn, do not over ti ghten.
(14) Lower vehi cl e and fi l l crankcase wi th speci fi ed
type and amount of engi ne oi l descri bed i n thi s sec-
ti on.
(15) I nstal l oi l fi l l cap.
(16) Start engi ne and i nspect for l eaks.
(17) Stop engi ne and i nspect oi l l evel .
CRANKCASE OIL LEVEL INSPECTION
CAUTION: Do not overfill crankcase with engine oil,
oil foaming and oil pressure loss can result.
The engi ne oi l l evel i ndi cator (Di psti ck) i s l ocated
at the ri ght rear of the 4.0L engi ne. I nspect engi ne
oi l l evel approxi matel y every 800 ki l ometers (500
mi l es). Unl ess the engi ne has exhi bi ted l oss of oi l
pressure, run the engi ne for about fi ve mi nutes
before checki ng oi l l evel . Checki ng engi ne oi l l evel on
a col d engi ne i s not accurate.
To ensure proper l ubri cati on of an engi ne, the
engi ne oi l must be mai ntai ned at an acceptabl e l evel .
The acceptabl e l evel s are i ndi cated between the ADD
and SAFE marks on the engi ne oi l di psti ck.
(1) Posi ti on vehi cl e on l evel surface.
(2) Wi th engi ne OFF, al l ow approxi matel y ten mi n-
utes for oi l to settl e to bottom of crankcase, remove
engi ne oi l di psti ck.
(3) Wi pe di psti ck cl ean.
(4) I nstal l di psti ck and veri fy i t i s seated i n the
tube.
Fig. 79 Oil Filter Sealing Surface—Typical
1 - SEALING SURFACE
2 - RUBBER GASKET
3 - OIL FILTER
9 - 120 ENGINE 4. 0L TJ
(5) Remove di psti ck, wi th handl e hel d above the
ti p, take oi l l evel readi ng.
(6) Add oi l onl y i f l evel i s bel ow the ADD mark on
di psti ck.
USED ENGINE OIL DISPOSAL
Care shoul d be exerci sed when di sposi ng used
engi ne oi l after i t has been drai ned from a vehi cl e
engi ne. Refer to the WARNI NG at begi nni ng of thi s
procedure.
OIL FILTER
REMOVAL
CAUTION: Do not use oil filter with metric threads.
The proper oil filter has SAE type 3/4 X 16 threads.
An oil filter with metric threads can result in oil
leaks and engine failure.
Al l Jeep engi nes are equi pped wi th a hi gh qual i ty
ful l -fl ow, throw-away type oi l fi l ter. Dai ml erChrysl er
Corporati on recommends a Mopar௡ or equi val ent oi l
fi l ter be used.
(1) Posi ti on a drai n pan under the oi l fi l ter.
(2) Usi ng a sui tabl e oi l fi l ter wrench l oosen fi l ter.
(3) Rotate the oi l fi l ter countercl ockwi se to remove
i t from the cyl i nder bl ock oi l fi l ter boss or fi l ter
adapter housi ng.
(4) When fi l ter separates from adapter ni ppl e, ti p
gasket end upward to mi ni mi ze oi l spi l l . Remove fi l -
ter from vehi cl e.
(5) Make sure ol d gasket comes off wi th oi l fi l ter.
Wi th a wi pi ng cl oth, cl ean the gasket seal i ng surface
of oi l and gri me.
INSTALLATION
(1) Li ghtl y l ubri cate oi l fi l ter gasket wi th engi ne
oi l or chassi s grease.
(2) Thread fi l ter onto adapter ni ppl e. When gasket
makes contact wi th seal i ng surface, (Fi g. 80) hand
ti ghten fi l ter one ful l turn, do not over ti ghten.
(3) Add oi l , veri fy crankcase oi l l evel and start
engi ne. I nspect for oi l l eaks.
OIL PAN
DESCRIPTION
The oi l pan i s made of stamped steel . The oi l pan
gasket i s a one pi ece steel backbone si l i cone coated
gasket (Fi g. 81).
REMOVAL
(1) Di sconnect negati ve cabl e from battery.
(2) Rai se the vehi cl e.
(3) Remove the oi l pan drai n pl ug and drai n the
engi ne oi l .
(4) Di sconnect the exhaust pi pe at the exhaust
mani fol d.
(5) Di sconnect the exhaust hanger at the catal yti c
converter and l ower the pi pe.
(6) Remove the starter motor. (Refer to 8 - ELEC-
TRI CAL/STARTI NG/STARTER MOTOR -
REMOVAL).
(7) Remove the engi ne fl ywheel and transmi ssi on
torque converter housi ng access cover.
(8) I f equi pped wi th an oi l l evel sensor, di sconnect
the sensor.
(9) Posi ti on a jack stand di rectl y under the engi ne
vi brati on damper.
(10) Pl ace a pi ece of wood (2 x 2) between the jack
stand and the engi ne vi brati on damper.
(11) Remove the engi ne mount through bol ts.
(12) Usi ng the jack stand, rai se the engi ne unti l
adequate cl earance i s obtai ned to remove the oi l pan.
Fig. 80 Oil Filter Sealing Surface—Typical
1 - SEALING SURFACE
2 - RUBBER GASKET
3 - OIL FILTER
Fig. 81 Oil Pan
1 - OIL PAN
2 - OIL PAN DRAIN PLUG
TJ ENGINE 4. 0L 9 - 121
OIL (Continued)
(13) Remove transmi ssi on oi l cool i ng l i nes (i f
equi pped) and oxygen sensor wi ri ng supports that
are attached to the oi l pan studs.
(14) Remove the oi l pan bol ts and studs. Careful l y
sl i de the oi l pan and gasket to the rear. I f equi pped
wi th an oi l l evel sensor, take care not to damage the
sensor.
INSTALLATION
(1) Cl ean the bl ock and pan gasket surfaces.
(2) Fabri cate 4 al i gnment dowel s from 1 1/2 x 1/4
i nch bol ts. Cut the head off the bol ts and cut a sl ot
i nto the top of the dowel . Thi s wi l l al l ow easi er
i nstal l ati on and removal wi th a screwdri ver (Fi g. 82).
(3) I nstal l two dowel s i n the ti mi ng case cover.
I nstal l the other two dowel s i n the cyl i nder bl ock
(Fi g. 83).
(4) Appl y Mopar௡ Si l i cone Rubber Adhesi ve Seal -
ant on cyl i nder bl ock to rear mai n beari ng cap cor-
ners and cyl i nder bl ock to front cover joi nts (four
pl aces) (Fi g. 84).
(5) Sl i de the one-pi ece gasket over the dowel s and
onto the bl ock and ti mi ng case cover.
(6) Posi ti on the oi l pan over the dowel s and onto
the gasket. I f equi pped wi th an oi l l evel sensor, take
care not to damage the sensor.
(7) I nstal l the 1/4 i nch oi l pan bol ts. Ti ghten these
bol ts to 9.5 N·m (84 i n. l bs.) torque. I nstal l the 5/16
i nch oi l pan bol ts (Fi g. 85). Ti ghten these bol ts to 15
N·m (132 i n. l bs.) torque.
(8) Remove the dowel s. I nstal l the remai ni ng 1/4
i nch oi l pan bol ts. Ti ghten these bol ts to 9.5 N·m (84
i n. l bs.) torque.
(9) Lower the engi ne unti l i t i s properl y l ocated on
the engi ne mounts.
(10) I nstal l the through bol ts and ti ghten the nuts.
(11) Lower the jack stand and remove the pi ece of
wood.
(12) I nstal l the engi ne fl ywheel and transmi ssi on
torque converter housi ng access cover.
Fig. 82 Fabrication of Alignment Dowels
1 - 1/4ЈЈ × 1 1/2ЈЈ BOLT
2 - DOWEL
3 - SLOT
Fig. 83 Position of Dowels in Cylinder Block
1 - DOWEL HOLES
2 - CYLINDER BLOCK
3 - 5/16ЈЈ HOLES
4 - 5/16ЈЈ HOLES
Fig. 84 Oil Pan Sealer Location
1 - SEALER LOCATIONS
Fig. 85 Position of 5/16 inch Oil Pan Bolts
1 - OIL PAN
2 - OIL PAN DRAIN PLUG
9 - 122 ENGINE 4. 0L TJ
OIL PAN (Continued)
(13) I nstal l the engi ne starter motor. (Refer to 8 -
ELECTRI CAL/STARTI NG/STARTER MOTOR -
I NSTALLATI ON).
(14) Connect the exhaust pi pe to the hanger and to
the engi ne exhaust mani fol d.
(15) I nstal l transmi ssi on oi l cool i ng l i nes (i f
equi pped) and oxygen sensor wi ri ng supports that
attach to the oi l pan studs.
(16) I nstal l the oi l pan drai n pl ug (Fi g. 85).
Ti ghten the pl ug to 34 N·m (25 ft. l bs.) torque.
(17) Lower the vehi cl e.
(18) Connect negati ve cabl e to battery.
(19) Fi l l the oi l pan wi th engi ne oi l to the speci fi ed
l evel .
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHING.
(20) Start the engi ne and i nspect for l eaks.
ENGINE OIL PRESSURE
SENSOR
DESCRIPTION
The 3 wi re, sol i d-state engi ne oi l pressure sensor
(sendi ng uni t) i s l ocated i n an engi ne oi l pressure
gal l ery.
OPERATION
The oi l pressure sensor uses three ci rcui ts. They
are:
• A 5 vol t power suppl y from the Powertrai n Con-
trol Modul e (PCM)
• A sensor ground through the PCM’s sensor
return
• A si gnal to the PCM rel ati ng to engi ne oi l pres-
sure
The oi l pressure sensor has a 3 wi re el ectri cal
functi on very much l i ke the Mani fol d Absol ute Pres-
sure (MAP) sensor. Meani ng di fferent pressures
rel ate to di fferent output vol tages.
A 5 vol t suppl y i s sent to the sensor from the PCM
to power up the sensor. The sensor returns a vol tage
si gnal back to the PCM rel ati ng to engi ne oi l pres-
sure. Thi s si gnal i s then transferred (bussed) to the
i nstrument panel on ei ther a CCD or PCI bus ci rcui t
(dependi ng on vehi cl e l i ne) to operate the oi l pressure
gauge and the check gauges l amp. Ground for the
sensor i s provi ded by the PCM through a l ow-noi se
sensor return.
OIL PUMP
REMOVAL
A gear-type oi l pump i s mounted at the undersi de
of the cyl i nder bl ock opposi te the No.4 mai n beari ng.
(1) Drai n the engi ne oi l .
(2) Remove the oi l pan (Refer to 9 - ENGI NE/LU-
BRI CATI ON/OI L PAN - REMOVAL).
(3) Remove the pump-to-cyl i nder bl ock attachi ng
bol ts. Remove the pump assembl y wi th gasket (Fi g.
86).
CAUTION: If the oil pump is not to be serviced, DO
NOT disturb position of oil inlet tube and strainer
assembly in pump body. If the tube is moved within
the pump body, a replacement tube and strainer
assembly must be installed to assure an airtight
seal.
INSTALLATION
A gear-type oi l pump i s mounted at the undersi de
of the cyl i nder bl ock opposi te the No.4 mai n beari ng.
(1) I nstal l the oi l pump on the cyl i nder bl ock usi ng
a repl acement gasket. Ti ghten the bol ts to 23 N·m
(17 ft. l bs.) torque.
(2) I nstal l the oi l pan (Refer to 9 - ENGI NE/LU-
BRI CATI ON/OI L PAN - I NSTALLATI ON).
Fig. 86 Oil Pump Assembly
1 - OIL FILTER ADAPTOR
2 - BLOCK
3 - GASKET
4 - OIL INLET TUBE
5 - OIL PUMP
6 - STRAINER ASSEMBLY
7 - ATTACHING BOLTS
TJ ENGINE 4. 0L 9 - 123
OIL PAN (Continued)
(3) Fi l l the oi l pan wi th oi l to the speci fi ed l evel .
VALVE TIMING
STANDARD PROCEDURE - VALVE TIMING
(1) Di sconnect the spark pl ug wi res and remove
the spark pl ugs.
(2) Remove the engi ne cyl i nder head cover .
(3) Remove the capscrews, bri dge and pi vot assem-
bl y, and rocker arms from above the No.1 cyl i nder.
(4) Al ternatel y l oosen each capscrew, one turn at a
ti me, to avoi d damagi ng the bri dge.
(5) Rotate the crankshaft unti l the No.6 pi ston i s
at top dead center (TDC) on the compressi on stroke.
(6) Rotate the crankshaft countercl ockwi se (vi ewed
from the front of the engi ne) 90°.
(7) I nstal l a di al i ndi cator on the end of the No.1
cyl i nder i ntake val ve push rod. Use rubber tubi ng to
secure the i ndi cator stem on the push rod.
(8) Set the di al i ndi cator poi nter at zero.
(9) Rotate the crankshaft cl ockwi se (vi ewed from
the front of the engi ne) unti l the di al i ndi cator
poi nter i ndi cates 0.305 mm (0.012 i nch) travel di s-
tance (l i ft).
(10) The ti mi ng notch i ndex on the vi brati on
damper shoul d be al i gned wi th the TDC mark on the
ti mi ng degree scal e.
(11) I f the ti mi ng notch i s more than 13 mm (1/2
i nch) away from the TDC mark i n ei ther di recti on,
the val ve ti mi ng i s i ncorrect.
NOTE: If the valve timing is incorrect, the cause
may be a broken camshaft pin. It is not necessary
to replace the camshaft because of pin failure. A
spring pin is available for service replacement.
TIMING BELT / CHAIN
COVER(S)
REMOVAL
(1) Di sconnect negati ve cabl e from battery.
(2) Remove the vi brati on damper (Refer to 9 -
ENGI NE/ENGI NE BLOCK/VI BRATI ON DAMPER -
REMOVAL).
(3) Remove the fan, hub assembl y and fan shroud
(Refer to 7 - COOLI NG/ENGI NE/RADI ATOR FAN -
REMOVAL).
(4) Remove the accessory dri ve brackets that are
attached to the ti mi ng case cover.
(5) Remove the A/C compressor (Refer to 24 -
HEATI NG & AI R CONDI TI ONI NG/PLUMBI NG/A/C
COMPRESSOR - REMOVAL) (i f equi pped) and gen-
erator bracket assembl y from the engi ne cyl i nder
head and move to one si de.
(6) Remove the oi l pan-to-ti mi ng case cover bol ts
and ti mi ng case cover-to-cyl i nder bl ock bol ts.
(7) Remove the ti mi ng case cover and gasket from
the engi ne.
(8) Pry the crankshaft oi l seal from the front of the
ti mi ng case cover (Fi g. 87).
INSTALLATION
Cl ean the ti mi ng case cover, oi l pan and cyl i nder
bl ock gasket surfaces.
(1) I nstal l a new crankshaft oi l seal i n the ti mi ng
case cover. The open end of the seal shoul d be toward
the i nsi de of the cover. Support the cover at the seal
area whi l e i nstal l i ng the seal . Force i t i nto posi ti on
wi th Seal I nstal l ati on Tool 6139.
(2) Posi ti on the gasket on the cyl i nder bl ock.
(3) Posi ti on the ti mi ng case cover on the oi l pan
gasket and the cyl i nder bl ock.
(4) I nsert Ti mi ng Case Cover Al i gnment and Seal
I nstal l ati on Tool 6139 i n the crankshaft openi ng i n
the cover (Fi g. 88).
(5) I nstal l the ti mi ng case cover-to-cyl i nder bl ock
and the oi l pan-to-ti mi ng case cover bol ts.
(6) Ti ghten the 1/4 i nch cover-to-bl ock bol ts to 7
N·m (60 i n. l bs.) torque. Ti ghten the 5/16 i nch front
cover-to-bl ock bol ts to 22 N·m (192 i n. l bs.) torque.
Ti ghten the oi l pan-to-cover 1/4 i nch bol ts to 9.5 N·m
(84 i n. l bs.) torque.
(7) Remove the cover al i gnment tool .
(8) Appl y a l i ght fi l m of engi ne oi l on the vi brati on
damper hub contact surface of the seal .
(9) Appl y Mopar௡ Si l i cone Rubber Adhesi ve Seal -
ant to the keyway i n the crankshaft and i nsert the
key. Wi th the key i nserted i n the keyway i n the
Fig. 87 Timing Case Cover Components
1 - TIMING CASE COVER
2 - OIL SLINGER
3 - CRANKSHAFT OIL SEAL
4 - VIBRATION DAMPER PULLEY
9 - 124 ENGINE 4. 0L TJ
OIL PUMP (Continued)
crankshaft, i nstal l the vi brati on damper (Refer to 9 -
ENGI NE/ENGI NE BLOCK/VI BRATI ON DAMPER -
I NSTALLATI ON).
(10) I nstal l the A/C compressor (Refer to 24 -
HEATI NG & AI R CONDI TI ONI NG/PLUMBI NG/A/C
COMPRESSOR - I NSTALLATI ON) (i f equi pped) and
generator bracket assembl y.
(11) I nstal l the engi ne fan, hub assembl y and
shroud (Refer to 7 - COOLI NG/ENGI NE/RADI ATOR
FAN - I NSTALLATI ON).
(12) I nstal l the serpenti ne dri ve bel t (Refer to 7 -
COOLI NG/ACCESSORY DRI VE/DRI VE BELTS -
I NSTALLATI ON).
(13) Connect negati ve cabl e to battery.
TIMING BELT/CHAIN AND
SPROCKETS
REMOVAL
(1) Di sconnect negati ve cabl e from battery.
(2) Remove the fan and shroud (Refer to 7 -
COOLI NG/ENGI NE/RADI ATOR FAN - REMOVAL).
(3) Remove the serpenti ne dri ve bel t (Refer to 7 -
COOLI NG/ACCESSORY DRI VE/DRI VE BELTS -
REMOVAL).
(4) Remove the crankshaft vi brati on damper (Refer
to 9 - ENGI NE/ENGI NE BLOCK/VI BRATI ON
DAMPER - REMOVAL).
(5) Remove the ti mi ng case cover (Refer to 9 -
ENGI NE/VALVE TI MI NG/TI MI NG BELT / CHAI N
COVER(S) - REMOVAL).
(6) Rotate crankshaft unti l the “0” ti mi ng mark i s
cl osest to and on the center l i ne wi th camshaft
sprocket ti mi ng mark (Fi g. 89).
(7) Remove the oi l sl i nger from the crankshaft.
(8) Remove the camshaft sprocket bol t and washer
(Fi g. 90).
(9) Remove the crankshaft sprocket, camshaft
sprocket and ti mi ng chai n as an assembl y.
(10) I nstal l ati on of the ti mi ng chai n wi th the ti m-
i ng marks on the crankshaft and camshaft sprockets
properl y al i gned ensures correct val ve ti mi ng. A worn
or stretched ti mi ng chai n wi l l adversel y affect val ve
Fig. 88 Timing Case Cover Alignment
1 - TIMING CASE COVER ALIGNMENT AND SEAL INSTALLATION
TOOL
Fig. 89 Crankshaft—Camshaft Alignment
1 - CAMSHAFT SPROCKET
2 - TIMING MARKS
3 - CRANKSHAFT SPROCKET
Fig. 90 Camshaft Sprocket and Thrust Plate
1 - CAMSHAFT
2 - CAMSHAFT SPROCKET W/INTEGRAL KEY
3 - BOLT AND WASHER
4 - THRUST PLATE
TJ ENGINE 4. 0L 9 - 125
TIMING BELT / CHAIN COVER(S) (Continued)
ti mi ng. I f the ti mi ng chai n defl ects more than 12.7
mm (1/2 i nch) repl ace i t.
INSTALLATION
Assembl e the ti mi ng chai n, crankshaft sprocket
and camshaft sprocket wi th the ti mi ng marks
al i gned (Fi g. 89).
(1) Appl y Mopar௡ Si l i cone Rubber Adhesi ve Seal -
ant to the keyway i n the crankshaft and i nsert the
key. Wi th the key i n the keyway on the crankshaft,
i nstal l the assembl y on the crankshaft and camshaft.
(2) I nstal l the camshaft sprocket bol t and washer
(Fi g. 90). Ti ghten the bol t to 68 N·m (50 ft. l bs.)
torque.
(3) To veri fy correct i nstal l ati on of the ti mi ng
chai n, rotate the crankshaft 2 revol uti ons. The cam-
shaft and crankshaft sprocket ti mi ng mark shoul d
al i gn (Fi g. 89).
(4) I nstal l the crankshaft oi l sl i nger.
(5) Repl ace the oi l seal i n the ti mi ng case cover
(Refer to 9 - ENGI NE/ENGI NE BLOCK/CRANK-
SHAFT OI L SEAL - FRONT - REMOVAL).
(6) I nstal l the ti mi ng case cover and gasket (Refer
to 9 - ENGI NE/VALVE TI MI NG/TI MI NG BELT /
CHAI N COVER(S) - I NSTALLATI ON).
(7) Wi th the key i nstal l ed i n the crankshaft key-
way, i nstal l the vi brati on damper (Refer to 9 -
ENGI NE/ENGI NE BLOCK/VI BRATI ON DAMPER -
I NSTALLATI ON).
(8) I nstal l the serpenti ne dri ve bel t (Refer to 7 -
COOLI NG/ACCESSORY DRI VE/DRI VE BELTS -
I NSTALLATI ON).
(9) I nstal l the fan, hub assembl y and shroud
(Refer to 7 - COOLI NG/ENGI NE/RADI ATOR FAN -
I NSTALLATI ON).
(10) Connect negati ve cabl e to battery.
INTAKE MANIFOLD
DESCRIPTION
The i ntake mani fol d (Fi g. 91) i s made of cast al u-
mi num and uses el even bol ts to mount to the cyl i n-
der head. Thi s mounti ng styl e i mproves seal i ng and
reduces the chance of l eaks.
DIAGNOSIS AND TESTING - INTAKE
MANIFOLD LEAKAGE
An i ntake mani fol d ai r l eak i s characteri zed by
l ower than normal mani fol d vacuum. Al so, one or
more cyl i nders may not be functi oni ng.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR THE FAN.
DO NOT WEAR LOOSE CLOTHING.
(1) Start the engi ne.
(2) Spray a smal l stream of water at the suspected
l eak area.
(3) I f a change i n RPM i s observed the area of the
suspected l eak has been found.
(4) Repai r as requi red.
REMOVAL
NOTE: THE ENGINE INTAKE AND EXHAUST MANI-
FOLD MUST BE REMOVED AND INSTALLED
TOGETHER. THE MANIFOLDS USE A COMMON
GASKET AT THE CYLINDER HEAD.
(1) Di sconnect the battery negati ve cabl e.
(2) Remove ai r cl eaner i nl et hose from the resona-
tor assembl y.
(3) Remove the ai r cl eaner assembl y.
(4) Remove the throttl e cabl e, vehi cl e speed control
cabl e (i f equi pped) and the transmi ssi on l i ne pres-
sure cabl e (Refer to 21 - TRANSMI SSI ON/TRANS-
AXLE/AUTOMATI C - AW4/THROTTLE VALVE
CABLE - REMOVAL).
(5) Di sconnect the fol l owi ng el ectri cal connecti ons
and secure thei r harness out of the way:
• Throttl e Posi ti on Sensor
• I dl e Ai r Control Motor
• Cool ant Temperature Sensor (at thermostat
housi ng)
• I ntake Ai r Temperature Sensor
• Oxygen Sensor
• Crank Posi ti on Sensor
• Si x (6) Fuel I njector Connectors
• Mani fol d Absol ute Pressure (MAP) Sensor.
(6) Di sconnect HVAC, and Brake Booster vacuum
suppl y hoses at the i ntake mani fol d.
(7) Perform the fuel pressure rel ease procedure.
(Refer to 14 - FUEL SYSTEM/FUEL DELI VERY -
STANDARD PROCEDURE).
Fig. 91 Intake Manifold 4.0L Engine
9 - 126 ENGINE 4. 0L TJ
TIMING BELT/CHAIN AND SPROCKETS (Continued)
(8) Di sconnect and remove the fuel system suppl y
l i ne from the fuel rai l assembl y.
(9) Remove the accessory dri ve bel t (Refer to 7 -
COOLI NG/ACCESSORY DRI VE/DRI VE BELTS -
REMOVAL).
(10) Remove the power steeri ng pump from the
i ntake mani fol d and set asi de.
(11) Rai se the vehi cl e.
(12) Di sconnect the exhaust pi pes from the engi ne
exhaust mani fol ds.
(13) Lower the vehi cl e.
(14) Remove the i ntake mani fol d and exhaust
mani fol d bol ts and mani fol ds (Fi g. 92).
INSTALLATION
I f the mani fol d i s bei ng repl aced, ensure al l the fi t-
ti ng, etc. are transferred to the repl acement mani -
fol d.
(1) I nstal l a new engi ne exhaust/i ntake mani fol d
gasket over the al i gnment dowel s on the cyl i nder
head.
(2) Posi ti on the engi ne exhaust mani fol ds to the
cyl i nder head. I nstal l fastener Number 3 and fi nger
ti ghten at thi s ti me (Fi g. 92).
(3) I nstal l i ntake mani fol d on the cyl i nder head
dowel s.
(4) I nstal l washer and fastener Numbers 1, 2, 4, 5,
8, 9, 10 and 11 (Fi g. 92).
(5) I nstal l washer and fastener Numbers 6 and 7
(Fi g. 92).
(6) Ti ghten the fasteners i n sequence and to the
speci fi ed torque (Fi g. 92).
• Fastener Numbers 1 through 5—Ti ghten to 33
N·m (24 ft. l bs.) torque.
• Fastener Numbers 6 and 7—Ti ghten to 31 N·m
(23 ft. l bs.) torque.
• Fastener Numbers 8 through 11—Ti ghten to 33
N·m (24 ft. l bs.) torque.
(7) I nstal l the power steeri ng pump to the i ntake
mani fol d.
(8) I nstal l the accessory dri ve bel t (Refer to 7 -
COOLI NG/ACCESSORY DRI VE/DRI VE BELTS -
I NSTALLATI ON).
(9) I nstal l the fuel system suppl y l i ne to the fuel
rai l assembl y.
(10) Connect al l el ectri cal connecti ons on the
i ntake mani fol d.
(11) Connect the vacuum hoses previ ousl y
removed.
(12) I nstal l throttl e cabl e, vehi cl e speed control
cabl e (i f equi pped).
(13) I nstal l the transmi ssi on l i ne pressure cabl e (i f
equi pped) (Refer to 21 - TRANSMI SSI ON/TRANS-
AXLE/AUTOMATI C - AW4/THROTTLE VALVE
CABLE - I NSTALLATI ON).
(14) I nstal l ai r cl eaner assembl y.
(15) Connect ai r i nl et hose to the resonator assem-
bl y.
(16) Rai se the vehi cl e.
(17) Connect the exhaust pi pes to the engi ne
exhaust mani fol ds. Ti ghten the bol ts to 31 N·m (23
ft. l bs.)
(18) Lower the vehi cl e.
(19) Connect the battery negati ve cabl e.
(20) Start the engi ne and check for l eaks.
Fig. 92 Intake and Exhaust Manifolds Installation
TJ ENGINE 4. 0L 9 - 127
INTAKE MANIFOLD (Continued)
EXHAUST MANIFOLD
DESCRIPTION
The two exhaust mani fol ds (Fi g. 93) are l og styl e
and are made of hi gh si l i con mol ybdenum cast i ron.
The exhaust mani fol ds share a common gasket wi th
the i ntake mani fol d. The exhaust mani fol ds al so
i ncorporate bal l fl ange outl ets for i mproved seal i ng
and strai n free connecti ons.
REMOVAL
The i ntake and engi ne exhaust mani fol ds on the
4.0L engi ne must be removed together. The mani fol ds
use a common gasket at the cyl i nder head.
(Refer to 9 - ENGI NE/MANI FOLDS/I NTAKE
MANI FOLD - REMOVAL).
Fig. 93 EXHAUST MANIFOLDS 4.0L ENGINE
9 - 128 ENGINE 4. 0L TJ
EXHAUST SYSTEM
TABLE OF CONTENTS
page page
EXHAUST SYSTEM
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DIAGNOSIS AND TESTING - EXHAUST
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SPECIFICATIONS
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CATALYTIC CONVERTER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 4
REMOVAL
REMOVAL - 2.4L . . . . . . . . . . . . . . . . . . . . . . . 5
REMOVAL - 4.0L . . . . . . . . . . . . . . . . . . . . . . . 5
INSTALLATION
INSTALLATION - 2.4L . . . . . . . . . . . . . . . . . . . 6
INSTALLATION - 4.0L . . . . . . . . . . . . . . . . . . . 6
EXHAUST PIPE
REMOVAL
REMOVAL - 2.4L . . . . . . . . . . . . . . . . . . . . . . . 6
REMOVAL - 4.0L . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLATION
INSTALLATION - 2.4L . . . . . . . . . . . . . . . . . . . 7
INSTALLATION - 4.0L . . . . . . . . . . . . . . . . . . . 8
HEAT SHIELDS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
MUFFLER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 9
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10
TAILPIPE
DESCRIPTION
TAILPIPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
EXHAUST SYSTEM
DESCRIPTION
WARNING: THE NORMAL OPERATING TEMPERA-
TURE OF THE EXHAUST SYSTEM IS VERY HIGH.
THEREFORE, NEVER WORK AROUND OR ATTEMPT
TO SERVICE ANY PART OF THE EXHAUST SYSTEM
UNTIL IT IS COOLED. SPECIAL CARE SHOULD BE
TAKEN WHEN WORKING NEAR THE CATALYTIC
CONVERTER. THE TEMPERATURE OF THE CON-
VERTER RISES TO A HIGH LEVEL AFTER A SHORT
PERIOD OF ENGINE OPERATION TIME.
The basi c exhaust system consi sts of exhaust man-
i fol d(s), exhaust pi pe wi th oxygen sensors, catal yti c
converter(s), heat shi el d(s), muffl er and tai l pi pe (Fi g.
1) and (Fi g. 2)
TJ EXHAUST SYSTEM 11 - 1
Fig. 1 Exhaust system - 2.4L Engine
1 - CATALYTIC CONVERTER
2 - TAILPIPE
3 - MUFFLER
4 - EXHAUST PIPE TO EXHAUST MANIFOLD FLANGE
5 - MINI CATALYTIC CONVERTER
11 - 2 EXHAUST SYSTEM TJ
EXHAUST SYSTEM (Continued)
Fig. 2 Exhaust System - 4.0L
1 - TAILPIPE
2 - MUFFLER
3 - CATALYTIC CONVERTER
4 - MINI CATALYTIC CONVERTER
5 - EXHAUST PIPE
TJ EXHAUST SYSTEM 11 - 3
EXHAUST SYSTEM (Continued)
DIAGNOSIS AND TESTING - EXHAUST SYSTEM
EXHAUST SYSTEM DIAGNOSIS CHART
CONDITION POSSIBLE CAUSE CORRECTION
EXCESSIVE EXHAUST NOISE OR
LEAKING EXHAUST GASES
1. Leaks at pipe joints. 1. Tighten clamps/bolts to specified
torque at leaking joints.
2. Rusted or blown out muffler. 2. Replace muffler. Inspect exhaust
system.
3. Broken or rusted out exhaust
pipe.
3. Replace exhaust pipe.
4. Exhaust pipe leaking at manifold
flange.
4. Tighten/replace flange attaching
nuts/bolts.
5. Exhaust manifold cracked or
broken.
5. Replace exhaust manifold.
6. Leak between exhaust manifold
and cylinder head.
6. Tighten exhaust manifold to
cylinder head bolts.
7. Catalytic converter rusted or
blown out.
7. Replace catalytic converter assy.
8. Restriction in exhaust system. 8. Remove restriction, if possible.
Replace restricted part if necessary.
CAUTION:
When servicing and replacing exhaust system components, disconnect the oxygen sensor connector(s). Allowing
the exhaust to hang by the oxygen sensor wires will damage the harness and/or sensor.
SPECIFICATIONS
TORQUE
DESCRIPTION N·m Ft. In.
Lbs. Lbs.
Bolts, Crossmember to Sill 42 31 -
Nuts, Crossmember to
Transmission Mount
22 16 -
Nuts, Exhaust Pipe to
Manifold
31 23 -
Nuts/Bolt, Exhaust Manifold to
Engine
#6&7 31 23 -
#1,2,3,4,5,8,9,10&11 33 24 -
Nuts, Exhaust Pipe to
Catalytic Converter Flange
28.5 21 -
Clamp, Tailpipe to Rear
Tailpipe Hanger
27 20 -
Oxygen Sensors 27 20 -
Heat Shields 45 33 -
CATALYTIC CONVERTER
DESCRIPTION
WARNING: THE NORMAL OPERATING TEMPERA-
TURE OF THE EXHAUST SYSTEM IS VERY HIGH.
THEREFORE, NEVER WORK AROUND OR ATTEMPT
TO SERVICE ANY PART OF THE EXHAUST SYSTEM
UNTIL IT IS COOLED. SPECIAL CARE SHOULD BE
TAKEN WHEN WORKING NEAR THE CATALYTIC
CONVERTER. THE TEMPERATURE OF THE CON-
VERTER RISES TO A HIGH LEVEL AFTER A SHORT
PERIOD OF ENGINE OPERATION TIME.
CAUTION: DO NOT remove spark plug wires from
plugs or by any other means short out cylinders.
Failure of the catalytic converter can occur due to a
temperature increase caused by unburned fuel
passing through the converter.
The stai nl ess steel catal yti c converter body i s
desi gned to l ast the l i fe of the vehi cl e. Excessi ve heat
can resul t i n bul gi ng or other di storti on, but exces-
si ve heat wi l l not be the faul t of the converter. I f
unburned fuel enters the converter, overheati ng may
occur. I f a converter i s heat-damaged, correct the
11 - 4 EXHAUST SYSTEM TJ
EXHAUST SYSTEM (Continued)
cause of the damage at the same ti me the converter
i s repl aced. Al so, i nspect al l other components of the
exhaust system for heat damage.
The catal yti c converter and muffl er are servi ced as
an assembl y.
Unl eaded gasol i ne must be used to avoi d contami -
nati ng the catal yst core.
REMOVAL
REMOVAL - 2. 4L
WARNING: THE NORMAL OPERATING TEMPERA-
TURE OF THE EXHAUST SYSTEM IS VERY HIGH.
THEREFORE, NEVER ATTEMPT TO SERVICE ANY
PART OF THE EXHAUST SYSTEM UNTIL IT IS
COOLED. SPECIAL CARE SHOULD BE TAKEN
WHEN WORKING NEAR THE CATALYTIC CON-
VERTER. THE TEMPERATURE OF THE CONVERTER
RISES TO A HIGH LEVEL AFTER A SHORT PERIOD
OF ENGINE OPERATION TIME.
WARNING: IF TORCHES ARE USED WHEN WORK-
ING ON THE EXHAUST SYSTEM, DO NOT ALLOW
THE FLAME NEAR THE FUEL LINES.
CAUTION: When servicing exhaust system compo-
nents, disconnect the oxygen sensor connector(s).
Allowing the exhaust system to hang by the oxygen
sensor harness will damage the wiring and/or sen-
sor.
(1) Di sconnect the oxygen sensors.
(2) Remove the two bol ts and fl anged nuts at the
mani fol d (Fi g. 3).
(3) Remove the two bol ts and fl anged nuts at the
fl ange.
(4) Remove the mi ni catal yst assembl y from the
vehi cl e.
(5) Sl i de exhaust pi pe forward unti l exhaust pi pe
hanger di sengages from transmi ssi on support.
Remove exhaust pi pe and catal yti c converter from
vehi cl e.
REMOVAL - 4. 0L
WARNING: THE NORMAL OPERATING TEMPERA-
TURE OF THE EXHAUST SYSTEM IS VERY HIGH.
THEREFORE, NEVER ATTEMPT TO SERVICE ANY
PART OF THE EXHAUST SYSTEM UNTIL IT IS
COOLED. SPECIAL CARE SHOULD BE TAKEN
WHEN WORKING NEAR THE CATALYTIC CON-
VERTER. THE TEMPERATURE OF THE CONVERTER
RISES TO A HIGH LEVEL AFTER A SHORT PERIOD
OF ENGINE OPERATION TIME.
WARNING: IF TORCHES ARE USED WHEN WORK-
ING ON THE EXHAUST SYSTEM, DO NOT ALLOW
THE FLAME NEAR THE FUEL LINES.
CAUTION: When servicing exhaust system compo-
nents, disconnect the oxygen sensor connector(s).
Allowing the exhaust system to hang by the oxygen
sensor harness will damage the wiring and/or sen-
sor.
(1) Rai se and support the vehi cl e.
(2) Saturate the studs and nuts wi th a Mopar௡
rust penetrant. Al l ow 5 mi nutes for penetrati on.
(3) Remove the oxygen sensors from the exhaust
pi pe and the catal yti c converter.
(4) Di sconnect the exhaust pi pe from the engi ne
exhaust mani fol d (Fi g. 4).
(5) Remove mi ni catal yti c converter fl ange retai n-
i ng nuts (Fi g. 4).
(6) Sl i de exhaust pi pe forward unti l exhaust pi pe
hanger di sengages from transmi ssi on support.
Remove exhaust pi pe and catal yti c converter from
vehi cl e.
Fig. 3 2.4L Exhaust Pipe and Catalytic Converter -
4x4
1- FLANGED NUT
2- MINI CATALYST ASSEMBLY
3- BOLT
4- HANGER
5- NUT
TJ EXHAUST SYSTEM 11 - 5
CATALYTIC CONVERTER (Continued)
INSTALLATION
INSTALLATION - 2. 4L
(1) Posi ti on the mi ni catal yti c converter assembl y
onto the exhaust pi pe fl ange and the exhaust mani -
fol d. Ti ghten the nuts to 31 N·m (23 ft.l bs.) torque.
Ti ghten the fl ange nuts to 28 N·m (21 ft. l bs.).
(2) Connect oxygen sensor wi ri ng.
(3) Lower the vehi cl e.
(4) Start engi ne and i nspect for l eaks. Repai r
exhaust l eaks as necessary.
(5) Check the exhaust system for contact wi th the
body panel s. Make the necessary adjustments, i f
needed.
INSTALLATION - 4. 0L
(1) Posi ti on exhaust pi pe and catal yti c converter
i nto vehi cl e.
(2) I nsert exhaust pi pe hanger i nto transmi ssi on
support (Fi g. 4).
(3) I nstal l exhaust pi pe onto exhaust mani fol d DO
NOT ti ghten bol ts at thi s ti me.
(4) Posi ti on muffl er fl ange onto catal yti c converter
fl ange and i nstal l retai ni ng bol ts and nuts (Fi g. 4).
DO NOT ti ghten nuts at thi s ti me.
(5) Make sure the exhaust system i s al i gned and
has the proper cl earance. The mi ni mum cl earance i s
25mm (1 i nch).
(6) Ti ghten muffl er to catal yti c converter fl ange
retai ni ng nuts to 28.5 N·m (21 ft. l bs.).
(7) Ti ghten exhaust pi pe to exhaust mani fol d
mounti ng bol ts to 31 N·m (23 ft. l bs.).
(8) I nstal l the oxygen sensors i n the exhaust pi pe
and catal yti c converter.
(9) Lower vehi cl e.
(10) Start engi ne and i nspect for l eaks. Repai r
exhaust l eaks as necessary.
(11) Check the exhaust system for contact wi th the
body panel s. Make the necessary adjustments, i f
needed.
EXHAUST PIPE
REMOVAL
REMOVAL - 2. 4L
WARNING: THE NORMAL OPERATING TEMPERA-
TURE OF THE EXHAUST SYSTEM IS VERY HIGH.
THEREFORE, NEVER ATTEMPT TO SERVICE ANY
PART OF THE EXHAUST SYSTEM UNTIL IT IS
COOLED. SPECIAL CARE SHOULD BE TAKEN
WHEN WORKING NEAR THE CATALYTIC CON-
VERTER. THE TEMPERATURE OF THE CONVERTER
RISES TO A HIGH LEVEL AFTER A SHORT PERIOD
OF ENGINE OPERATION TIME.
WARNING: IF TORCHES ARE USED WHEN WORK-
ING ON THE EXHAUST SYSTEM, DO NOT ALLOW
THE FLAME NEAR THE FUEL LINES.
CAUTION: When servicing exhaust system compo-
nents, disconnect the oxygen sensor connector(s).
Allowing the exhaust system to hang by the oxygen
sensor harness will damage the wiring and/or sen-
sor.
(1) Rai se and support the vehi cl e.
(2) Saturate the studs and nuts wi th a Mopar௡
rust penetrant. Al l ow 5 mi nutes for penetrati on.
(3) Remove the oxygen sensors from the exhaust
pi pe and the catal yti c converter.
(4) Di sconnect the exhaust pi pe from the engi ne
exhaust mani fol d (Fi g. 5).
(5) Remove catal yti c converter to muffl er fl ange
retai ni ng nuts (Fi g. 5).
(6) Sl i de exhaust pi pe forward unti l exhaust pi pe
hanger di sengages from transmi ssi on support.
Remove exhaust pi pe and catal yti c converter from
vehi cl e.
Fig. 4 Exhaust Pipe and Catalytic Converter - 4.0L
1 - CATALYTIC CONVERTER
2 - TRANSMISSION SUPPORT
3 - EXHAUST HANGER
4 - EXHAUST PIPE
11 - 6 EXHAUST SYSTEM TJ
CATALYTIC CONVERTER (Continued)
REMOVAL - 4. 0L
WARNING: THE NORMAL OPERATING TEMPERA-
TURE OF THE EXHAUST SYSTEM IS VERY HIGH.
THEREFORE, NEVER ATTEMPT TO SERVICE ANY
PART OF THE EXHAUST SYSTEM UNTIL IT IS
COOLED. SPECIAL CARE SHOULD BE TAKEN
WHEN WORKING NEAR THE CATALYTIC CON-
VERTER. THE TEMPERATURE OF THE CONVERTER
RISES TO A HIGH LEVEL AFTER A SHORT PERIOD
OF ENGINE OPERATION TIME.
WARNING: IF TORCHES ARE USED WHEN WORK-
ING ON THE EXHAUST SYSTEM, DO NOT ALLOW
THE FLAME NEAR THE FUEL LINES.
CAUTION: When servicing exhaust system compo-
nents, disconnect the oxygen sensor connector(s).
Allowing the exhaust system to hang by the oxygen
sensor harness will damage the wiring and/or sen-
sor.
(1) Rai se and support the vehi cl e.
(2) Saturate the studs and nuts wi th a Mopar௡
rust penetrant. Al l ow 5 mi nutes for penetrati on.
(3) Remove the oxygen sensors from the exhaust
pi pe and the catal yti c converter.
(4) Di sconnect the exhaust pi pe from the engi ne
exhaust mani fol d (Fi g. 6).
(5) Remove catal yti c converter to muffl er fl ange
retai ni ng nuts (Fi g. 6).
(6) Sl i de exhaust pi pe foward unti l exhaust pi pe
hanger di sengages from transmi ssi on support.
Remove exhaust pi pe and catal yti c converter from
vehi cl e.
INSTALLATION
INSTALLATION - 2. 4L
(1) Posi ti on exhaust pi pe and catal yti c converter
i nto vehi cl e.
(2) I nsert exhaust pi pe hanger i nto transmi ssi on
support (Fi g. 5).
(3) I nstal l exhaust pi pe onto exhaust mani fol d DO
NOT ti ghten bol ts at thi s ti me.
(4) Posi ti on muffl er fl ange onto catal yti c converter
fl ange and i nstal l retai ni ng bol ts and nuts (Fi g. 5).
DO NOT ti ghten nuts at thi s ti me.
(5) Make sure the exhaust system i s al i gned and
has the proper cl earance. The mi ni mum cl earance i s
25mm (1 i nch).
(6) Ti ghten muffl er to catal yti c converter fl ange
retai ni ng nuts to 28.5 N·m (21 ft. l bs.).
(7) Ti ghten exhaust pi pe to exhaust mani fol d
mounti ng bol ts to 31 N·m (23 ft. l bs.).
(8) I nstal l the oxygen sensors i n the exhaust pi pe
and catal yti c converter.
(9) Lower vehi cl e.
(10) Start engi ne and i nspect for l eaks. Repai r
exhaust l eaks as necessary.
(11) Check the exhaust system for contact wi th the
body panel s. Make the necessary adjustments, i f
needed.
Fig. 5 Exhaust Pipe and Calalytic Converter - 2.4L
1 - CATALYTIC CONVERTER
2 - TRANSMISSION SUPPORT
3 - EXHAUST HANGER
4 - EXHAUST PIPE
Fig. 6 Exhaust Pipe and Catalytic Converter - 4.0L
1 - CATALYTIC CONVERTER
2 - TRANSMISSION SUPPORT
3 - EXHAUST HANGER
4 - EXHAUST PIPE
TJ EXHAUST SYSTEM 11 - 7
EXHAUST PIPE (Continued)
INSTALLATION - 4. 0L
(1) Posi ti on exhaust pi pe and catal yti c converter
i nto vehi cl e.
(2) I nsert exhaust pi pe hanger i nto transmi ssi on
support (Fi g. 6).
(3) I nstal l exhaust pi pe onto exhaust mani fol d DO
NOT ti ghten bol ts at thi s ti me.
(4) Posi ti on muffl er fl ange onto catal yti c converter
fl ange and i nstal l retai ni ng bol ts and nuts (Fi g. 6).
DO NOT ti ghten nuts at thi s ti me.
(5) Make sure the exhaust system i s al i gned and
has the proper cl earance. The mi ni mum cl earance i s
25mm (1 i nch).
(6) Ti ghten muffl er to catal yti c converter fl ange
retai ni ng nuts to 28.5 N·m (21 ft. l bs.).
(7) Ti ghten exhaust pi pe to exhaust mani fol d
mounti ng bol ts to 31 N·m (23 ft. l bs.).
(8) I nstal l the oxygen sensors i n the exhaust pi pe
and catal yti c converter.
(9) Lower vehi cl e.
(10) Start engi ne and i nspect for l eaks. Repai r
exhaust l eaks as necessary.
(11) Check the exhaust system for contact wi th the
body panel s. Make the necessary adjustments, i f
needed.
HEAT SHIELDS
DESCRIPTION
Heat shi el ds (Fi g. 7) are made of stamped/formed
steel , or metal foi l .
Exhaust heat shi el ds are needed to protect both the
vehi cl e and the envi ronment from the hi gh tempera-
tures devel oped by the catal yti c converter. The cata-
l yti c converter rel eases addi ti onal heat i nto the
exhaust system. Under severe operati ng condi ti ons,
the temperature i ncreases i n the area of the converter.
Such condi ti ons can exi st when the engi ne mi sfi res or
otherwi se does not operate at peak effi ci ency.
REMOVAL
(1) Rai se and support the vehi cl e.
(2) Remove the screws and/or nuts hol di ng the
heat shi el ds to the frame and/or fl oor pan (Fi g. 8)
and (Fi g. 9).
(3) When removi ng muffl er heat shi el d, the muf-
fl er front support bracket must be removed fi rst.
(4) Sl i de the shi el ds out around the exhaust system.
INSTALLATION
(1) Posi ti on the heat shi el ds to the fl oor pan or
the frame and i nstal l the screws and/or nuts (Fi g. 8)
and (Fi g. 9).
(2) Ti ghten the nuts and/or screws to 45 N·m (33
ft. l bs.).
(3) Lower the vehi cl e.
Fig. 7 Exhaust Heat Shield - Typical
1 - HEAT SHIELD
Fig. 8 Muffler Heat Shield - Rear
1 - MUFFLER HEAT SHIELD - REAR
2 - NUTS
3 - SELF TAPPING SCREWS
Fig. 9 Muffler Heat Shield - Middle
1 - MUFFLER HEAT SHIELD - MIDDLE
2 - NUTS
3 - SELF TAPPING SCREWS
11 - 8 EXHAUST SYSTEM TJ
EXHAUST PIPE (Continued)
MUFFLER
DESCRIPTION
Both the 2.4L and 4.0L engi nes use a gal vani zed
steel muffl er (Fi g. 10) to control exhaust noi se l evel s
and exhaust back pressure.
REMOVAL
WARNING: THE NORMAL OPERATING TEMPERA-
TURE OF THE EXHAUST SYSTEM IS VERY HIGH.
THEREFORE, NEVER ATTEMPT TO SERVICE ANY
PART OF THE EXHAUST SYSTEM UNTIL IT IS
COOLED. SPECIAL CARE SHOULD BE TAKEN
WHEN WORKING NEAR THE CATALYTIC CON-
VERTER. THE TEMPERATURE OF THE CONVERTER
RISES TO A HIGH LEVEL AFTER A SHORT PERIOD
OF ENGINE OPERATION TIME.
WARNING: IF TORCHES ARE USED WHEN WORK-
ING ON THE EXHAUST SYSTEM, DO NOT ALLOW
THE FLAME NEAR THE FUEL LINES.
CAUTION: When servicing exhaust system compo-
nents, disconnect the oxygen sensor connector(s).
Allowing the exhaust system to hang by the oxygen
sensor harness will damage the wiring and/or sen-
sor.
Al l ori gi nal equi pment exhaust systems are manu-
factured wi th the exhaust tai l pi pe wel ded to the muf-
fl er. Servi ce repl acement muffl ers and exhaust
tai l pi pes are ei ther cl amped together or wel ded
together.
(1) Rai se the vehi cl e and support the rear of the
vehi cl e by the si de rai l s and al l ow the axl e to hang
free.
(2) Remove the tai l pi pe hangers from the i nsul a-
tors (Fi g. 11).
(3) Remove muffl er to catal yti c converter fl ange
retai ni ng nuts (Fi g. 11).
(4) Remove muffl er and tai l pi pe assembl y from
vehi cl e.
Fig. 10 Muffler
1 - MUFFLER
TJ EXHAUST SYSTEM 11 - 9
INSTALLATION
(1) Posi ti on muffl er and tai l pi pe assembl y i nto
vehi cl e.
(2) Posi ti on muffl er and catal yti c converter fl anges
together and i nstal l nuts (Fi g. 11). DO NOT ti ghten
nuts at thi s ti me.
(3) I nstal l tai l pi pe hangers i nto the i nsul ators (Fi g.
11).
(4) Make sure the muffl er and tai l pi pe are cor-
rectl y posi ti oned and the proper al i gnment. The mi n-
i mum cl earance between components i s 25mm (1
i nch).
(5) Ti ghten muffl er to catal yti c converter fl ange
nuts to 28.5 N·m (21 ft. l bs.).
(6) Lower vehi cl e.
(7) Start engi ne and i nspect for l eaks. Repai r
exhaust l eaks as necessary.
(8) Check the exhaust system for contact wi th the
body panel s. Make the necessary adjustments, i f
needed.
Fig. 11 Muffler and Tailpipe
1 - TRANSMISSION SUPPORT
2 - TAILPIPE HANGER INSULATORS
3 - TAILPIPE HANGERS
4 - TAILPIPE
5 - MUFFLER
6 - MUFFLER TO CATALYTIC CONVERTER FLANGE
7 - NUTS
8 - CATALYTIC CONVERTER
11 - 10 EXHAUST SYSTEM TJ
MUFFLER (Continued)
TAILPIPE
DESCRIPTION
TAILPIPE
DESCRIPTION
The tai l pi pe (Fi g. 12) i s made of gal vani zed steel
OPERATION
The tai l pi pe channel s the exhaust out of the muf-
fl er and out from under the vehi cl e to control noi se
and prevent exhaust gas fumes from enteri ng the
passenger compartment.
Fig. 12 Tailpipe - Typical
1 - TAILPIPE
TJ EXHAUST SYSTEM 11 - 11
FRAME & BUMPERS
TABLE OF CONTENTS
page page
FRAME & BUMPERS
SPECIFICATIONS
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . 1
FRONT EXTENSION
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 2
FRONT BUMPER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 2
REAR EXTENSION
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 2
REAR BUMPER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FRAME
STANDARD PROCEDURE - FRAME SERVICE . . 3
SPECIFICATIONS
FRAME DIMENSIONS . . . . . . . . . . . . . . . . . . . 4
TRANSFER CASE SKID PLATE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 9
FUEL TANK SKID PLATE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10
FRONT TOW HOOK
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10
REAR TOW HOOK
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11
TRANSMISSION SKID PLATE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11
FRAME & BUMPERS
SPECIFICATIONS
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
DESCRIPTION N·m Ft. Lbs. In. Lbs.
FRONT BUMPER SCREW 108 80 —
FRONT TOW HOOK SCREW 108 80 —
FUEL TANK SKID PLATE NUTS 16 12 138
FUEL TANK STRAP NUTS 5 — 40
MAIN FLOOR TO HOLD DOWN BOLT 68 50 —
RADIATOR TO FRAME HOLD DOWN BOLT 60 45 —
REAR BUMPER BOLT 77 57 —
REAR FLOOR TO FRAME BOLT 47 35 —
REAR TOE HOOK SCREW 77 57 —
TRANFER CASE SKID PLATE BOLTS 45 33 —
TRANSMISSION MOUNT NUTS 35 26 —
TRANSMISSION SKID PLATE TO FRAME BOLTS 45 33 —
TRANSMISSION SKID PLATE TO TRANSFER CASE SKID
PLATE BOLTS
28 21 —
TJ FRAME & BUMPERS 13 - 1
FRONT EXTENSION
REMOVAL
(1) Remove the bol ts attachi ng the bumper exten-
si on to the bumper (Fi g. 1).
(2) Separate the extensi on from the bumper.
INSTALLATION
(1) Posi ti on the extensi on to the bumper
(2) I nstal l the screws retai ni ng the front bumper
extensi on. (Fi g. 1)
FRONT BUMPER
REMOVAL
(1) I f equi pped, di sconnect the fog l amp harness
connector.
(2) Remove the screws that attach the bumper to
the frame rai l (Fi g. 2).
(3) I f equi pped, remove the tow hook. (Refer to 13 -
FRAME & BUMPERS/FRAME/FRONT TOW HOOK
- REMOVAL)
(4) Separate the bumper from the vehi cl e.
INSTALLATION
(1) Posi ti on the bumper on the vehi cl e.
(2) I f equi pped, i nstal l the tow hook. (Refer to 13 -
FRAME & BUMPERS/FRAME/FRONT TOW HOOK
- I NSTALLATI ON)
(3) I nstal l the screws that attach the bumper to
the frame rai l and ti ghten to 108 N·m (80 ft. l bs.).
(4) I f equi pped, Connect the fog l amp harness con-
nector.
REAR EXTENSION
REMOVAL
(1) Remove the screws attachi ng the bumper
extensi on to the bumper (Fi g. 3).
(2) Separate the extensi on from the bumper.
INSTALLATION
(1) Posi ti on the extensi on on the bumper.
(2) I nstal l the screws attachi ng the bumper exten-
si on to the bumper.
REAR BUMPER
REMOVAL
(1) Remove the bol t attachi ng the bumper to frame
rai l . (Fi g. 3)
(2) I f equi pped, remove the rear tow eye/hook.
(Refer to 13 - FRAME & BUMPERS/FRAME/REAR
TOW HOOK - REMOVAL)
(3) Di sconnect the rear fog l amp el ectri cal connec-
tor, i f equi pped.
(4) Remove the nuts attachi ng the bumper to the
rear frame crossmember.
(5) Separate the bumper from the vehi cl e.
Fig. 1 BUMPER EXTENSION
1 - BUMPER EXTENSION
2 - FRONT BUMPER
3 - BOLTS (2 ON TOP AND 1 ON BOTTOM)
Fig. 2 FRONT BUMPER COMPONENTS
1 - VALANCE
2 - BUMPER GUARD
3 - FRONT BUMPER
4 - BUMPER EXTENSION
5 - FRAME
13 - 2 FRAME & BUMPERS TJ
INSTALLATION
(1) Posi ti on the bumper on the vehi cl e.
(2) I nstal l the nuts attachi ng the bumper to the
rear frame crossmember and ti ghten to 77 N·m (57
ft. l bs.).
(3) I f equi pped, i nstal l the rear tow eye/hook.
(Refer to 13 - FRAME & BUMPERS/FRAME/REAR
TOW HOOK - I NSTALLATI ON)
(4) I nstal l the bol t attachi ng the bumper to frame
rai l and ti ghten to 77 N·m (57 ft. l bs.).
(5) Connect the rear fog l amp el ectri cal connectors,
i f equi pped.
FRAME
STANDARD PROCEDURE - FRAME SERVICE
SAFETY PRECAUTIONS AND WARNINGS
WARNING: USE EYE PROTECTION WHEN GRIND-
ING OR WELDING METAL, SERIOUS EYE INJURY
CAN RESULT. BEFORE PROCEEDING WITH FRAME
REPAIR INVOLVING GRINDING OR WELDING, VER-
IFY THAT VEHICLE FUEL SYSTEM IS NOT LEAKING
OR IN CONTACT WITH REPAIR AREA, PERSONAL
INJURY CAN RESULT. DO NOT ALLOW OPEN
FLAME TO CONTACT PLASTIC BODY PANELS.
FIRE OR EXPLOSION CAN RESULT. WHEN
WELDED FRAME COMPONENTS ARE REPLACED,
100% PENETRATION WELD MUST BE ACHIEVED
DURING INSTALLATION. IF NOT, DANGEROUS
OPERATING CONDITIONS CAN RESULT. STAND
CLEAR OF CABLES OR CHAINS ON PULLING
EQUIPMENT DURING FRAME STRAIGHTENING
OPERATIONS, PERSONAL INJURY CAN RESULT.
DO NOT VENTURE UNDER A HOISTED VEHICLE
THAT IS NOT SUPPORTED ON SAFETY STANDS,
PERSONAL INJURY CAN RESULT.
CAUTION: Do not reuse damaged fasteners, quality
of repair would be suspect. Do not drill holes in top
or bottom frame rail flanges, frame rail failure can
result. Do Not use softer than Grade 3 bolts to
replace production fasteners, loosening or failure
can result. When using heat to straighten frame
components do not exceed 566°C (1050°F), metal
fatigue can result. Welding the joints around riveted
cross members and frame side rails can weaken
frame.
FRAME STRAIGHTENING
When necessary, a conventi onal frame that i s bent
or twi sted can be strai ghtened by appl i cati on of heat.
The temperature must not exceed 566°C (1050°F).
The metal wi l l have a dul l red gl ow at the desi red
temperature. Excessi ve heat wi l l decrease the
strength of the metal and resul t i n a weakened
frame.
Wel di ng the joi nts around ri veted cross members
and frame si de rai l s i s not recommended.
A strai ghteni ng repai r process shoul d be l i mi ted to
frame members that are not severel y damaged. The
repl acement bol ts, nuts and ri vets that are used to
joi n the frame members shoul d conform to the same
speci fi cati ons as the ori gi nal bol ts, nuts and ri vets.
FRAME REPAIRS
DRILLING HOLES
Do not dri l l hol es i n the top and bottom of frame
rai l , metal fati gue can resul t causi ng frame fai l ure.
Hol es dri l l ed i n the si de of the frame rai l must be at
l east 38 mm (1.5 i n.) from the top and bottom
fl anges.
Addi ti onal dri l l hol es shoul d be l ocated away from
exi sti ng hol es.
WELDING
Use MI G, TI G or arc wel di ng equi pment to repai r
wel ded frame components.
Fig. 3 REAR BUMPER COMPONENTS
1 - BODY
2 - CROSSMEMBER
3 - FRAME
4 - REAR BUMPER
5 - REAR BUMPER
6 - BRACE
7 - REAR BUMPER EXTENSION
TJ FRAME & BUMPERS 13 - 3
REAR BUMPER (Continued)
Frame components that have been damaged shoul d
be i nspected for cracks before returni ng the vehi cl e
to use. I f cracks are found i n accessi bl e frame com-
ponents perform the fol l owi ng procedures.
(1) Dri l l a hol e at each end of the crack wi th a 3
mm (O.125 i n.) di ameter dri l l bi t.
(2) Usi ng a sui tabl e di e gri nder wi th 3 i nch cut off
wheel , V-groove the crack to al l ow 100% wel d pene-
trati on.
(3) Wel d the crack.
(4) I f necessary when a si de rai l i s repai red, gri nd
the wel d smooth and i nstal l a rei nforcement channel
(Fi g. 4) over the repai red area.
CAUTION: A reinforcement should never be used on
the front section of the frame. The frame section
forward of the suspension mounts contains energy
management holes (Fig. 5). Reinforcing this area
may effect energy management.
NOTE: If a reinforcement is required, it should com-
pletely cover the repaired area. The reinforcement
should also overlap the top and bottom of the
frame by more than 50% of its width. Weld as indi-
cated (Fig. 4).
FRAME FASTENERS
Bol ts and nuts can be used to repai r frames or to
i nstal l a rei nforcement secti on on the frame.
Coni cal -type washers are preferred over the spl i t-
ri ng type l ock washers. Normal l y, grade-5 bol ts are
adequate for frame repai r. Grade-3 bolts or softer
should not be used. Ti ghteni ng bol ts/nuts wi th the
correct torque, refer to the I ntroducti on Group at the
front of thi s manual for ti ghteni ng i nformati on.
SPECIFICATIONS
FRAME DIMENSIONS
Frame di mensi ons are l i sted i n metri c scal e. Al l
di mensi ons are from center to center of Pri nci pl e
Locati ng Poi nt (PLP), or from center to center of PLP
and fastener l ocati on.
VEHICLE PREPARATION
Posi ti on the vehi cl e on a l evel work surface. Usi ng
screw or bottl e jacks, adjust the vehi cl e PLP hei ghts
to the speci fi ed di mensi on above a l evel work surface.
Verti cal di mensi ons can be taken from the work sur-
face to the l ocati ons i ndi cated were appl i cabl e.
INDEX
DESCRIPTION FIGURE
FRAME SIDE VIEW 6
FRAME TOP VIEW 7
FRAME SIDE VIEW LWB 8
FRAME TOP VIEW LWB 9
Fig. 4 FRAME REINFORCEMENT
1 - FRAME CENTER LINE
2 - FRAME
3 - FRAME REPAIR REINFORCEMENT
Fig. 5 ENERGY MANAGEMENT HOLES
1 - ENERGY MANAGEMENT HOLES
13 - 4 FRAME & BUMPERS TJ
FRAME (Continued)
F
i
g
.
6
F
R
A
M
E
S
I
D
E
V
I
E
W
TJ FRAME & BUMPERS 13 - 5
FRAME (Continued)
Fig. 7 FRAME TOP VIEW
13 - 6 FRAME & BUMPERS TJ
FRAME (Continued)
F
i
g
.
8
F
R
A
M
E
S
I
D
E
V
I
E
W
L
W
B
TJ FRAME & BUMPERS 13 - 7
FRAME (Continued)
F
i
g
.
9
F
R
A
M
E
T
O
P
V
I
E
W
L
W
B
13 - 8 FRAME & BUMPERS TJ
FRAME (Continued)
TRANSFER CASE SKID PLATE
REMOVAL
NOTE: The transmission and transfer case cross-
member is integrated with the transfer case skid
plate.
WARNING: THE TRANSFER CASE AND TRANSMIS-
SION ARE SUPPORTED BY THE TRANSFER CASE
SKID PLATE. BEFORE REMOVING THE TRANSFER
CASE SKID PLATE, ENSURE THAT THE TRANSMIS-
SION IS PROPERLY SUPPORTED.
(1) Rai se and support the vehi cl e. (Refer to
LUBRI CATI ON & MAI NTENANCE/HOI STI NG -
STANDARD PROCEDURE)
(2) Remove the transmi ssi on ski d pl ate, i f
equi pped. (Refer to 13 - FRAME & BUMPERS/
FRAME/FRONT SKI D PLATE - REMOVAL)
(3) Support the transmi ssi on wi th a sui tabl e l i fti ng
devi ce.
(4) Remove the nuts attachi ng the transmi ssi on
mount to the ski d pl ate. (Fi g. 10)
(5) Remove the bol ts attachi ng the ski d pl ate to
the frame and remove the ski d pl ate. (Fi g. 11)
INSTALLATION
(1) Posi ti on the ski d pl ate on the vehi cl e.
(2) I nstal l the bol ts attachi ng the ski d pl ate to the
frame and ti ghten to 74 N·m (55 ft. l bs.).
(3) I nstal l the nuts attachi ng the transmi ssi on
mount to the ski d pl ate and ti ghten to 35 N·m (26 ft.
l bs.).
(4) I nstal l the transmi ssi on ski d pl ate. (Refer to 13
- FRAME & BUMPERS/FRAME/FRONT SKI D
PLATE - I NSTALLATI ON)
Fig. 10 TRANSMISSION MOUNT (Auto shown,
manual similar)
1 - TRANSMISSION ASSEMBLY
2 - SUPPORT BRACKET BOLTS (4)
3 - TRANSMISSION MOUNT
4 - SKID PLATE/CROSSMEMBER NUTS (4)
5 - SKID PLATE/CROSSMEMBER
6 - MOUNT NUTS (4)
7 - SUPPORT BRACKET
Fig. 11 TRANSFER CASE SKID PLATE
1 - SKID PLATE
2 - BOLTS
3 - FRAME
TJ FRAME & BUMPERS 13 - 9
FUEL TANK SKID PLATE
REMOVAL
(1) Posi ti on a support under the fuel tank ski d
pl ate.
(2) Remove the protecti ve caps from the end of the
strap studs.
(3) Remove the nuts that attach the ski d pl ate to
the straps and to the crossmembers (Fi g. 12).
(4) Separate the fuel tank strap from the ski d
pl ate.
(5) Support the fuel tank and remove the ski d
pl ate from the vehi cl e.
INSTALLATION
(1) Attach the ski d pl ate to the fuel tank strap.
(2) Posi ti on and support the ski d pl ate under the
fuel tank.
(3) I nstal l the nuts to attach the ski d pl ate to the
straps and to the frame crossmembers. Ti ghten the
fuel tank strap nuts to 5 N·m (40 i n. l bs.). Ti ghten
the ski d pl ate-to-crossmember nuts wi th 16 N·m (138
i n. l bs.).
(4) I nstal l the protecti ve caps on the end of the
strap studs.
(5) Remove the support from under the ski d pl ate.
FRONT TOW HOOK
REMOVAL
(1) Remove the torx bol ts that attach the tow hook
to the bumper (Fi g. 13).
(2) Separate the tow hook from the bumper.
INSTALLATION
(1) Posi ti on the tow hook on the bumper.
(2) I nstal l the torx bol ts that attach the tow hook
to the bumper and ti ghten to 108 N·m (80 ft. l bs.).
Fig. 12 FUEL TANK SKID PLATE
1 - STRAP
2 - FRAME
3 - SKID PLATE
4 - PROTECTIVE CAP
5 - FUEL TANK
Fig. 13 FRONT TOW HOOK
1 - FRAME
2 - BUMPER
3 - TOW HOOK
13 - 10 FRAME & BUMPERS TJ
REAR TOW HOOK
REMOVAL
(1) Remove the fasteners that attach the rear tow
hook to the frame (Fi g. 14).
(2) Separate the tow hook from the frame.
INSTALLATION
(1) Posi ti on the tow hook on the frame.
(2) I nstal l the bol ts and ti ghten to 77 N·m (57 ft.
l bs.).
TRANSMISSION SKID PLATE
REMOVAL
(1) Rai se and support the vehi cl e. (Refer to
LUBRI CATI ON & MAI NTENANCE/HOI STI NG -
STANDARD PROCEDURE)
(2) Support the ski d pl ate.
(3) Remove the bol ts and remove the ski d pl ate.
(Fi g. 15)
INSTALLATION
(1) Posi ti on the ski d pl ate i n pl ace and support.
(2) I nstal l the bol ts and ti ghten the pl ate to frame
bol ts to 45 N·m (33 ft. l bs.).
(3) Ti ghten the pl ate to transfer case ski d pl ate
bol ts to 35 N·m (26 ft. l bs.).
Fig. 14 REAR TOW HOOK
1 - FRAME
2 - REAR BUMPER
3 - TOW HOOK
4 - BOLT
5 - NUT
Fig. 15 TRANSMISSION SKID PLATE
1 - FRONT BOLTS (2)
2 - REAR BOLTS (2)
3 - SKID PLATE
TJ FRAME & BUMPERS 13 - 11
FUEL SYSTEM
TABLE OF CONTENTS
page page
FUEL DELIVERY . . . . . . . . . . . . . . . . . . . . . . . . . . 1 FUEL INJECTION . . . . . . . . . . . . . . . . . . . . . . . . 21
FUEL DELIVERY
TABLE OF CONTENTS
page page
FUEL DELIVERY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
STANDARD PROCEDURE - FUEL SYSTEM
PRESSURE RELEASE . . . . . . . . . . . . . . . . . . . 2
SPECIFICATIONS
FUEL SYSTEM PRESSURE . . . . . . . . . . . . . . 3
TORQUE - FUEL DELIVERY . . . . . . . . . . . . . . 3
SPECIAL TOOLS
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 4
FUEL FILTER/PRESSURE REGULATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 5
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FUEL LEVEL SENDING UNIT / SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 6
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
FUEL LINES
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
FUEL PUMP
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
FUEL PUMP MODULE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 9
FUEL RAIL/FUEL DAMPER - 2.4L
DESCRIPTION - 2.4L . . . . . . . . . . . . . . . . . . . . 10
OPERATION - 2.4L . . . . . . . . . . . . . . . . . . . . . . 10
REMOVAL - 2.4L . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTALLATION - 2.4L . . . . . . . . . . . . . . . . . . . . 10
FUEL RAIL - 4.0L ENGINE
DESCRIPTION - 4.0L . . . . . . . . . . . . . . . . . . . . 12
OPERATION - 4.0L . . . . . . . . . . . . . . . . . . . . . . 12
REMOVAL - 4.0L . . . . . . . . . . . . . . . . . . . . . . . . 12
INSTALLATION - 4.0L . . . . . . . . . . . . . . . . . . . . 12
FUEL TANK
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 13
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 15
INLET FILTER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 17
QUICK CONNECT FITTING
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 17
STANDARD PROCEDURE - QUICK-CONNECT
FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
FLOW MANAGEMENT VALVE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 20
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
FUEL DELIVERY
DESCRIPTION
The fuel del i very system consi sts of:
• the fuel pump modul e contai ni ng the el ectri c
fuel pump, fuel fi l ter/fuel pressure regul ator, fuel
gauge sendi ng uni t (fuel l evel sensor) and a separate
fuel fi l ter l ocated at bottom of pump modul e
• fuel tubes/l i nes/hoses
• qui ck-connect fi tti ngs
• fuel i njector rai l
• fuel i njectors
• fuel tank
• fuel tank fi l l er/vent tube assembl y
TJ FUEL SYSTEM 14 - 1
• fuel tank fi l l er tube cap
• check val ve(s)
• accel erator pedal
• throttl e cabl e
OPERATION
Fuel i s returned through the fuel pump modul e
and back i nto the fuel tank through the fuel fi l ter/
fuel pressure regul ator. A separate fuel return l i ne
from the engi ne to the tank i s not used.
The fuel tank assembl y consi sts of: the fuel tank,
fuel pump modul e assembl y, fuel pump modul e l ock-
nut/gasket, and fuel tank check val ve (refer to Emi s-
si on Control System for fuel tank check val ve
i nformati on).
A fuel fi l l er/vent tube assembl y usi ng a pressure/
vacuum fuel fi l l er cap i s used. The fuel fi l l er tube
contai ns a fl ap door l ocated bel ow the fuel fi l l cap.
Al so to be consi dered part of the fuel system i s the
evaporati on control system. Thi s i s desi gned to
reduce the emi ssi on of fuel vapors i nto the atmo-
sphere. The descri pti on and functi on of the Evapora-
ti ve Control System i s l ocated i n Emi ssi on Control
Systems.
Both fuel fi l ters (at bottom of fuel pump modul e
and wi thi n fuel pressure regul ator) are desi gned for
extended servi ce. They do not requi re normal sched-
ul ed mai ntenance. Fi l ters shoul d onl y be repl aced i f
a di agnosti c procedure i ndi cates to do so.
STANDARD PROCEDURE - FUEL SYSTEM
PRESSURE RELEASE
Use following procedure if the fuel injector
rail is, or is not equipped with a fuel pressure
test port.
(1) Remove fuel fi l l cap.
(2) Remove fuel pump rel ay from Power Di stri bu-
ti on Center (PDC). For l ocati on of rel ay, refer to l abel
on undersi de of PDC cover.
(3) Start and run engi ne unti l i t stal l s.
(4) Attempt restarti ng engi ne unti l i t wi l l no
l onger run.
(5) Turn i gni ti on key to OFF posi ti on.
CAUTION: Steps 1, 2, 3 and 4 must be performed to
relieve high pressure fuel from within fuel rail. Do
not attempt to use following steps to relieve this
pressure as excessive fuel will be forced into a cyl-
inder chamber.
(6) Unpl ug connector from any fuel i njector.
(7) Attach one end of a jumper wi re wi th al l i gator
cl i ps (18 gauge or smal l er) to ei ther i njector termi nal .
(8) Connect other end of jumper wi re to posi ti ve
si de of battery.
(9) Connect one end of a second jumper wi re to
remai ni ng i njector termi nal .
CAUTION: Powering an injector for more than a few
seconds will permanently damage the injector.
(10) Momentari l y touch other end of jumper wi re
to negati ve termi nal of battery for no more than a
few seconds.
(11) Pl ace a rag or towel bel ow fuel l i ne qui ck-con-
nect fi tti ng at fuel rai l .
(12) Di sconnect qui ck-connect fi tti ng at fuel rai l .
Refer to Qui ck-Connect Fi tti ngs.
(13) Return fuel pump rel ay to PDC.
(14) One or more Di agnosti c Troubl e Codes (DTC’s)
may have been stored i n PCM memory due to fuel
pump rel ay removal . The DRB௡ scan tool must be
used to erase a DTC.
14 - 2 FUEL DELIVERY TJ
FUEL DELIVERY (Continued)
SPECIFICATIONS
FUEL SYSTEM PRESSURE
339 kPa +/- 34 kPa (49.2 psi +/- 2 psi ).
TORQUE - FUEL DELIVERY
DESCRIPTION N-m Ft. Lbs. In. Lbs.
Accelerator Pedal Bracket
Mounting Nuts
8.5 - 75
Fuel Hose Clamps 3 - 25
Fuel Rail Mounting Bolts -
2.4L
28 - 250
Fuel Rail Mounting Bolts
or Nuts - 4.0L
11 -
100
Fuel Tank Mounting Strap
Bolts
Refer to service manual
text.
- -
Fuel Pump Module
Locknut
74 55 -
Fuel Tank Skidplate Bolts 16 - 141
TJ FUEL DELIVERY 14 - 3
FUEL DELIVERY (Continued)
SPECIAL TOOLS
FUEL SYSTEM
FUEL PRESSURE TESTER - #8978
TEST KIT, FUEL PRESSURE, 8.0L ENGINE - #5069
ADAPTERS, FUEL PRESSURE TEST, 8.0L - #6539
AND/OR #6631
SPANNER WRENCH - #6856
FITTING, AIR METERING - #6714
O2S (OXYGEN SENSOR) REMOVER/INSTALLER -
#C-4907
14 - 4 FUEL DELIVERY TJ
FUEL DELIVERY (Continued)
FUEL FILTER/PRESSURE
REGULATOR
DESCRIPTION
The combi nati on fuel fi l ter and fuel pressure regul a-
tor i s l ocated on the top of fuel pump modul e (Fi g. 6).
OPERATION
A combi nati on fuel fi l ter and fuel pressure regul a-
tor i s used on al l engi nes. A separate frame mounted
fuel fi l ter i s not used wi th any engi ne.
Fuel Pressure Regulator Operation: The pres-
sure regul ator i s a mechani cal devi ce that i s not con-
trol l ed by engi ne vacuum or the Powertrai n Control
Modul e (PCM).
The regul ator i s cal i brated to mai ntai n fuel system
operati ng pressure of approxi matel y 339 ± 34 kPa
(49.2 ± 5 psi ) at the fuel i njectors. I t contai ns a di a-
phragm, cal i brated spri ngs and a fuel return val ve.
The i nternal fuel fi l ter i s al so part of the assembl y.
Fuel i s suppl i ed to the fi l ter/regul ator by the el ec-
tri c fuel pump through an openi ng tube at the bot-
tom of fi l ter/regul ator (Fi g. 3).
The regul ator acts as a check val ve to mai ntai n
some fuel pressure when the engi ne i s not operati ng.
Thi s wi l l hel p to start the engi ne. A second check
val ve i s l ocated at the outl et end of the el ectri c fuel
pump.
I f fuel pressure at the pressure regul ator exceeds
approxi matel y 49 psi , an i nternal di aphragm cl oses
and excess fuel pressure i s routed back i nto the tank
through the pressure regul ator. A separate fuel
return l i ne i s not used wi th any engi ne.
REMOVAL
The combi nati on Fuel Fi l ter/Fuel Pressure Regul a-
tor i s l ocated on the fuel pump modul e. The fuel
pump modul e i s l ocated on top of fuel tank.
(1) Remove fuel tank. Refer to Fuel Tank Removal /
I nstal l ati on.
(2) Cl ean area around fi l ter/regul ator.
(3) Di sconnect fuel l i ne at fi l ter/regul ator. Refer to
Qui ck-Connect Fi tti ngs i n thi s group for procedures.
(4) Remove retai ner cl amp from top of fi l ter/regu-
l ator (Fi g. 1). Cl amp snaps to tabs on pump modul e.
Di scard ol d cl amp.
(5) Pry fi l ter/regul ator from top of pump modul e
wi th 2 screwdri vers. Uni t i s snapped i nto modul e.
(6) Di scard gasket bel ow fi l ter/regul ator (Fi g. 2).
Fig. 1 Fuel Filter/Fuel Pressure Regulator
1 - RETAINER CLAMP
2 - FUEL FILTER/FUEL PRESSURE REGULATOR
3 - FUEL SUPPLY TUBE
4 - ALIGNMENT ARROW
Fig. 2 Fuel Filter/Fuel Pressure Regulator Gasket
1 - TOP OF MODULE
2 - GASKET
TJ FUEL DELIVERY 14 - 5
(7) Before di scardi ng fi l ter/regul ator assembl y,
i nspect assembl y to veri fy that o-ri ngs (Fi g. 3) are
i ntact. I f the smal l est of the two o-ri ngs can not be
found on bottom of fi l ter/regul ator, i t may be neces-
sary to remove i t from the fuel i nl et passage i n fuel
pump modul e.
INSTALLATION
The combi nati on Fuel Fi l ter/Fuel Pressure Regul a-
tor i s l ocated on the fuel pump modul e. The fuel
pump modul e i s l ocated on top of fuel tank.
(1) Cl ean recessed area i n pump modul e where fi l -
ter/regul ator i s to be i nstal l ed.
(2) Obtai n new fi l ter/regul ator (two new o-ri ngs
shoul d al ready be i nstal l ed) .
(3) Appl y a smal l amount of cl ean engi ne oi l to
o-ri ngs. Do not install o-rings separately into
fuel pump module. They will be damaged when
installing filter/regulator.
(4) I nstal l new gasket to top of fuel pump modul e.
(5) Press new fi l ter/regul ator i nto top of pump
modul e unti l i t snaps i nto posi ti on (a posi ti ve cl i ck
must be heard or fel t).
(6) The mol ded arrow (Fi g. 1) on top of fuel pump
modul e shoul d be poi nted towards front of vehi cl e (12
o’cl ock posi ti on).
(7) Rotate fi l ter/regul ator unti l fuel suppl y tube
(fi tti ng) i s poi nted to 10 o’cl ock posi ti on.
(8) I nstal l new retai ner cl amp (cl amp snaps over
top of fi l ter/regul ator and l ocks to fl anges on pump
modul e).
(9) Connect fuel l i ne at fi l ter/regul ator. Refer to
Qui ck-Connect Fi tti ngs i n thi s group for procedures.
(10) I nstal l fuel tank. Refer to Fuel Tank Removal /
I nstal l ati on.
FUEL LEVEL SENDING UNIT /
SENSOR
DESCRIPTION
The fuel gauge sendi ng uni t (fuel l evel sensor) i s
attached to the si de of the fuel pump modul e. The
sendi ng uni t consi sts of a fl oat, an arm, and a vari -
abl e resi stor track (card).
OPERATION
The fuel pump modul e has 4 di fferent ci rcui ts
(wi res). Two of these ci rcui ts are used for the fuel
gauge sendi ng uni t for fuel gauge operati on, and for
certai n OBD I I emi ssi on requi rements. The other 2
wi res are used for el ectri c fuel pump operati on.
For Fuel Gauge Operation: A constant i nput
vol tage source of about 12 vol ts (battery vol tage) i s
suppl i ed to the resi stor track on the fuel gauge send-
i ng uni t. Thi s i s fed di rectl y from the Powertrai n
Control Modul e (PCM). NOTE: For diagnostic pur-
poses, this 12V power source can only be veri-
fied with the circuit opened (fuel pump module
electrical connector unplugged). With the con-
nectors plugged, output voltages will vary from
about 0.6 volts at FULL, to about 8.6 volts at
EMPTY (about 8.6 volts at EMPTY for J eep
models, and about 7.0 volts at EMPTY for
Dodge Truck models). The resi stor track i s used to
vary the vol tage (resi stance) dependi ng on fuel tank
fl oat l evel . As fuel l evel i ncreases, the fl oat and arm
move up, whi ch decreases vol tage. As fuel l evel
decreases, the fl oat and arm move down, whi ch
i ncreases vol tage. The vari ed vol tage si gnal i s
returned back to the PCM through the sensor return
ci rcui t.
Both of the el ectri cal ci rcui ts between the fuel
gauge sendi ng uni t and the PCM are hard-wi red (not
mul ti -pl exed). After the vol tage si gnal i s sent from
the resi stor track, and back to the PCM, the PCM
wi l l i nterpret the resi stance (vol tage) data and send
a message across the mul ti -pl ex bus ci rcui ts to the
i nstrument panel cl uster. Here i t i s transl ated i nto
the appropri ate fuel gauge l evel readi ng. Refer to
I nstrument Panel for addi ti onal i nformati on.
For OBD II Emission Monitor Requirements:
The PCM wi l l moni tor the vol tage output sent from
the resi stor track on the sendi ng uni t to i ndi cate fuel
l evel . The purpose of thi s feature i s to prevent the
OBD I I system from recordi ng/setti ng fal se mi sfi re
and fuel system moni tor di agnosti c troubl e codes.
Fig. 3 Fuel Filter/Fuel Pressure Regulator
1 - FUEL FILTER/FUEL PRESSURE REGULATOR
2 - TO FUEL INJECTORS
3 - FUEL SUPPLY TUBE
4 - O-RINGS
5 - FUEL INLET FROM PUMP
6 - FUEL RETURN TO TANK
14 - 6 FUEL DELIVERY TJ
FUEL FILTER/PRESSURE REGULATOR (Continued)
The feature i s acti vated i f the fuel l evel i n the tank
i s l ess than approxi matel y 15 percent of i ts rated
capaci ty. I f equi pped wi th a Leak Detecti on Pump
(EVAP system moni tor), thi s feature wi l l al so be acti -
vated i f the fuel l evel i n the tank i s more than
approxi matel y 85 percent of i ts rated capaci ty.
REMOVAL
The fuel l evel sendi ng uni t (fuel l evel sensor) and
fl oat assembl y i s l ocated on the si de of fuel pump
modul e (Fi g. 4). The fuel pump modul e i s l ocated
wi thi n the fuel tank.
(1) Remove fuel tank. Refer to Fuel Tank Removal /
I nstal l ati on.
(2) Remove fuel pump modul e. Refer to Fuel Pump
Modul e Removal /I nstal l ati on.
(3) Remove el ectri cal wi re connector at sendi ng
uni t termi nal s.
(4) Press on rel ease tab (Fi g. 5) to remove sendi ng
uni t from pump modul e.
INSTALLATION
(1) Posi ti on sendi ng uni t to pump modul e and
snap i nto pl ace.
(2) Connect el ectri cal connector to termi nal s.
(3) I nstal l fuel pump modul e. Refer to Fuel Pump
Modul e Removal /I nstal l ati on.
(4) I nstal l fuel tank. Refer to Fuel Tank Removal /
I nstal l ati on.
FUEL LINES
DESCRIPTION
Al so refer to Qui ck-Connect Fi tti ngs.
WARNING: THE FUEL SYSTEM IS UNDER A CON-
STANT PRESSURE (EVEN WITH THE ENGINE OFF).
BEFORE SERVICING ANY FUEL SYSTEM HOSES,
FITTINGS OR LINES, THE FUEL SYSTEM PRES-
SURE MUST BE RELEASED. REFER TO THE FUEL
SYSTEM PRESSURE RELEASE PROCEDURE IN
THIS GROUP.
The l i nes/tubes/hoses used on fuel i njected vehi cl es
are of a speci al constructi on. Thi s i s due to the
hi gher fuel pressures and the possi bi l i ty of contami -
nated fuel i n thi s system. I f i t i s necessary to repl ace
these l i nes/tubes/hoses, onl y those marked EFM/EFI
may be used.
If equipped: The hose cl amps used to secure rub-
ber hoses on fuel i njected vehi cl es are of a speci al
rol l ed edge constructi on. Thi s constructi on i s used to
prevent the edge of the cl amp from cutti ng i nto the
hose. Onl y these rol l ed edge type cl amps may be
used i n thi s system. Al l other types of cl amps may
cut i nto the hoses and cause hi gh-pressure fuel l eaks.
Use new ori gi nal equi pment type hose cl amps.
Fig. 4 Fuel Level Sending Unit Location
1 - FUEL GAUGE FLOAT
2 - PICK-UP FILTER
3 - FUEL GAUGE SENDING UNIT
4 - FUEL FILTER/FUEL PRESSURE REGULATOR
5 - ELECTRIC FUEL PUMP
6 - PIGTAIL WIRING HARNESS
Fig. 5 Fuel Level Sending Unit Release Tab
1 - ELECTRICAL CONNECTOR
2 - FUEL GAUGE SENDING UNIT
3 - RELEASE TAB
4 - FUEL PUMP MODULE
TJ FUEL DELIVERY 14 - 7
FUEL LEVEL SENDING UNIT / SENSOR (Continued)
FUEL PUMP
DESCRIPTION
The el ectri c fuel pump i s l ocated i nsi de of the fuel
pump modul e. A 12 vol t, permanent magnet, el ectri c
motor powers the fuel pump. The el ectri c fuel pump
i s not a separate, servi ceabl e component.
OPERATION
Vol tage to operate the el ectri c pump i s suppl i ed
through the fuel pump rel ay.
Fuel i s drawn i n through a fi l ter at the bottom of
the modul e and pushed through the el ectri c motor
gearset to the pump outl et.
Check Valve Operation: The pump outl et con-
tai ns a one-way check val ve to prevent fuel fl ow back
i nto the tank and to mai ntai n fuel suppl y l i ne pres-
sure (engi ne warm) when pump i s not operati onal . I t
i s al so used to keep the fuel suppl y l i ne ful l of gaso-
l i ne when pump i s not operati onal . After the vehi cl e
has cool ed down, fuel pressure may drop to 0 psi
(col d fl ui d contracts), but l i qui d gasol i ne wi l l remai n
i n fuel suppl y l i ne between the check val ve and fuel
i njectors. Fuel pressure that has dropped to 0
psi on a cooled down vehicle (engine off) is a
normal condition. Refer to the Fuel Pressure Leak
Down Test for more i nformati on.
The el ectri c fuel pump i s not a separate, servi ce-
abl e component.
FUEL PUMP MODULE
DESCRIPTION
The fuel pump modul e on al l model s i s i nstal l ed
i nto the top of the fuel tank (Fi g. 6). The fuel pump
modul e contai ns the fol l owi ng components (Fi g. 6) or
(Fi g. 7):
• A combi nati on fuel fi l ter/fuel pressure regul ator
• A separate fuel pi ck-up fi l ter (strai ner)
• An el ectri c fuel pump
• A threaded l ocknut to retai n modul e to tank
• A gasket between tank fl ange and modul e
• Fuel gauge sendi ng uni t (fuel l evel sensor)
• Fuel suppl y tube (l i ne) connecti on
The fuel gauge sendi ng uni t, pi ck-up fi l ter and fuel
fi l ter/fuel pressure regul ator may be servi ced sepa-
ratel y. I f the el ectri cal fuel pump requi res servi ce,
the enti re fuel pump modul e must be repl aced.
Fig. 6 FUEL TANK/FUEL PUMP MODULE (TOP VIEW)
1 - VAPOR LINES (2) 8 - CHECK VALVE
2 - FUEL SUPPLY LINE 9 - FUEL MANAGEMENT VALVE
3 - ELECTRICAL CONNECTOR 10 - SKID PLATE
4 - MODULE LOCKNUT 11 - CHECK VALVE
5 - FUEL PUMP MODULE ASSEMBLY 12 - CLAMPS (2)
6 - FUEL FILTER/FUEL PRESSURE REGULATOR 13 - VENT LINE
7 - FUEL TANK STRAPS (2) 14 - FUEL FILL TUBE
14 - 8 FUEL DELIVERY TJ
OPERATION
Refer to Fuel Pump, Fuel Fi l ter/Fuel Pressure Reg-
ul ator and Fuel Gauge Sendi ng Uni t.
REMOVAL
Fuel tank removal wi l l be necessary for fuel pump
modul e removal .
WARNING: THE FUEL SYSTEM IS UNDER A CON-
STANT PRESSURE (EVEN WITH THE ENGINE OFF).
BEFORE SERVICING THE FUEL PUMP MODULE,
THE FUEL SYSTEM PRESSURE MUST BE
RELEASED.
(1) Drai n fuel tank and remove tank. Refer to the
Fuel Tank Removal /I nstal l ati on secti on of thi s group.
(2) Thoroughl y wash and cl ean area around pump
modul e to prevent contami nants from enteri ng tank.
(3) The pl asti c fuel pump modul e l ocknut i s
threaded onto fuel tank (Fi g. 6). I nstal l Speci al Tool
6856 to fuel pump modul e l ocknut and remove l ock-
nut (Fi g. 8). The fuel pump modul e wi l l spri ng up
when l ocknut i s removed.
(4) Remove modul e from fuel tank.
INSTALLATION
Fuel tank removal wi l l be necessary for fuel pump
modul e removal .
CAUTION: Whenever the fuel pump module is ser-
viced, the module gasket must be replaced.
(1) Thoroughl y cl ean l ocknut threads and mati ng
fuel tank threads. Use a soap/water sol uti on. Do not
use carburetor cl eaner to cl ean threads.
(2) Usi ng new gasket, posi ti on fuel pump modul e
i nto openi ng i n fuel tank.
(3) Appl y cl ean water to l ocknut threads.
(4) Posi ti on l ocknut over top of fuel pump modul e.
(5) Rotate modul e unti l arrow (Fi g. 1) i s poi nted
toward front of vehi cl e (12 o’cl ock posi ti on). Thi s step
must be done to prevent fl oat/fl oat rod assembl y from
contacti ng si des of fuel tank.
(6) I nstal l Speci al Tool 6856 to l ocknut.
(7) Ti ghten l ocknut to 74 N·m (55 ft. l bs.) torque.
(8) Rotate fuel fi l ter/fuel pressure regul ator unti l
i ts fi tti ng i s poi nted to 10 o’cl ock posi ti on.
(9) I nstal l fuel tank. Refer to Fuel Tank I nstal l a-
ti on.
Fig. 7 FUEL PUMP MODULE COMPONENTS
1 - FUEL GAUGE FLOAT
2 - PICK-UP FILTER
3 - FUEL GAUGE SENDING UNIT
4 - FUEL FILTER/FUEL PRESSURE REGULATOR
5 - ELECTRIC FUEL PUMP
6 - PIGTAIL WIRING HARNESS
Fig. 8 LOCKNUT REMOVAL/INSTALLATION—
TYPICAL
1 - SPECIAL TOOL #6856
2 - LOCKNUT
TJ FUEL DELIVERY 14 - 9
FUEL PUMP MODULE (Continued)
FUEL RAIL/FUEL DAMPER -
2.4L
DESCRIPTION - 2. 4L
The fuel i njector rai l i s used to mount the fuel
i njectors to the engi ne (Fi g. 9). On the 2.4L 4-cyl i n-
der engi ne, a fuel damper i s l ocated near the front
of the fuel rai l (Fi g. 9).
OPERATION - 2. 4L
The fuel i njector rai l suppl i es the necessary fuel to
each i ndi vi dual fuel i njector.
The fuel damper i s used onl y to hel p control fuel
pressure pul sati ons. These pul sati ons are the resul t
of the fi ri ng of the fuel i njectors. I t i s not used as a
fuel pressure regul ator. The fuel pressure regul ator i s
not mounted to the fuel rai l on any engi ne. I t i s
l ocated on the fuel tank mounted fuel pump modul e.
Refer to Fuel Pressure Regul ator for addi ti onal i nfor-
mati on.
The fuel rai l i s not repai rabl e.
A qui ck-connect fi tti ng wi th a safety l atch i s used
to attach the fuel l i ne to the fuel rai l .
REMOVAL - 2. 4L
WARNING: THE FUEL SYSTEM IS UNDER CON-
STANT PRESSURE EVEN WITH ENGINE OFF.
BEFORE SERVICING FUEL RAIL, FUEL SYSTEM
PRESSURE MUST BE RELEASED.
The fuel rai l can be removed wi thout removi ng the
i ntake mani fol d i f the fol l owi ng procedures are fol -
l owed.
(1) Remove fuel tank fi l l er tube cap.
(2) Perform Fuel System Pressure Rel ease Proce-
dure.
(3) Remove negati ve battery cabl e at battery.
(4) Remove ai r duct at throttl e body.
(5) Di sconnect fuel l i ne l atch cl i p and fuel l i ne at
fuel rai l . A speci al tool wi l l be necessary for fuel l i ne
di sconnecti on. Refer to Qui ck-Connect Fi tti ngs.
(6) Remove necessary vacuum l i nes at throttl e
body.
(7) Drai n engi ne cool ant and remove thermostat
and thermostat housi ng.
(8) Remove PCV hose and val ve at val ve cover.
(9) Remove 3 upper i ntake mani fol d mounti ng
bol ts (Fi g. 11), but onl y l oosen 2 l ower bol ts about 2
turns.
(10) Di sconnect 2 mai n engi ne harness connectors
at rear of i ntake mani fol d (Fi g. 10).
(11) Di sconnect 2 i njecti on wi ri ng harness cl i ps at
harness mounti ng bracket (Fi g. 11).
(12) Di sconnect el ectri cal connectors at al l 4 fuel
i njectors. To remove connector refer to (Fi g. 12). Push
red col ored sl i der away from i njector (1). Whi l e push-
i ng sl i der, depress tab (2) and remove connector (3)
from i njector. The factory fuel i njecti on wi ri ng har-
ness i s numeri cal l y tagged (I NJ 1, I NJ 2, etc.) for
i njector posi ti on i denti fi cati on. I f harness i s not
tagged, note wi ri ng l ocati on before removal .
(13) Remove 2 i njecti on rai l mounti ng bol ts (Fi g.
9).
(14) Gentl y rock and pul l fuel rai l unti l fuel i njec-
tors just start to cl ear machi ned hol es i n i ntake man-
i fol d.
(15) Remove fuel rai l (wi th i njectors attached)
from i ntake mani fol d.
(16) I f fuel i njectors are to be removed, refer to
Fuel I njector Removal /I nstal l ati on.
INSTALLATION - 2. 4L
(1) I f fuel i njectors are to be i nstal l ed, refer to Fuel
I njector Removal /I nstal l ati on.
(2) Cl ean out fuel i njector machi ned bores i n
i ntake mani fol d.
(3) Appl y a smal l amount of engi ne oi l to each fuel
i njector o-ri ng. Thi s wi l l hel p i n fuel rai l i nstal l ati on.
Fig. 9 FUEL RAIL - 2.4L
1 - FUEL RAIL
2 - MOUNTING BOLTS
3 - TEST PORT (IF USED)
4 - QUICK-CONNECT FITTING
5 - INJ. #1
6 - DAMPER
7 - INJ #2
8 - INJ #3
9 - INJ #4
10- INJECTOR RETAINING CLIP
14 - 10 FUEL DELIVERY TJ
(4) Posi ti on fuel rai l /fuel i njector assembl y to
machi ned i njector openi ngs i n i ntake mani fol d.
(5) Gui de each i njector i nto cyl i nder head. Be care-
ful not to tear i njector o-ri ngs.
(6) Push fuel rai l down unti l fuel i njectors have
bottomed on shoul ders.
(7) I nstal l 2 fuel rai l mounti ng bol ts and ti ghten.
Refer to torque speci fi cati ons.
(8) Connect el ectri cal connectors at al l fuel i njec-
tors. To i nstal l connector, refer to (Fi g. 12). Push con-
nector onto i njector (1) and then push and l ock red
col ored sl i der (2). Veri fy connector i s l ocked to i njec-
tor by l i ghtl y tuggi ng on connector.
(9) Snap 2 i njecti on wi ri ng harness cl i ps (Fi g. 11)
i nto brackets.
(10) Connect 2 mai n engi ne harness connectors at
rear of i ntake mani fol d (Fi g. 10).
(11) Ti ghten 5 i ntake mani fol d mounti ng bol ts.
Refer to Engi ne Torque Speci fi cati ons.
(12) I nstal l PCV val ve and hose.
(13) I nstal l thermostat and radi ator hose. Fi l l wi th
cool ant. Refer to Cool i ng.
(14) Connect necessary vacuum l i nes to throttl e
body.
(15) Connect fuel l i ne l atch cl i p and fuel l i ne to
fuel rai l . Refer to Qui ck-Connect Fi tti ngs.
(16) I nstal l ai r duct to throttl e body.
(17) Connect battery cabl e to battery.
(18) Start engi ne and check for l eaks.
Fig. 10 MAP SENSOR LOCATION - 2.4L
1 - REAR OF INTAKE MANIFOLD
2 - MAP SENSOR
3 - ALIGNMENT PIN
4 - MOUNTING BOLT (TORX)
5 - ELECTRICAL CONNECTOR
6 - MAIN ENGINE HARNESS CONNECTORS
Fig. 11 FUEL RAIL MOUNTING - 2.4L
1 - FUEL RAIL
2 - INJECTION HARNESS CLIPS
3 - LOWER MOUNTING HOLES
4 - UPPER MOUNTING HOLES
5 - INTAKE MANIFOLD
Fig. 12 REMOVE/INSTALL INJECTOR CONNECTOR
TJ FUEL DELIVERY 14 - 11
FUEL RAIL/FUEL DAMPER - 2.4L (Continued)
FUEL RAIL - 4.0L ENGINE
DESCRIPTION - 4. 0L
The fuel rai l i s mounted to the i ntake mani fol d
(Fi g. 13). I t i s used to mount the fuel i njectors to the
engi ne. On the 4.0L 6–cyl i nder engi ne, a fuel
damper i s l ocated near the center of the fuel rai l
(Fi g. 13).
OPERATION - 4. 0L
The fuel i njector rai l suppl i es the necessary fuel to
each i ndi vi dual fuel i njector.
The fuel damper i s used onl y to hel p control fuel
pressure pul sati ons. These pul sati ons are the resul t
of the fi ri ng of the fuel i njectors. I t i s not used as a
fuel pressure regul ator. The fuel pressure regul ator i s
not mounted to the fuel rai l on any engi ne. I t i s
l ocated on the fuel tank mounted fuel pump modul e.
Refer to Fuel Fi l ter/Fuel Pressure Regul ator for
i nformati on.
The fuel rai l i s not repai rabl e.
REMOVAL - 4. 0L
The fuel damper i s not servi ced separatel y.
WARNING: THE FUEL SYSTEM IS UNDER CON-
STANT FUEL PRESSURE EVEN WITH ENGINE OFF.
THIS PRESSURE MUST BE RELEASED BEFORE
SERVICING FUEL RAIL.
(1) Remove fuel tank fi l l er tube cap.
(2) Perform Fuel System Pressure Rel ease Proce-
dure.
(3) Di sconnect negati ve battery cabl e from battery.
(4) Remove ai r tube at top of throttl e body. Note:
Some engi ne/vehi cl es may requi re removal of ai r
cl eaner ducts at throttl e body.
(5) Di sconnect el ectri cal connectors at al l 6 fuel
i njectors. To remove connector refer to (Fi g. 14). Push
red col ored sl i der away from i njector (1). Whi l e push-
i ng sl i der, depress tab (2) and remove connector (3)
from i njector. The factory fuel i njecti on wi ri ng har-
ness i s numeri cal l y tagged (I NJ 1, I NJ 2, etc.) for
i njector posi ti on i denti fi cati on. I f harness i s not
tagged, note wi ri ng l ocati on before removal .
(6) Di sconnect fuel suppl y l i ne l atch cl i p and fuel
l i ne at fuel rai l . Refer to Qui ck-Connect Fi tti ngs.
(7) Di sconnect throttl e cabl e at throttl e body. Refer
to Throttl e Cabl e Removal /I nstal l ati on.
(8) Di sconnect speed control cabl e at throttl e body
(i f equi pped). Refer to Speed Control Cabl e i n Speed
Control System.
(9) Di sconnect automati c transmi ssi on cabl e at
throttl e body (i f equi pped).
(10) Remove cabl e routi ng bracket at i ntake man-
i fol d.
(11) I f equi pped, remove wi ri ng harnesses at i njec-
ti on rai l studs by removi ng nuts.
(12) Cl ean di rt/debri s from each fuel i njector at
i ntake mani fol d.
(13) Remove fuel rai l mounti ng nuts/bol ts (Fi g.
15).
(14) Remove fuel rai l by gentl y rocki ng unti l al l
the fuel i njectors are out of i ntake mani fol d.
INSTALLATION - 4. 0L
(1) Cl ean each i njector bore at i ntake mani fol d.
(2) Appl y a smal l amount of cl ean engi ne oi l to
each i njector o-ri ng. Thi s wi l l ai d i n i nstal l ati on.
(3) Posi ti on ti ps of al l fuel i njectors i nto the corre-
spondi ng i njector bore i n i ntake mani fol d. Seat i njec-
tors i nto mani fol d.
(4) I nstal l and ti ghten fuel rai l mounti ng bol ts to
11 ±3 N·m (100 ±25 i n. l bs.) torque.
(5) I f equi pped, connect wi ri ng harnesses to i njec-
ti on rai l studs.
(6) Connect el ectri cal connectors at al l fuel i njec-
tors. To i nstal l connector, refer to (Fi g. 14). Push con-
Fig. 13 FUEL RAIL/FUEL DAMPER - 4.0L ENGINE
1 - INJ. #1
2 - INJ. #2
3 - INJ. #3
4 - INJ. #4
5 - INJ. #5
6 - INJ. #6
7 - FUEL INJECTOR RAIL
8 - FUEL DAMPER
9 - PRESSURE TEST PORT CAP
10 - MOUNTING BOLTS (4)
11 - QUICK-CONNECT FITTING
14 - 12 FUEL DELIVERY TJ
nector onto i njector (1) and then push and l ock red
col ored sl i der (2). Veri fy connector i s l ocked to i njec-
tor by l i ghtl y tuggi ng on connector.
(7) Connect fuel l i ne and fuel l i ne l atch cl i p to fuel
rai l . Refer Qui ck-Connect Fi tti ngs.
(8) I nstal l protecti ve cap to pressure test port fi t-
ti ng (i f equi pped).
(9) I nstal l cabl e routi ng bracket to i ntake mani -
fol d.
(10) Connect throttl e cabl e at throttl e body.
(11) Connect speed control cabl e at throttl e body (i f
equi pped).
(12) Connect automati c transmi ssi on cabl e at
throttl e body (i f equi pped).
(13) I nstal l ai r tube (or duct) at top of throttl e
body.
(14) I nstal l fuel tank cap.
(15) Connect negati ve battery cabl e to battery.
(16) Start engi ne and check for fuel l eaks.
FUEL TANK
DESCRIPTION
The fuel tank i s constructed of a pl asti c materi al .
I ts mai n functi ons are for fuel storage and for pl ace-
ment of the fuel pump modul e.
OPERATION
Al l model s pass a ful l 360 degree rol l over test
wi thout fuel l eakage. To accompl i sh thi s, fuel and
vapor fl ow control s are requi red for al l fuel tank con-
necti ons.
A fuel tank check val ve(s) i s mounted i nto the top
of the fuel tank (or pump modul e). Refer to Fuel
Tank Check Val ve for addi ti onal i nformati on.
An evaporati on control system i s connected to the
check val ve(s) to reduce emi ssi ons of fuel vapors i nto
the atmosphere. When fuel evaporates from the fuel
tank, vapors pass through vent hoses or tubes to a
charcoal cani ster where they are temporari l y hel d.
When the engi ne i s runni ng, the vapors are drawn
i nto the i ntake mani fol d. Certai n model s are al so
equi pped wi th a sel f-di agnosi ng system usi ng ei ther
a Leak Detecti on Pump (LDP), or an NVLD pump.
Refer to Emi ssi on Control System for addi ti onal
i nformati on.
Refer to ORVR for On-Board Refuel i ng Vapor
Recovery system i nformati on.
Fig. 14 REMOVE/INSTALL FUEL INJECTOR
CONNECTOR
Fig. 15 FUEL RAIL MOUNTING - 4.0L
1 - INJ. #1
2 - INJ. #2
3 - INJ. #3
4 - INJ. #4
5 - INJ. #5
6 - INJ. #6
7 - FUEL INJECTOR RAIL
8 - FUEL DAMPER
9 - PRESSURE TEST PORT CAP
10 - MOUNTING BOLTS (4)
11 - QUICK-CONNECT FITTING
TJ FUEL DELIVERY 14 - 13
FUEL RAIL - 4.0L ENGINE (Continued)
REMOVAL
Thi s vehi cl e i s equi pped wi th an ORVR (On-Board
Refuel i ng Vapor Recovery) system. Because of thi s,
the fuel tank may be drai ned the conventi onal way
through the fi l l er cap openi ng.
On thi s model , the fuel tank i s mounted to the
vehi cl e ski d pl ate. The ski d pl ate i s mounted to vehi -
cl e body. The tank and ski d pl ate are removed as 1
assembl y.
(1) Remove fuel fi l l er cap.
(2) Perform the Fuel System Pressure Rel ease Pro-
cedure as descri bed el sewhere i n thi s group.
(3) Di sconnect negati ve battery cabl e.
(4) Usi ng an approved portabl e gasol i ne si phon/
storage tank, drai n fuel from tank through fi l l er cap
openi ng.
(5) Remove 8 screws retai ni ng pl asti c fuel fi l l er bezel
to body (Fi g. 16). Remove pl asti c fuel fi l l er bezel .
(6) To prevent contami nants from enteri ng tank,
temporari l y i nstal l fuel cap to fi l l hoses.
(7) Remove ri ght/rear ti re/wheel .
(8) Remove wheel house l i ner at ri ght/rear wheel .
(9) Remove verti cal support bracket (Fi g. 17) to
gai n access to 2 ORVR vapor l i nes.
(10) Two vapor l i nes connect the fuel tank to the
EVAP cani ster and Leak Detecti on Pump (LDP). Thi s
connecti on i s made near the ri ght/rear corner of the
fuel tank. Careful l y di sconnect these 2 vapor l i nes
(Fi g. 18) near top of fl ow management val ve (Fi g.
18). Be very careful not to bend or ki nk the vapor
Fig. 16 FUEL FILL HOSE AT BODY
1 - FILLER HOSE CLAMP
2 - BEZEL
3 - FUEL FILLER CAP
4 - BEZEL SCREWS (8)
5 - FUEL FILLER HOSE
6 - FUEL TANK
Fig. 17 EVAP CANISTER / LDP LOCATION
1 - RIGHT / REAR FENDER (WHEELHOUSE)
2 - BRACKET
3 - EVAP CANISTER
Fig. 18 DISCONNECTING ORVR VAPOR LINES
1 - EVAP CANISTER
2 - LDP FILTER
3 - LDP
4 - FLOW MANAGEMENT VALVE
5 - FUEL TANK
6 - VAPOR LINES (2)
14 - 14 FUEL DELIVERY TJ
FUEL TANK (Continued)
l i nes. I f l i nes l eak, a Di agnosti c Troubl e Code (DTC)
wi l l be set.
(11) Cut pl asti c ti e wrap securi ng rear axl e vent
hose to fuel fi l l hose.
(12) Di sconnect fuel tank el ectri cal connector at
l eft/front of fuel tank (Fi g. 19).
(13) Di sconnect 2 vapor l i nes (Fi g. 19) at l eft/front
of fuel tank.
(14) Di sconnect qui ck-connect fi tti ng from fuel sup-
pl y l i ne at front of fuel tank (Fi g. 19). Refer to Qui ck-
Connect Fi tti ngs i n thi s group for procedures.
(15) The fuel tank and ski d pl ate are removed as
an assembl y. Central l y posi ti on a transmi ssi on jack
(or equi val ent l i fti ng devi ce) under ski d pl ate/fuel
tank assembl y. Secure tank assembl y to jack.
(16) Remove three ski d pl ate-to-body nuts at front
of tank (Fi g. 21). Remove one of the nuts through
access hol e on ski d pl ate (Fi g. 21).
(17) Remove four ski d pl ate-to-body nuts at rear of
tank (Fi g. 20). Do not loosen tank strap nuts
(Fig. 20).
(18) Lower the tank assembl y.
(19) I f fuel pump modul e i s to be removed, refer to
Fuel Pump Modul e Removal /I nstal l ati on.
(20) Di sconnect fuel fi l l er hose at tank. Before di s-
connecti ng, mark and note the hose rotati onal posi -
ti on i n rel ati on to tank fi tti ng.
(21) To separate tank from ski d pl ate, remove two
protecti ve caps at tank strap studs (Fi g. 20) and
remove tank strap nuts.
(22) Remove both straps and remove tank from
ski d pl ate.
INSTALLATION
(1) I f necessary, i nstal l fuel pump modul e to fuel
tank. Refer to Fuel Pump Modul e Removal / I nstal -
l ati on.
(2) Pl ace fuel tank i nto ski d pl ate. Wrap straps
around tank wi th strap studs i nserted through hol es
i n ski d pl ate. Ti ghten strap nuts to attai n 30 mm (±2
mm) between bottom of nut to end of strap stud (Fi g.
20). Do not over tighten nuts.
(3) I nstal l two protecti ve caps to tank strap studs.
(4) Connect fuel fi l l hose at tank. Ti ghten hose
cl amp.
Fig. 19 FUEL TANK/FUEL PUMP MODULE (TOP VIEW)
1 - VAPOR LINES (2) 8 - CHECK VALVE
2 - FUEL SUPPLY LINE 9 - FUEL MANAGEMENT VALVE
3 - ELECTRICAL CONNECTOR 10 - SKID PLATE
4 - MODULE LOCKNUT 11 - CHECK VALVE
5 - FUEL PUMP MODULE ASSEMBLY 12 - CLAMPS (2)
6 - FUEL FILTER/FUEL PRESSURE REGULATOR 13 - VENT LINE
7 - FUEL TANK STRAPS (2) 14 - FUEL FILL TUBE
TJ FUEL DELIVERY 14 - 15
FUEL TANK (Continued)
(5) Rai se ski d pl ate/fuel tank assembl y i nto posi -
ti on on body whi l e careful l y gui di ng pl asti c vapor
l i nes and fi l l hose.
(6) I nstal l 7 ski d pl ate mounti ng nuts. Ti ghten to
16 N·m (141 i n. l bs.) torque.
(7) Remove tank jacki ng devi ce.
(8) Careful l y connect the 2 vapor l i nes (Fi g. 18)
near top of fl ow management val ve (Fi g. 18). Be very
careful not to bend or ki nk the vapor l i nes. I f l i nes
l eak, a Di agnosti c Troubl e Code (DTC) wi l l be set.
(9) I nstal l EVAP cani ster bracket (Fi g. 17).
(10) I nstal l wheel house l i ner at ri ght/rear wheel .
(11) I nstal l ri ght/rear ti re/wheel .
(12) Connect el ectri cal connector at l eft/front of
fuel tank.
(13) Connect 2 vapor l i nes at l eft/front of fuel tank.
(14) Connect qui ck-connect fi tti ng to fuel suppl y
l i ne at l eft/front of fuel tank. Refer to Qui ck-Connect
Fi tti ngs i n thi s group for procedures.
(15) Use a new pl asti c ti e wrap to secure rear axl e
vent hose to fuel fi l l hose.
(16) Posi ti on fuel fi l l bezel to body. I nstal l 8 screws
and ti ghten.
(17) Fi l l fuel tank. I nstal l fi l l er cap.
(18) Connect negati ve battery cabl e to battery.
(19) Start vehi cl e and i nspect for l eaks.
INLET FILTER
REMOVAL
The fuel pump i nl et fi l ter (strai ner) i s l ocated on
the bottom of fuel pump modul e (Fi g. 22). The fuel
pump modul e i s l ocated on top of fuel tank.
(1) Remove fuel tank. Refer to Fuel Tank Removal /
I nstal l ati on.
(2) Remove fuel pump modul e. Refer to Fuel Pump
Modul e Removal /I nstal l ati on.
(3) Remove fi l ter by pryi ng from bottom of modul e
wi th 2 screwdri vers. Fi l ter i s snapped to modul e.
(4) Cl ean bottom of pump modul e.
Fig. 20 FUEL TANK MOUNTING NUTS - REAR
1 - REAR SKID PLATE NUTS (4)
2 - SKID PLATE
3 - TANK STRAP STUD
4 - TANK STRAP NUT
5 - TANK STRAP NUTS (2)
6 - PROTECTIVE CAPS (2)
Fig. 21 FUEL TANK MOUNTING NUTS - FRONT
1 - FRONT SKID PLATE NUTS (3)
2 - SKID PLATE
3 - ACCESS HOLE
Fig. 22 Fuel Pump Inlet Filter
1 - FUEL PUMP MODULE
2 - FUEL PUMP INLET FILTER
14 - 16 FUEL DELIVERY TJ
FUEL TANK (Continued)
INSTALLATION
The fuel pump i nl et fi l ter (strai ner) i s l ocated on
the bottom of fuel pump modul e (Fi g. 23). The fuel
pump modul e i s l ocated on top of fuel tank.
(1) Snap new fi l ter to bottom of modul e.
(2) I nstal l fuel pump modul e. Refer to Fuel Pump
Modul e Removal /I nstal l ati on.
(3) I nstal l fuel tank. Refer to Fuel Tank Removal /
I nstal l ati on.
QUICK CONNECT FITTING
DESCRIPTION
Di fferent types of qui ck-connect fi tti ngs are used to
attach vari ous fuel system components, l i nes and tubes.
These are: a si ngl e-tab type, a two-tab type or a pl asti c
retai ner ri ng type. Some are equi pped wi th safety l atch
cl i ps. Some may requi re the use of a speci al tool for di s-
connecti on and removal . Refer to Qui ck-Connect Fi t-
ti ngs Removal /I nstal l ati on for more i nformati on.
CAUTION: The interior components (o-rings, clips)
of quick-connect fittings are not serviced sepa-
rately, but new plastic spacers are available for
some types. If service parts are not available, do
not attempt to repair the damaged fitting or fuel line
(tube). If repair is necessary, replace the complete
fuel line (tube) assembly.
STANDARD PROCEDURE - QUICK-CONNECT
FITTINGS
Al so refer to Fuel Tubes/Li nes/Hoses and Cl amps.
Di fferent types of qui ck-connect fi tti ngs are used to
attach vari ous fuel system components, l i nes and
tubes. These are: a si ngl e-tab type, a two-tab type or
a pl asti c retai ner ri ng type. Safety l atch cl i ps are
used on certai n components/l i nes. Certai n fi tti ngs
may requi re use of a speci al tool for di sconnecti on.
DISCONNECTING
WARNING: THE FUEL SYSTEM IS UNDER A CON-
STANT PRESSURE (EVEN WITH ENGINE OFF).
BEFORE SERVICING ANY FUEL SYSTEM HOSE,
FITTING OR LINE, FUEL SYSTEM PRESSURE MUST
BE RELEASED. REFER TO FUEL SYSTEM PRES-
SURE RELEASE PROCEDURE.
CAUTION: The interior components (o-rings, spac-
ers) of some types of quick-connect fitting are not
serviced separately. If service parts are not avail-
able, do not attempt to repair a damaged fitting or
fuel line. If repair is necessary, replace complete
fuel line assembly.
(1) Perform fuel pressure rel ease procedure. Refer
to Fuel Pressure Rel ease Procedure.
(2) Di sconnect negati ve battery cabl e from battery.
(3) Cl ean fi tti ng of any forei gn materi al before di s-
assembl y.
(4) 2–Button Type Fitting: Thi s type of fi tti ng i s
equi pped wi th a push-button l ocated on each si de of
qui ck-connect fi tti ng (Fi g. 24). Press on both buttons
si mul taneousl y for removal . Speci al tool s are not
requi red for di sconnecti on.
Fig. 23 Fuel Pump Inlet Filter
1 - FUEL PUMP MODULE
2 - FUEL PUMP INLET FILTER
Fig. 24 2-BUTTON TYPE FITTING
1 - QUICK-CONNECT FITTING
2 - PUSH-BUTTONS (2)
TJ FUEL DELIVERY 14 - 17
INLET FILTER (Continued)
(5) Pinch-Type Fitting: Thi s fi tti ng i s equi pped
wi th two fi nger tabs. Pi nch both tabs together whi l e
removi ng fi tti ng (Fi g. 25). Speci al tool s are not
requi red for di sconnecti on.
(6) Single-Tab Type Fitting: Thi s type of fi tti ng
i s equi pped wi th a si ngl e pul l tab (Fi g. 26). The tab
i s removabl e. After tab i s removed, qui ck-connect fi t-
ti ng can be separated from fuel system component.
Speci al tool s are not requi red for di sconnecti on.
(a) Press rel ease tab on si de of fi tti ng to rel ease
pul l tab (Fi g. 27). If release tab is not pressed
prior to releasing pull tab, pull tab will be
damaged.
(b) Whi l e pressi ng rel ease tab on si de of fi tti ng,
use screwdri ver to pry up pul l tab (Fi g. 27).
(c) Rai se pul l tab unti l i t separates from qui ck-
connect fi tti ng (Fi g. 28).
(7) Two-Tab Type Fitting: Thi s type of fi tti ng i s
equi pped wi th tabs l ocated on both si des of fi tti ng
(Fi g. 29). The tabs are suppl i ed for di sconnecti ng
qui ck-connect fi tti ng from component bei ng servi ced.
Fig. 26 SINGLE-TAB TYPE FITTING
1 - PULL TAB
2 - QUICK-CONNECT FITTING
3 - PRESS HERE TO REMOVE PULL TAB
4 - INSERTED TUBE END
Fig. 25 PINCH TYPE QUICK-CONNECT FITTING
1 - QUICK-CONNECT FITTINGS
2 - PINCH TABS
Fig. 27 DISCONNECTING SINGLE-TAB TYPE
FITTING
1 - PULL TAB
2 - SCREWDRIVER
3 - QUICK-CONNECT FITTING
Fig. 28 REMOVING PULL TAB
1 - FUEL TUBE OR FUEL SYSTEM COMPONENT
2 - PULL TAB
3 - QUICK-CONNECT FITTING
4 - FUEL TUBE STOP
14 - 18 FUEL DELIVERY TJ
QUICK CONNECT FITTING (Continued)
(a) To di sconnect qui ck-connect fi tti ng, squeeze
pl asti c retai ner tabs (Fi g. 29) agai nst si des of
qui ck-connect fi tti ng wi th your fi ngers. Tool use i s
not requi red for removal and may damage pl asti c
retai ner.
(b) Pul l fi tti ng from fuel system component
bei ng servi ced.
(c) The pl asti c retai ner wi l l remai n on compo-
nent bei ng servi ced after fi tti ng i s di sconnected.
The o-ri ngs and spacer wi l l remai n i n qui ck-con-
nect fi tti ng connector body.
(8) Plastic Retainer Ring Type Fitting: Thi s
type of fi tti ng can be i denti fi ed by the use of a ful l -
round pl asti c retai ner ri ng (Fi g. 30) usual l y bl ack i n
col or.
(a) To rel ease fuel system component from qui ck-
connect fi tti ng, fi rml y push fi tti ng towards compo-
Fig. 29 TYPICAL 2–TAB TYPE FITTING
1 - TAB(S)
2 - QUICK-CONNECT FITTING
Fig. 30 PLASTIC RETAINER RING TYPE FITTING
1 - FUEL TUBE
2 - QUICK CONNECT FITTING
3 - PUSH
4 - PLASTIC RETAINER
5 - PUSH
6 - PUSH
7 - PUSH
8 - PUSH
Fig. 31 LATCH CLIP-TYPE 1
1 - TETHER STRAP
2 - FUEL LINE
3 - SCREWDRIVER
4 - LATCH CLIP
5 - FUEL RAIL
Fig. 32 LATCH CLIP-TYPE 2
1 - LATCH CLIP
TJ FUEL DELIVERY 14 - 19
QUICK CONNECT FITTING (Continued)
nent bei ng servi ced whi l e fi rml y pushi ng pl asti c
retai ner ri ng i nto fi tti ng (Fi g. 30). Wi th pl asti c ri ng
depressed, pul l fi tti ng from component. The plas-
tic retainer ring must be pressed squarely
into fitting body. If this retainer is cocked
during removal, it may be difficult to discon-
nect fitting. Use an open-end wrench on
shoulder of plastic retainer ring to aid in dis-
connection.
(b) After di sconnecti on, pl asti c retai ner ri ng wi l l
remai n wi th qui ck-connect fi tti ng connector body.
(c) I nspect fi tti ng connector body, pl asti c retai ner
ri ng and fuel system component for damage.
Repl ace as necessary.
(9) Latch Clips: Dependi ng on vehi cl e model and
engi ne, 2 di fferent types of safety l atch cl i ps are used
(Fi g. 31) or (Fi g. 32). Type-1 i s tethered to fuel l i ne
and type-2 i s not. A speci al tool wi l l be necessary to
di sconnect fuel l i ne after l atch cl i p i s removed. The
l atch cl i p may be used on certai n fuel l i ne/fuel rai l
connecti on, or to joi n fuel l i nes together.
(a) Type 1: Pry up on l atch cl i p wi th a screw-
dri ver (Fi g. 31).
(b) Type 2: Separate and unl atch 2 smal l arms
on end of cl i p (Fi g. 32) and swi ng away from fuel
l i ne.
(c) Sl i de l atch cl i p toward fuel rai l whi l e l i fti ng
wi th screwdri ver.
(d) I nsert speci al fuel l i ne removal tool (Snap-On
number FI H 9055-1 or equi val ent) i nto fuel l i ne
(Fi g. 33). Use tool to rel ease l ocki ng fi ngers i n end
of l i ne.
(e) Wi th speci al tool sti l l i nserted, pul l fuel l i ne
from fuel rai l .
(f) After di sconnecti on, l ocki ng fi ngers wi l l
remai n wi thi n qui ck-connect fi tti ng at end of fuel
l i ne.
(10) Di sconnect qui ck-connect fi tti ng from fuel sys-
tem component bei ng servi ced.
CONNECTING
(1) I nspect qui ck-connect fi tti ng body and fuel sys-
tem component for damage. Repl ace as necessary.
(2) Pri or to connecti ng qui ck-connect fi tti ng to
component bei ng servi ced, check condi ti on of fi tti ng
and component. Cl ean parts wi th a l i nt-free cl oth.
Lubri cate wi th cl ean engi ne oi l .
(3) I nsert qui ck-connect fi tti ng i nto fuel tube or
fuel system component unti l bui l t-on stop on fuel
tube or component rests agai nst back of fi tti ng.
(4) Conti nue pushi ng unti l a cl i ck i s fel t.
(5) Si ngl e-tab type fi tti ng: Push new tab down
unti l i t l ocks i nto pl ace i n qui ck-connect fi tti ng.
(6) Veri fy a l ocked condi ti on by fi rml y pul l i ng on
fuel tube and fi tti ng (15-30 l bs.).
(7) Latch Cl i p Equi pped: I nstal l l atch cl i p (snaps
i nto posi ti on). If latch clip will not fit, this indi-
cates fuel line is not properly installed to fuel
rail (or other fuel line). Recheck fuel line con-
nection.
(8) Connect negati ve cabl e to battery.
(9) Start engi ne and check for l eaks.
FLOW MANAGEMENT VALVE
DESCRIPTION
The fl ow management val ve i s a part of the
On-Board Refuel i ng Vapor Recovery (ORVR) system.
Thi s pl asti c val ve i s pl aced i n-l i ne between the fuel
tank and the EVAP cani ster. I t i s l ocated near the
ri ght si de of the fuel tank (Fi g. 19).
OPERATION
The fl ow management val ve (Fi g. 19) i s one of the
components used i n the ORVR system. The val ve
meters the fl ow of fuel vapors to the EVAP cani ster
duri ng vehi cl e run and refuel i ng. Pressure from the
tank duri ng refuel i ng opens the mai n port val ve and
al l ows vapors to enter the EVAP cani ster. Duri ng
vehi cl e run, the vapors are metered through an ori -
fi ce to the EVAP cani ster. I t i s al so used as a l i qui d
separator to keep l i qui d fuel out of the EVAP cani s-
ter.
REMOVAL
The fuel tank must be l owered for fl ow manage-
ment val ve removal or repl acement. Refer to Fuel
Tank Removal /I nstal l ati on. The val ve i s repl aced as
an assembl y al ong wi th a vapor l i ne bundl e.
Fig. 33 FUEL LINE DISCONNECTION USING
SPECIAL TOOL
1 - SPECIAL FUEL LINE TOOL
2 - FUEL LINE
3 - FUEL RAIL
14 - 20 FUEL DELIVERY TJ
QUICK CONNECT FITTING (Continued)
FUEL INJ ECTION
TABLE OF CONTENTS
page page
FUEL INJECTION
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 21
SPECIFICATIONS
TORQUE - FUEL INJECTION . . . . . . . . . . . . . 22
ACCELERATOR PEDAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 22
CRANKSHAFT POSITION SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 23
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 25
FUEL INJECTOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 26
OPERATION
OPERATION - PCM OUTPUT . . . . . . . . . . . . 26
OPERATION - FUEL INJECTOR . . . . . . . . . . 27
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 27
FUEL PUMP RELAY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 27
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 28
IDLE AIR CONTROL MOTOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 28
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 29
INTAKE AIR TEMPERATURE SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 29
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 31
MAP SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 31
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 33
O2 HEATER RELAY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 33
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 33
O2 SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 33
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 36
THROTTLE BODY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 36
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 37
THROTTLE CONTROL CABLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 39
THROTTLE POSITION SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 40
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 41
FUEL INJ ECTION
DESCRIPTION
The Powertrai n Control Modul e (PCM) operates
the fuel i njecti on system. Refer to Powertrai n Control
Modul e i n El ectroni c Control Modul es for i nforma-
ti on.
TJ FUEL INJECTION 14 - 21
SPECIFICATIONS
TORQUE - FUEL INJECTION
DESCRIPTION N-m Ft. Lbs. In. Lbs.
Accelerator Pedal Bracket Mounting Nuts 8.5 - 75
Engine Coolant Temperature Sensor - 2.4L/4.0L 11 - 96
IAC Motor-To-Throttle Body Bolts - 2.4L/4.0L 7 - 60
Intake Manifold Air Temp. Sensor - 4.0L 28 20 -
MAP Sensor Mounting Screws - 2.4L/4.0L 3 - 25
Oxygen Sensor - 2.4L/4.0L 30 22 -
PCM Mounting Screws 4 - 35
Throttle Body Mounting Bolts - 2.4L/4.0L 11 - 100
Throttle Position Sensor Mounting Screws - 2.4L/4.0L 7 - 60
Vehicle Speed Sensor Mounting Bolt 2.2 - 20
ACCELERATOR PEDAL
REMOVAL
The accel erator pedal i s connected to the throttl e
body l i nkage by the throttl e cabl e. The cabl e i s pro-
tected by a pl asti c sheathi ng and i s connected to the
throttl e body l i nkage by a bal l socket. I t i s connected
to the upper part of the accel erator pedal arm by a
pl asti c retai ner (cl i p) (Fi g. 1). Thi s retai ner (cl i p)
snaps i nto the top of the accel erator pedal arm.
Retai ner tabs (bui l t i nto the cabl e sheathi ng) (Fi g. 1)
fasten the cabl e to the dash panel .
CAUTION: Be careful not to damage or kink the
cable core wire (within the cable sheathing) while
servicing the accelerator pedal or throttle cable.
(1) From i nsi de vehi cl e, hol d up accel erator pedal .
Remove pl asti c cabl e retai ner (cl i p) and throttl e cabl e
core wi re from upper end of accel erator pedal arm
(Fi g. 1). Pl asti c cabl e retai ner (cl i p) snaps i nto pedal
arm.
(2) Remove accel erator pedal mounti ng bracket
nuts.
(3) Remove accel erator pedal assembl y.
INSTALLATION
(1) Pl ace accel erator pedal assembl y over mount-
i ng studs protrudi ng from fl oor pan. Ti ghten mount-
i ng nuts to 8.5 N·m (75 i n. l bs.) torque.
(2) Sl i de throttl e cabl e i nto openi ng (sl ot) i n top of
pedal arm. An i ndex tab i s l ocated on pedal arm.
Rotate and push pl asti c cabl e retai ner (cl i p) i nto
accel erator pedal arm openi ng unti l i t snaps i nto
pl ace on i ndex tab.
(3) Before starti ng engi ne, operate accel erator
pedal to check for any bi ndi ng.
Fig. 1 Accelerator Pedal Mounting
1 - CABLE RETAINER
2 - SLOT
3 - MOUNTING STUDS (2)
4 - PEDAL/BRACKET ASSEMBLY
5 - MOUNTING STUDS
6 - RETAINER TABS
7 - CABLE
8 - CABLE STOP
14 - 22 FUEL INJECTION TJ
FUEL INJ ECTION (Continued)
CRANKSHAFT POSITION
SENSOR
DESCRIPTION
2. 4L
The Crankshaft Posi ti on (CKP) sensor i s mounted
i nto the ri ght front si de of the cyl i nder bl ock. I t i s
posi ti oned and bol ted i nto a machi ned hol e.
4. 0L
The Crankshaft Posi ti on (CKP) sensor i s l ocated
near the outer edge of the fl ywheel (starter ri ngear).
OPERATION
2. 4L
Engi ne speed and crankshaft posi ti on are provi ded
through the CKP (Crankshaft Posi ti on) sensor. The
sensor generates pul ses that are the i nput sent to the
Powertrai n Control Modul e (PCM). The PCM i nter-
prets the sensor i nput to determi ne the crankshaft
posi ti on. The PCM then uses thi s posi ti on, al ong wi th
other i nputs, to determi ne i njector sequence and i gni -
ti on ti mi ng.
The sensor i s a hal l effect devi ce combi ned wi th an
i nternal magnet. I t i s al so sensi ti ve to steel wi thi n a
certai n di stance from i t.
A tonewheel (targetwheel ) i s a part of the engi ne
crankshaft (Fi g. 2). Thi s tonewheel has sets of
notches at i ts outer edge.
The notches cause a pul se to be generated when
they pass under the sensor. The pul ses are the i nput
to the PCM.
4. 0L
Engi ne speed and crankshaft posi ti on are provi ded
through the CKP sensor. The sensor generates pul ses
that are the i nput sent to the Powertrai n Control
Modul e (PCM). The PCM i nterprets the sensor i nput
to determi ne the crankshaft posi ti on. The PCM then
uses thi s posi ti on, al ong wi th other i nputs, to deter-
mi ne i njector sequence and i gni ti on ti mi ng.
The sensor i s a hal l effect devi ce combi ned wi th an
i nternal magnet. I t i s al so sensi ti ve to steel wi thi n a
certai n di stance from i t.
The fl ywheel /dri ve pl ate has groups of four notches
at i ts outer edge. On 4.0L 6-cyl i nder engi nes there
are three sets of notches (Fi g. 3).
The notches cause a pul se to be generated when
they pass under the sensor. The pul ses are the i nput
to the PCM. For each engi ne revol uti on there are 3
groups of four pul ses generated on 4.0L 6-cyl i nder
engi nes.
The trai l i ng edge of the fourth notch, whi ch causes
the pul se, i s four degrees before top dead center
(TDC) of the correspondi ng pi ston.
The engi ne wi l l not operate i f the PCM does not
recei ve a CKP sensor i nput.
Fig. 2 CKP OPERATION - 2.4L
1 - NOTCHES
2 - CRANKSHAFT
Fig. 3 CKP OPERATION - 4.0L
1 - CRANKSHAFT POSITION SENSOR
2 - FLYWHEEL
3 - FLYWHEEL NOTCHES
TJ FUEL INJECTION 14 - 23
REMOVAL
2. 4L
The Crankshaft Posi ti on (CKP) sensor i s mounted
i nto the ri ght front si de of the cyl i nder bl ock (Fi g. 4).
I t i s posi ti oned and bol ted i nto a machi ned hol e.
(1) Di sconnect sensor el ectri cal connector.
(2) Remove sensor bol t.
(3) Careful l y twi st sensor from cyl i nder bl ock.
(4) Check condi ti on of sensor o-ri ng (Fi g. 5).
4. 0L
The crankshaft posi ti on (CKP) sensor i s mounted
to the transmi ssi on bel l housi ng near the rear of the
engi ne bl ock.
The sensor may be mounted to the transmi ssi on
wi th one of the fol l owi ng four di fferent confi gura-
ti ons:
• wi th one bol t to the ri ght si de of the transmi s-
si on i f equi pped wi th a 42RLE automati c transmi s-
si on (Fi g. 6).
Fig. 6 CKP (WITH 42RLE AUTO. TRANS.)
1 - CKP SENSOR
2 - MOUNTING BOLT
3 - ELEC. CONNECTOR
4 - TRANS. BELLHOUSING
Fig. 4 CKP SENSOR LOCATION - 2.4L
1 - RIGHT FRONT ENGINE MOUNT
2 - CKP SENSOR
3 - MOUNTING BOLT
4 - ELECTRICAL CONNECTOR
Fig. 5 CKP AND O-RING - 2.4L
1 - CKP SENSOR
2 - O-RING
14 - 24 FUEL INJECTION TJ
CRANKSHAFT POSITION SENSOR (Continued)
• wi th one bol t to the l eft si de of the transmi ssi on
(Fi g. 7). I f sensor i s equi pped wi th one mounti ng bol t,
it is adjustable..
• wi th two nuts to the l eft si de of the transmi ssi on
(Fi g. 8).
• wi th two bol ts to the l eft si de of the transmi s-
si on (Fi g. 9).
(1) Di sconnect sensor pi gtai l harness (el ectri cal
connector) from mai n el ectri cal harness.
(2) Dependi ng upon appl i cati on, remove ei ther sen-
sor mounti ng bol t(s) or nuts.
(3) Remove sensor from engi ne.
INSTALLATION
2. 4L
(1) Cl ean out machi ned hol e i n engi ne bl ock.
(2) Appl y a smal l amount of engi ne oi l to sensor
o-ri ng.
(3) I nstal l sensor i nto engi ne bl ock wi th a sl i ght
rocki ng acti on. Do not twi st sensor i nto posi ti on as
damage to o-ri ng may resul t.
CAUTION: Before tightening sensor mounting bolt,
be sure sensor is completely flush to cylinder
block. If sensor is not flush, damage to sensor
mounting tang may result.
(4) I nstal l mounti ng bol t and ti ghten to 28 N·m
(21 ft. l bs.) torque.
(5) Connect el ectri cal connector to sensor.
Fig. 7 CKP - ONE-BOLT MOUNTING (EXCEPT 42RLE
AUTO. TRANS.)
1 - SENSOR PIGTAIL
2 - CRANKSHAFT POSITION SENSOR
3 - MOUNTING BOLT
4 - TRANSMISSION HOUSING
5 - PAPER SPACER
6 - SLOTTED HOLE
Fig. 8 CKP - TWO-NUT MOUNTING
1 - TRANSMISSION BELLHOUSING
2 - MOUNTING NUTS (2)
3 - CRANKSHAFT POSITION SENSOR
4 - MOUNTING STUDS (2)
5 - RUBBER GROMMET
6 - SENSOR PIGTAIL
Fig. 9 CKP - TWO-BOLT MOUNTING
1 - TRANSMISSION BELLHOUSING
2 - MOUNTING BOLTS (2)
3 - CRANKSHAFT POSITION SENSOR
4 - RUBBER GROMMET
5 - SENSOR PIGTAIL
TJ FUEL INJECTION 14 - 25
CRANKSHAFT POSITION SENSOR (Continued)
4. 0L
Sensor With 1–Bolt Mounting (Equipped With
42 RLE Automatic Transmission):
(1) I nstal l sensor fl ush agai nst openi ng i n trans-
mi ssi on housi ng.
(2) I nstal l and ti ghten sensor mounti ng bol t to 12
N·m (9 ft. l bs.) torque.
(3) Connect el ectri cal connector to sensor.
Sensor With 2–Bolt Mounting:
(4) I nstal l sensor fl ush agai nst openi ng i n trans-
mi ssi on housi ng.
(5) I nstal l and ti ghten two sensor mounti ng bol ts
to 12 N·m (9 ft. l bs.) torque. The two sensor mount-
i ng bol ts are speci al l y machi ned to correctl y space
uni t to fl ywheel . Do not attempt to i nstal l any other
bol ts.
(6) Connect sensor pi gtai l harness el ectri cal con-
nector to mai n wi ri ng harness.
Sensor With 2–Nut Mounting:
(7) I nstal l and ti ghten two sensor mounti ng nuts
to 12 N·m (9 ft. l bs.) torque.
(8) Connect sensor pi gtai l harness el ectri cal con-
nector to mai n wi ri ng harness.
Sensor With One-Bolt Mounting (Not
Equipped With 42 RLE Automatic Transmis-
sion):
New repl acement sensors wi l l be equi pped wi th a
paper spacer gl ued to bottom of sensor. I f i nstal l i ng
(returni ng) a used sensor to vehi cl e, a new paper
spacer must be i nstal l ed to bottom of sensor. Thi s
spacer wi l l be ground off the fi rst ti me engi ne i s
started. I f spacer i s not used, sensor wi l l be broken
the fi rst ti me engi ne i s started.
(9) New Sensors: Be sure paper spacer i s i nstal l ed
to bottom of sensor. I f not, obtai n spacer
PN05252229.
(10) Used Sensors: Cl ean bottom of sensor and
i nstal l spacer PN05252229.
(11) I nstal l sensor i nto transmi ssi on bel l housi ng
hol e.
(12) Push sensor agai nst fl ywheel /dri ve pl ate. Wi th
sensor pushed agai nst fl ywheel /dri ve pl ate, ti ghten
mounti ng bol t to 7 N·m (60 i n. l bs.) torque.
(13) Connect sensor pi gtai l harness el ectri cal con-
nector to mai n wi ri ng harness.
FUEL INJ ECTOR
DESCRIPTION
An i ndi vi dual fuel i njector (Fi g. 10) i s used for each
i ndi vi dual cyl i nder.
OPERATION
OPERATION - PCM OUTPUT
The nozzl e ends of the i njectors are posi ti oned i nto
openi ngs i n the i ntake mani fol d just above the i ntake
val ve ports of the cyl i nder head. The engi ne wi ri ng
harness connector for each fuel i njector i s equi pped
wi th an attached numeri cal tag (I NJ 1, I NJ 2 etc.).
Thi s i s used to i denti fy each fuel i njector wi th i ts
respecti ve cyl i nder number.
The i njectors are energi zed i ndi vi dual l y i n a
sequenti al order by the Powertrai n Control Modul e
(PCM). The PCM wi l l adjust i njector pul se wi dth by
swi tchi ng the ground path to each i ndi vi dual i njector
on and off. I njector pul se wi dth i s the peri od of ti me
that the i njector i s energi zed. The PCM wi l l adjust
i njector pul se wi dth based on vari ous i nputs i t
recei ves.
Battery vol tage (12 vol ts +) i s suppl i ed to the i njec-
tors through the ASD rel ay. The ASD rel ay wi l l shut-
down the 12 vol t power source to the fuel i njectors i f
the PCM senses the i gni ti on i s on, but the engi ne i s
not runni ng. Thi s occurs after the engi ne has not
been runni ng for approxi matel y 1.8 seconds.
The PCM determi nes i njector on-ti me (pul se wi dth)
based on vari ous i nputs.
Fig. 10 FUEL INJECTOR - TYPICAL
1 - FUEL INJECTOR
2 - NOZZLE
3 - TOP (FUEL ENTRY)
14 - 26 FUEL INJECTION TJ
CRANKSHAFT POSITION SENSOR (Continued)
OPERATION - FUEL INJECTOR
The top (fuel entry) end of the i njector (Fi g. 10) i s
attached i nto an openi ng on the fuel rai l .
The fuel i njectors are el ectri cal sol enoi ds. The
i njector contai ns a pi ntl e that cl oses off an ori fi ce at
the nozzl e end. When el ectri c current i s suppl i ed to
the i njector, the armature and needl e move a short
di stance agai nst a spri ng, al l owi ng fuel to fl ow out
the ori fi ce. Because the fuel i s under hi gh pressure, a
fi ne spray i s devel oped i n the shape of a penci l
stream. The sprayi ng acti on atomi zes the fuel , add-
i ng i t to the ai r enteri ng the combusti on chamber.
The nozzl e (outl et) ends of the i njectors are posi -
ti oned i nto openi ngs i n the i ntake mani fol d just
above the i ntake val ve ports of the cyl i nder head.
The engi ne wi ri ng harness connector for each fuel
i njector i s equi pped wi th an attached numeri cal tag
(I NJ 1, I NJ 2 etc.). Thi s i s used to i denti fy each fuel
i njector.
The i njectors are energi zed i ndi vi dual l y i n a
sequenti al order by the powertrai n control modul e
(PCM). The PCM wi l l adjust i njector pul se wi dth by
swi tchi ng the ground path to each i ndi vi dual i njector
on and off. I njector pul se wi dth i s the peri od of ti me
that the i njector i s energi zed. The PCM wi l l adjust
i njector pul se wi dth based on vari ous i nputs i t
recei ves.
Battery vol tage i s suppl i ed to the i njectors through
the ASD rel ay.
The PCM determi nes i njector pul se wi dth based on
vari ous i nputs.
REMOVAL
(1) Remove fuel rai l . Refer to Fuel I njector Rai l
Removal i n thi s secti on.
(2) Di sconnect cl i p(s) that retai n fuel i njector(s) to
fuel rai l (Fi g. 11).
INSTALLATION
(1) I nstal l fuel i njector(s) i nto fuel rai l assembl y
and i nstal l retai ni ng cl i p(s).
(2) I f same i njector(s) i s bei ng rei nstal l ed, i nstal l
new o-ri ng(s).
(3) Appl y a smal l amount of cl ean engi ne oi l to
each i njector o-ri ng. Thi s wi l l ai d i n i nstal l ati on.
(4) I nstal l fuel rai l . Refer to Fuel Rai l I nstal l ati on.
(5) Start engi ne and check for fuel l eaks.
FUEL PUMP RELAY
DESCRIPTION
The 5–pi n, 12–vol t, fuel pump rel ay i s l ocated i n
the Power Di stri buti on Center (PDC). Refer to the
l abel on the PDC cover for rel ay l ocati on.
OPERATION
The Powertrai n Control Modul e (PCM) energi zes
the el ectri c fuel pump through the fuel pump rel ay.
The fuel pump rel ay i s energi zed by fi rst appl yi ng
battery vol tage to i t when the i gni ti on key i s turned
ON, and then appl yi ng a ground si gnal to the rel ay
from the PCM.
Whenever the i gni ti on key i s turned ON, the el ec-
tri c fuel pump wi l l operate. But, the PCM wi l l shut-
down the ground ci rcui t to the fuel pump rel ay i n
approxi matel y 1–3 seconds unl ess the engi ne i s oper-
ati ng or the starter motor i s engaged.
Fig. 11 FUEL INJECTOR MOUNTING
1 - INLET FITTING
2 - FUEL INJECTOR RAIL
3 - CLIP
4 - FUEL INJECTOR
TJ FUEL INJECTION 14 - 27
FUEL INJ ECTOR (Continued)
REMOVAL
The fuel pump rel ay i s l ocated i n the Power Di stri -
buti on Center (PDC) (Fi g. 12). Refer to l abel on PDC
cover for rel ay l ocati on.
(1) Remove PDC cover.
(2) Remove rel ay from PDC.
(3) Check condi ti on of rel ay termi nal s and PDC
connector termi nal s for damage or corrosi on. Repai r
i f necessary before i nstal l i ng rel ay.
(4) Check for pi n hei ght (pi n hei ght shoul d be the
same for al l termi nal s wi thi n the PDC connector).
Repai r i f necessary before i nstal l i ng rel ay.
INSTALLATION
The fuel pump rel ay i s l ocated i n the Power Di stri -
buti on Center (PDC) (Fi g. 12). Refer to l abel on PDC
cover for rel ay l ocati on.
(1) I nstal l rel ay to PDC.
(2) I nstal l cover to PDC.
IDLE AIR CONTROL MOTOR
DESCRIPTION
The I AC stepper motor i s mounted to the throttl e
body, and regul ates the amount of ai r bypassi ng the
control of the throttl e pl ate. As engi ne l oads and
ambi ent temperatures change, engi ne rpm changes.
A pi ntl e on the I AC stepper motor protrudes i nto a
passage i n the throttl e body, control l i ng ai r fl ow
through the passage. The I AC i s control l ed by the
Powertrai n Control Modul e (PCM) to mai ntai n the
target engi ne i dl e speed.
OPERATION
At i dl e, engi ne speed can be i ncreased by retract-
i ng the I AC motor pi ntl e and al l owi ng more ai r to
pass through the port, or i t can be decreased by
restri cti ng the passage wi th the pi ntl e and di mi ni sh-
i ng the amount of ai r bypassi ng the throttl e pl ate.
The I AC i s cal l ed a stepper motor because i t i s
moved (rotated) i n steps, or i ncrements. Openi ng the
I AC opens an ai r passage around the throttl e bl ade
whi ch i ncreases RPM.
The PCM uses the I AC motor to control i dl e speed
(al ong wi th ti mi ng) and to reach a desi red MAP dur-
i ng decel (keep engi ne from stal l i ng).
The I AC motor has 4 wi res wi th 4 ci rcui ts. Two of
the wi res are for 12 vol ts and ground to suppl y el ec-
tri cal current to the motor wi ndi ngs to operate the
stepper motor i n one di recti on. The other 2 wi res are
al so for 12 vol ts and ground to suppl y el ectri cal cur-
rent to operate the stepper motor i n the opposi te
di recti on.
To make the I AC go i n the opposi te di recti on, the
PCM just reverses pol ari ty on both wi ndi ngs. I f onl y
1 wi re i s open, the I AC can onl y be moved 1 step
(i ncrement) i n ei ther di recti on. To keep the I AC
motor i n posi ti on when no movement i s needed, the
PCM wi l l energi ze both wi ndi ngs at the same ti me.
Thi s l ocks the I AC motor i n pl ace.
I n the I AC motor system, the PCM wi l l count
every step that the motor i s moved. Thi s al l ows the
PCM to determi ne the motor pi ntl e posi ti on. I f the
memory i s cl eared, the PCM no l onger knows the
posi ti on of the pi ntl e. So at the fi rst key ON, the
PCM dri ves the I AC motor cl osed, regardl ess of
where i t was before. Thi s zeros the counter. From
thi s poi nt the PCM wi l l back out the I AC motor and
keep track of i ts posi ti on agai n.
When engi ne rpm i s above i dl e speed, the I AC i s
used for the fol l owi ng:
• Off-i dl e dashpot (throttl e bl ade wi l l cl ose qui ckl y
but i dl e speed wi l l not stop qui ckl y)
• Decel erati on ai r fl ow control
• A/C compressor l oad control (al so opens the pas-
sage sl i ghtl y before the compressor i s engaged so
that the engi ne rpm does not di p down when the
compressor engages)
• Power steeri ng l oad control
The PCM can control pol ari ty of the ci rcui t to con-
trol di recti on of the stepper motor.
IAC Stepper Motor Program: The PCM i s al so
equi pped wi th a memory program that records the
number of steps the I AC stepper motor most recentl y
advanced to duri ng a certai n set of parameters. For
exampl e: The PCM was attempti ng to mai ntai n a
1000 rpm target duri ng a col d start-up cycl e. The l ast
recorded number of steps for that may have been
125. That val ue woul d be recorded i n the memory
Fig. 12 Power Distribution Center (PDC)
1 - BATTERY
2 - POWER DISTRIBUTION CENTER (PDC)
14 - 28 FUEL INJECTION TJ
FUEL PUMP RELAY (Continued)
cel l so that the next ti me the PCM recogni zes the
i denti cal condi ti ons, the PCM recal l s that 125 steps
were requi red to mai ntai n the target. Thi s program
al l ows for greater customer sati sfacti on due to
greater control of engi ne i dl e.
Another functi on of the memory program, whi ch
occurs when the power steeri ng swi tch (i f equi pped),
or the A/C request ci rcui t, requi res that the I AC step-
per motor control engi ne rpm, i s the recordi ng of the
l ast targeted steps i nto the memory cel l . The PCM
can anti ci pate A/C compressor l oads. Thi s i s accom-
pl i shed by del ayi ng compressor operati on for approx-
i matel y 0.5 seconds unti l the PCM moves the I AC
stepper motor to the recorded steps that were l oaded
i nto the memory cel l . Usi ng thi s program hel ps el i m-
i nate i dl e-qual i ty changes as l oads change. Fi nal l y,
the PCM i ncorporates a ЉNo-LoadЉ engi ne speed l i m-
i ter of approxi matel y 1800 - 2000 rpm, when i t rec-
ogni zes that the TPS i s i ndi cati ng an i dl e si gnal and
I AC motor cannot mai ntai n engi ne i dl e.
A (factory adjusted) set screw i s used to mechani -
cal l y l i mi t the posi ti on of the throttl e body throttl e
pl ate. Never attempt to adjust the engine idle
speed using this screw. Al l i dl e speed functi ons are
control l ed by the I AC motor through the PCM.
REMOVAL
2. 4L
The I dl e Ai r Control (I AC) motor i s l ocated on the
rear si de of the throttl e body (Fi g. 13).
(1) Di sconnect el ectri cal connector from I AC motor.
(2) Remove two mounti ng bol ts (screws).
(3) Remove I AC motor from throttl e body.
4. 0L
The I AC motor i s l ocated on the si de of the throttl e
body.
(1) Remove ai r cl eaner tube at throttl e body.
(2) Di sconnect el ectri cal connector from I AC motor.
(3) Remove two mounti ng bol ts (screws) (Fi g. 14).
(4) Remove I AC motor from throttl e body.
INSTALLATION
(1) I nstal l I AC motor to throttl e body.
(2) I nstal l and ti ghten two mounti ng bol ts (screws)
to 7 N·m (60 i n. l bs.) torque.
(3) I nstal l el ectri cal connector.
(4) I nstal l ai r cl eaner tube to throttl e body.
INTAKE AIR TEMPERATURE
SENSOR
DESCRIPTION
The 2–wi re I ntake Mani fol d Ai r Temperature (I AT)
sensor i s i nstal l ed i n the i ntake mani fol d wi th the
sensor el ement extendi ng i nto the ai r stream.
The I AT sensor i s a two-wi re Negati ve Thermal
Coeffi ci ent (NTC) sensor. Meani ng, as i ntake mani -
fol d temperature i ncreases, resi stance (vol tage) i n the
sensor decreases. As temperature decreases, resi s-
tance (vol tage) i n the sensor i ncreases.
Fig. 13 TPS/IAC MOTOR - 2.4L
1 - THROTTLE POSITION SENSOR (TPS)
2 - MOUNTING SCREWS
3 - IDLE AIR CONTROL MOTOR (IAC)
4 - MOUNTING SCREWS
Fig. 14 MOUNTING BOLTS
1 - IDLE AIR CONTROL MOTOR
2 - MOUNTING SCREWS
TJ FUEL INJECTION 14 - 29
IDLE AIR CONTROL MOTOR (Continued)
OPERATION
The I AT sensor provi des an i nput vol tage to the
Powertrai n Control Modul e (PCM) i ndi cati ng the
densi ty of the ai r enteri ng the i ntake mani fol d based
upon i ntake mani fol d temperature. At key-on, a
5–vol t power ci rcui t i s suppl i ed to the sensor from
the PCM. The sensor i s grounded at the PCM
through a l ow-noi se, sensor-return ci rcui t.
The PCM uses thi s i nput to cal cul ate the fol l owi ng:
• I njector pul se-wi dth
• Adjustment of spark ti mi ng (to hel p prevent
spark knock wi th hi gh i ntake mani fol d ai r-charge
temperatures)
The resi stance val ues of the I AT sensor i s the same
as for the Engi ne Cool ant Temperature (ECT) sensor.
REMOVAL
2. 4L
The i ntake mani fol d ai r temperature (I AT) sensor
i s i nstal l ed i nto the i ntake mani fol d pl enum at the
rear end of the i ntake mani fol d (Fi g. 15).
(1) Di sconnect el ectri cal connector from I AT sensor.
(2) Cl ean di rt from i ntake mani fol d at sensor base.
(3) Gentl y l i ft on smal l pl asti c rel ease tab (Fi g. 15)
or (Fi g. 16) and rotate sensor about 1/4 turn counter-
cl ockwi se for removal .
(4) Check condi ti on of sensor o-ri ng (Fi g. 16).
4. 0L
The i ntake mani fol d ai r temperature (I AT) sensor
i s i nstal l ed i nto i ntake mani fol d pl enum near throttl e
body (Fi g. 17).
(1) Di sconnect el ectri cal connector from I AT sensor.
(2) Remove sensor from i ntake mani fol d.
Fig. 15 IAT SENSOR - 2.4L
1 - RELEASE TAB
2 - IAT SENSOR
3 - PRESS HERE FOR REMOVAL
4 - ELECTRICAL CONNECTOR
5 - REAR END OF INTAKE MANIFOLD
Fig. 16 IAT SENSOR TAB / O-RING - 2.4L
1 - IAT SENSOR
2 - SENSOR O-RING
3 - RELEASE TAB
Fig. 17 IAT SENSOR - 4.0L
1 - MOUNTING BOLTS (4)
2 - THROTTLE BODY
3 - IAC MOTOR
4 - ELEC. CONN.
5 - TPS
6 - MAP SENSOR
7 - ELEC. CONN.
8 - IAT SENSOR
9 - ELEC. CONN.
14 - 30 FUEL INJECTION TJ
INTAKE AIR TEMPERATURE SENSOR (Continued)
INSTALLATION
2. 4L
(1) Check condi ti on of sensor o-ri ng.
(2) Cl ean sensor mounti ng hol e i n i ntake mani fol d.
(3) Posi ti on sensor i nto i ntake mani fol d and rotate
cl ockwi se unti l past rel ease tab.
(4) I nstal l el ectri cal connector.
4. 0L
(1) I nstal l I AT sensor i nto i ntake mani fol d.
Ti ghten sensor to 28 N·m (20 ft. l bs.) torque.
(2) Connect el ectri cal connector to sensor.
MAP SENSOR
DESCRIPTION
2. 4L
The Mani fol d Absol ute Pressure (MAP) sensor i s
mounted i nto the rear of the i ntake mani fol d wi th 1
screw.
4. 0L Early
The Mani fol d Absol ute Pressure (MAP) sensor i s
attached to the si de of the engi ne throttl e body wi th
2 screws. The sensor i s connected to the throttl e body
wi th a rubber L-shaped fi tti ng.
4. 0L Late
The Mani fol d Absol ute Pressure (MAP) sensor i s
attached to the si de of the engi ne throttl e body wi th
1 screw. The sensor i s connected to the throttl e body
wi th a rubber L-shaped fi tti ng.
OPERATION
The MAP sensor i s used as an i nput to the Power-
trai n Control Modul e (PCM). I t contai ns a si l i con
based sensi ng uni t to provi de data on the mani fol d
vacuum that draws the ai r/fuel mi xture i nto the com-
busti on chamber. The PCM requi res thi s i nformati on
to determi ne i njector pul se wi dth and spark advance.
When mani fol d absol ute pressure (MAP) equal s
Barometri c pressure, the pul se wi dth wi l l be at max-
i mum.
A 5 vol t reference i s suppl i ed from the PCM and
returns a vol tage si gnal to the PCM that refl ects
mani fol d pressure. The zero pressure readi ng i s 0.5V
and ful l scal e i s 4.5V. For a pressure swi ng of 0–15
psi , the vol tage changes 4.0V. To operate the sensor,
i t i s suppl i ed a regul ated 4.8 to 5.1 vol ts. Ground i s
provi ded through the l ow-noi se, sensor return ci rcui t
at the PCM.
The MAP sensor i nput i s the number one contri b-
utor to fuel i njector pul se wi dth. The most i mportant
functi on of the MAP sensor i s to determi ne baromet-
ri c pressure. The PCM needs to know i f the vehi cl e i s
at sea l evel or at a hi gher al ti tude, because the ai r
densi ty changes wi th al ti tude. I t wi l l al so hel p to cor-
rect for varyi ng barometri c pressure. Barometri c
pressure and al ti tude have a di rect i nverse correl a-
ti on; as al ti tude goes up, barometri c goes down. At
key-on, the PCM powers up and l ooks at MAP vol t-
age, and based upon the vol tage i t sees, i t knows the
current barometri c pressure (rel ati ve to al ti tude).
Once the engi ne starts, the PCM l ooks at the vol tage
agai n, conti nuousl y every 12 mi l l i seconds, and com-
pares the current vol tage to what i t was at key-on.
The di fference between current vol tage and what i t
was at key-on, i s mani fol d vacuum.
Duri ng key-on (engi ne not runni ng) the sensor
reads (updates) barometri c pressure. A normal range
can be obtai ned by moni tori ng a known good sensor.
As the al ti tude i ncreases, the ai r becomes thi nner
(l ess oxygen). I f a vehi cl e i s started and dri ven to a
very di fferent al ti tude than where i t was at key-on,
the barometri c pressure needs to be updated. Any
ti me the PCM sees Wi de Open Throttl e (WOT), based
upon Throttl e Posi ti on Sensor (TPS) angl e and RPM,
i t wi l l update barometri c pressure i n the MAP mem-
ory cel l . Wi th peri odi c updates, the PCM can make
i ts cal cul ati ons more effecti vel y.
The PCM uses the MAP sensor i nput to ai d i n cal -
cul ati ng the fol l owi ng:
• Mani fol d pressure
• Barometri c pressure
• Engi ne l oad
• I njector pul se-wi dth
• Spark-advance programs
• Shi ft-poi nt strategi es (certai n automati c trans-
mi ssi ons onl y)
• I dl e speed
• Decel fuel shutoff
The MAP sensor si gnal i s provi ded from a si ngl e
pi ezoresi sti ve el ement l ocated i n the center of a di a-
phragm. The el ement and di aphragm are both made
of si l i cone. As mani fol d pressure changes, the di a-
phragm moves causi ng the el ement to defl ect, whi ch
stresses the si l i cone. When si l i cone i s exposed to
stress, i ts resi stance changes. As mani fol d vacuum
i ncreases, the MAP sensor i nput vol tage decreases
proporti onal l y. The sensor al so contai ns el ectroni cs
that condi ti on the si gnal and provi de temperature
compensati on.
The PCM recogni zes a decrease i n mani fol d pres-
sure by moni tori ng a decrease i n vol tage from the
readi ng stored i n the barometri c pressure memory
cel l . The MAP sensor i s a l i near sensor; meani ng as
pressure changes, vol tage changes proporti onatel y.
The range of vol tage output from the sensor i s usu-
al l y between 4.6 vol ts at sea l evel to as l ow as 0.3
TJ FUEL INJECTION 14 - 31
INTAKE AIR TEMPERATURE SENSOR (Continued)
vol ts at 26 i n. of Hg. Barometri c pressure i s the pres-
sure exerted by the atmosphere upon an object. At
sea l evel on a standard day, no storm, barometri c
pressure i s approxi matel y 29.92 i n Hg. For every 100
feet of al ti tude, barometri c pressure drops 0.10 i n.
Hg. I f a storm goes through, i t can change baromet-
ri c pressure from what shoul d be present for that
al ti tude. You shoul d know what the average pressure
and correspondi ng barometri c pressure i s for your
area.
REMOVAL
2. 4L
The Mani fol d Absol ute Pressure (MAP) sensor i s
mounted i nto the rear of the i ntake mani fol d (Fi g.
18). An o-ri ng i s used to seal the sensor to the i ntake
mani fol d (Fi g. 19).
(1) Di sconnect el ectri cal connector at sensor.
(2) Cl ean area around MAP sensor.
(3) Remove sensor mounti ng screw (TORX head).
(4) Remove MAP sensor from i ntake mani fol d.
(5) Check condi ti on of sensor o-ri ng (Fi g. 19).
4. 0L Early
An L-shaped rubber fi tti ng i s used to connect the
MAP sensor to throttl e body (Fi g. 20).
(1) Remove ai r cl eaner i ntake tube at throttl e
body.
(2) Remove two MAP sensor mounti ng bol ts
(screws) (Fi g. 20).
(3) Whi l e removi ng MAP sensor, sl i de the rubber
L-shaped fi tti ng (Fi g. 20) from throttl e body.
(4) Remove rubber L-shaped fi tti ng from MAP sen-
sor.
4. 0L Late
An L-shaped rubber fi tti ng i s used to connect the
MAP sensor to throttl e body (Fi g. 21).
Fig. 18 MAP SENSOR LOCATION - 2.4L
1 - REAR OF INTAKE MANIFOLD
2 - MAP SENSOR
3 - ALIGNMENT PIN
4 - MOUNTING BOLT (TORX)
5 - ELECTRICAL CONNECTOR
6 - MAIN ENGINE HARNESS CONNECTORS
Fig. 19 MAP SENSOR O-RING - 2.4L
1 - MAP SENSOR
2 - O-RING
Fig. 20 4.0L MAP SENSOR MOUNTING - EARLY
1 - THROTTLE BODY
2 - MAP SENSOR
3 - RUBBER FITTING
4 - MOUNTING SCREWS (2)
14 - 32 FUEL INJECTION TJ
MAP SENSOR (Continued)
(1) Remove ai r cl eaner i ntake tube at throttl e
body.
(2) Remove MAP sensor mounti ng bol t (screw)
(Fi g. 21).
(3) Whi l e removi ng MAP sensor, sl i de the rubber
L-shaped fi tti ng (Fi g. 21) from throttl e body.
(4) Remove rubber L-shaped fi tti ng from MAP sen-
sor.
INSTALLATION
2. 4L
(1) Cl ean MAP sensor mounti ng hol e at i ntake
mani fol d.
(2) Check MAP sensor o-ri ng seal for cuts or tears.
(3) Posi ti on sensor i nto mani fol d.
(4) I nstal l MAP sensor mounti ng screws. Ti ghten
screw to 3 N·m (25 i n. l bs.) torque.
(5) Connect el ectri cal connector.
4. 0L
(1) I nstal l rubber L-shaped fi tti ng to MAP sensor.
(2) Posi ti on sensor to throttl e body whi l e gui di ng
rubber fi tti ng over throttl e body vacuum ni ppl e.
(3) I nstal l MAP sensor mounti ng bol t(s) (screws).
Ti ghten screw(s) to 3 N·m (25 i n. l bs.) torque.
(4) I nstal l ai r cl eaner i ntake tube.
(5) Connect el ectri cal connector.
O2 HEATER RELAY
DESCRIPTION
The oxygen (O2) sensor heater rel ay i s l ocated i n
the Powertrai n Di stri buti on Center (PDC).
OPERATION
Refer to Oxygen Sensor for oxygen sensor rel ay
i nformati on.
REMOVAL
The oxygen sensor heater rel ay i s l ocated i n the
Power Di stri buti on Center (PDC). Refer to l abel on
PDC cover for rel ay l ocati on.
(1) Remove PDC cover.
(2) Remove rel ay from PDC.
(3) Check condi ti on of rel ay termi nal s and PDC
connector termi nal s for damage or corrosi on. Repai r
i f necessary before i nstal l i ng rel ay.
(4) Check for pi n hei ght (pi n hei ght shoul d be the
same for al l termi nal s wi thi n the PDC connector).
Repai r i f necessary before i nstal l i ng rel ay.
INSTALLATION
The oxygen sensor heater rel ay i s l ocated i n the
Power Di stri buti on Center (PDC). Refer to l abel on
PDC cover for rel ay l ocati on.
(1) I nstal l rel ay to PDC.
(2) I nstal l cover to PDC.
O2 SENSOR
DESCRIPTION
The Oxygen Sensors (O2S) are attached to, and
protrude i nto the vehi cl e exhaust system. Dependi ng
on the engi ne or emi ssi on package, the vehi cl e may
use a total of ei ther 2 or 4 sensors.
OPERATION
An O2 sensor i s a gal vani c battery that provi des
the PCM wi th a vol tage si gnal (0-1 vol t) i nversel y
proporti onal to the amount of oxygen i n the exhaust.
I n other words, i f the oxygen content i s l ow, the vol t-
age output i s hi gh; i f the oxygen content i s hi gh the
output vol tage i s l ow. The PCM uses thi s i nformati on
to adjust i njector pul se-wi dth to achi eve the
14.7–to–1 ai r/fuel rati o necessary for proper engi ne
operati on and to control emi ssi ons.
The O2 sensor must have a source of oxygen from
outsi de of the exhaust stream for compari son. Cur-
rent O2 sensors recei ve thei r fresh oxygen (outsi de
ai r) suppl y through the O2 sensor case housi ng.
Four wi res (ci rcui ts) are used on each O2 sensor: a
12–vol t feed ci rcui t for the sensor heati ng el ement; a
ground ci rcui t for the heater el ement; a l ow-noi se
Fig. 21 4.0L MAP SENSOR MOUNTING - LATE
1 - MAP SENSOR
2 - RUBBER FITTING
3 - THROTTLE BODY
4 - MOUNTING SCREW (1)
TJ FUEL INJECTION 14 - 33
MAP SENSOR (Continued)
sensor return ci rcui t to the PCM, and an i nput ci r-
cui t from the sensor back to the PCM to detect sen-
sor operati on.
Oxygen Sensor Heater Relay: I f the vehi cl e i s
equi pped wi th 4 oxygen sensors, a separate oxygen
sensor rel ay i s used to suppl y vol tage to the sensor
heati ng el ements. Thi s parti cul ar rel ay i s used onl y
for the 1/2 and 2/2 downstream sensors. Vol tage for
the other 2 sensor heati ng el ements i s suppl i ed
di rectl y from the ASD rel ay. Refer to 8, Wi ri ng Di a-
grams to determi ne whi ch rel ay i s used.
To avoi d the l arge si mul taneous current surge
needed to operate al l 4 sensors, power i s del ayed to
the 2 downstream heater el ements by the PCM for
approxi matel y 2 seconds.
Oxygen Sensor Heater Elements:
The O2 sensor uses a Posi ti ve Thermal Co-effi ci ent
(PTC) heater el ement. As temperature i ncreases,
resi stance i ncreases. At ambi ent temperatures
around 70°F, the resi stance of the heati ng el ement i s
approxi matel y 4.5 ohms. As the sensor’s temperature
i ncreases, resi stance i n the heater el ement i ncreases.
Thi s al l ows the heater to mai ntai n the opti mum
operati ng temperature of approxi matel y 930°-1100°F
(500°-600° C). Al though the sensors operate the
same, there are physi cal di fferences, due to the envi -
ronment that they operate i n, that keep them from
bei ng i nterchangeabl e.
Mai ntai ni ng correct sensor temperature at al l
ti mes al l ows the system to enter i nto cl osed l oop
operati on sooner. Al so, i t al l ows the system to remai n
i n cl osed l oop operati on duri ng peri ods of extended
i dl e.
I n Cl osed Loop operati on, the PCM moni tors cer-
tai n O2 sensor i nput(s) al ong wi th other i nputs, and
adjusts the i njector pul se wi dth accordi ngl y. Duri ng
Open Loop operati on, the PCM i gnores the O2 sensor
i nput. The PCM adjusts i njector pul se wi dth based
on preprogrammed (fi xed) val ues and i nputs from
other sensors.
Upstream Sensor - Engine Equipped With 2
Sensors: The upstream sensor (1/1) provi des an
i nput vol tage to the PCM. The i nput tel l s the PCM
the oxygen content of the exhaust gas. The PCM uses
thi s i nformati on to fi ne tune fuel del i very to mai n-
tai n the correct oxygen content at the downstream
oxygen sensor. The PCM wi l l change the ai r/fuel
rati o unti l the upstream sensor i nputs a vol tage that
the PCM has determi ned wi l l make the downstream
sensor output (oxygen content) correct.
The upstream oxygen sensor al so provi des an i nput
to determi ne catal yti c convertor effi ci ency.
Downstream Sensor - Engine Equipped With
2 Sensors: The downstream oxygen sensor (1/2) i s
al so used to determi ne the correct ai r-fuel rati o. As
the oxygen content changes at the downstream sen-
sor, the PCM cal cul ates how much ai r-fuel rati o
change i s requi red. The PCM then l ooks at the
upstream oxygen sensor vol tage and changes fuel
del i very unti l the upstream sensor vol tage changes
enough to correct the downstream sensor vol tage
(oxygen content).
The downstream oxygen sensor al so provi des an
i nput to determi ne catal yti c convertor effi ci ency.
Upstream Sensors - Engine Equipped With 4
Sensors: Two upstream sensors are used (1/1 and
2/1). The 1/1 sensor i s the fi rst sensor to recei ve
exhaust gases from the #1 cyl i nder. They provi de an
i nput vol tage to the PCM. The i nput tel l s the PCM
the oxygen content of the exhaust gas. The PCM uses
thi s i nformati on to fi ne tune fuel del i very to mai n-
tai n the correct oxygen content at the downstream
oxygen sensors. The PCM wi l l change the ai r/fuel
rati o unti l the upstream sensors i nput a vol tage that
the PCM has determi ned wi l l make the downstream
sensors output (oxygen content) correct.
The upstream oxygen sensors al so provi de an i nput
to determi ne mi ni -catal yst effi ci ency. Mai n catal yti c
convertor effi ci ency i s not cal cul ated wi th thi s pack-
age.
Downstream Sensors - Engine Equipped With
4 Sensors: Two downstream sensors are used (1/2
and 2/2). The downstream sensors are used to deter-
mi ne the correct ai r-fuel rati o. As the oxygen content
changes at the downstream sensor, the PCM cal cu-
l ates how much ai r-fuel rati o change i s requi red. The
PCM then l ooks at the upstream oxygen sensor vol t-
age, and changes fuel del i very unti l the upstream
sensor vol tage changes enough to correct the down-
stream sensor vol tage (oxygen content).
The downstream oxygen sensors al so provi de an
i nput to determi ne mi ni -catal yst effi ci ency. Mai n cat-
al yti c convertor effi ci ency i s not cal cul ated wi th thi s
package.
Engi nes equi pped wi th ei ther a downstream sen-
sor(s), or a post-catal yti c sensor, wi l l moni tor cata-
l yti c convertor effi ci ency. I f effi ci ency i s bel ow
emi ssi on standards, the Mal functi on I ndi cator Lamp
(MI L) wi l l be i l l umi nated and a Di agnosti c Troubl e
Code (DTC) wi l l be set. Refer to Moni tored Systems
i n Emi ssi on Control Systems for addi ti onal i nforma-
ti on.
REMOVAL
2. 4L
CAUTION: Never apply any type of grease to the
oxygen sensor electrical connector, or attempt any
soldering of the sensor wiring harness.
Refer to (Fi g. 22) for O2S (oxygen sensor) l ocati on.
14 - 34 FUEL INJECTION TJ
O2 SENSOR (Continued)
WARNING: THE EXHAUST MANIFOLD, EXHAUST
PIPES AND CATALYTIC CONVERTER BECOME
VERY HOT DURING ENGINE OPERATION. ALLOW
ENGINE TO COOL BEFORE REMOVING OXYGEN
SENSOR.
(1) Rai se and support vehi cl e.
(2) Di sconnect wi re connector from O2S sensor.
CAUTION: When disconnecting sensor electrical
connector, do not pull directly on wire going into
sensor.
(3) Remove O2S sensor wi th an oxygen sensor
removal and i nstal l ati on tool .
(4) Cl ean threads i n exhaust pi pe usi ng appropri -
ate si ze tap.
4. 0L
CAUTION: Never apply any type of grease to the
oxygen sensor electrical connector, or attempt any
soldering of the sensor wiring harness.
Refer to (Fi g. 23), (Fi g. 24) for O2S (oxygen sensor)
l ocati on.
WARNING: THE EXHAUST MANIFOLD, EXHAUST
PIPES AND CATALYTIC CONVERTER BECOME
VERY HOT DURING ENGINE OPERATION. ALLOW
ENGINE TO COOL BEFORE REMOVING OXYGEN
SENSOR.
(1) Rai se and support vehi cl e.
(2) Di sconnect wi re connector from O2S sensor.
CAUTION: When disconnecting sensor electrical
connector, do not pull directly on wire going into
sensor.
(3) Remove O2S sensor wi th an oxygen sensor
removal and i nstal l ati on tool .
(4) Cl ean threads i n exhaust pi pe usi ng appropri -
ate si ze tap.
Fig. 22 OXYGEN SENSORS - 2.4L
1 - ELECTRICAL CONNECTORS
2 - UPSTREAM SENSOR (1/1)
3 - ELECTRICAL CONNECTORS
4 - DOWNSTREAM SENSOR (1/2)
Fig. 23 OXYGEN SENSORS - 4.0L - FEDERAL
EMISSIONS
1 - 1/2 O2S
2 - 1/1 02S
TJ FUEL INJECTION 14 - 35
O2 SENSOR (Continued)
INSTALLATION
Threads of new oxygen sensors are factory coated
wi th anti -sei ze compound to ai d i n removal . DO
NOT add any additional anti-seize compound to
the threads of a new oxygen sensor.
(1) I nstal l O2S sensor. Ti ghten to 30 N·m (22 ft.
l bs.) torque.
(2) Connect O2S sensor wi re connector.
(3) Lower vehi cl e.
THROTTLE BODY
DESCRIPTION
The throttl e body i s l ocated on the i ntake mani fol d.
Fuel does not enter the i ntake mani fol d through the
throttl e body. Fuel i s sprayed i nto the mani fol d by
the fuel i njectors.
OPERATION
Fi l tered ai r from the ai r cl eaner enters the i ntake
mani fol d through the throttl e body. The throttl e body
contai ns an ai r control passage control l ed by an I dl e
Ai r Control (I AC) motor. The ai r control passage i s
used to suppl y ai r for i dl e condi ti ons. A throttl e val ve
(pl ate) i s used to suppl y ai r for above i dl e condi ti ons.
Certai n sensors are attached to the throttl e body.
The accel erator pedal cabl e, speed control cabl e and
transmi ssi on control cabl e (when equi pped) are con-
nected to the throttl e body l i nkage arm.
A (factory adjusted) set screw i s used to mechani -
cal l y l i mi t the posi ti on of the throttl e body throttl e
pl ate. Never attempt to adjust the engine idle
speed using this screw. Al l i dl e speed functi ons are
control l ed by the PCM.
REMOVAL
2. 4L
A (factory adjusted) set screw i s used to mechani -
cal l y l i mi t the posi ti on of the throttl e body throttl e
pl ate. Never attempt to adjust the engine idle
speed using this screw. Al l i dl e speed functi ons are
control l ed by the Powertrai n Control Modul e (PCM).
(1) Remove ai r cl eaner tube at throttl e body.
(2) Di sconnect throttl e body el ectri cal connectors
at I AC motor and TPS.
(3) Remove al l control cabl es from throttl e body
(l ever) arm. Refer to the Accel erator Pedal and Throt-
tl e Cabl e secti on for removal /i nstal l ati on procedures.
(4) Di sconnect necessary vacuum l i nes at throttl e
body.
(5) Remove 3 throttl e body mounti ng bol ts (Fi g.
25).
(6) Remove throttl e body from i ntake mani fol d.
(7) Check condi ti on of ol d throttl e body-to-i ntake
mani fol d o-ri ng.
Fig. 24 OXYGEN SENSORS - 4.0L - CALIFORNIA
EMISSIONS
1 - 1/2 O2S
2 - 1/1 O2S
3 - 2/1 O2S
4 - 2/2 O2S
Fig. 25 THROTTLE BODY MOUNTING BOLTS - 2.4L
1 - THROTTLE BODY
2 - IGNITION COIL
3 - MOUNTING BOLTS (3)
14 - 36 FUEL INJECTION TJ
O2 SENSOR (Continued)
4. 0L
A (factory adjusted) set screw i s used to mechani -
cal l y l i mi t the posi ti on of the throttl e body throttl e
pl ate. Never attempt to adjust the engine idle
speed using this screw. Al l i dl e speed functi ons are
control l ed by the Powertrai n Control Modul e (PCM).
(1) Remove ai r cl eaner tube at throttl e body.
(2) Di sconnect throttl e body el ectri cal connectors
at MAP sensor, I AC motor and TPS (Fi g. 26).
(3) Remove al l control cabl es from throttl e body
(l ever) arm. Refer to the Accel erator Pedal and Throt-
tl e Cabl e secti on of thi s group for addi ti onal i nforma-
ti on.
(4) Remove four throttl e body mounti ng bol ts.
(5) Remove throttl e body from i ntake mani fol d.
(6) Di scard ol d throttl e body-to-i ntake mani fol d
gasket.
INSTALLATION
2. 4L
(1) Check condi ti on of throttl e body-to-i ntake man-
i fol d o-ri ng. Repl ace as necessary.
(2) Cl ean mati ng surfaces of throttl e body and
i ntake mani fol d.
(3) I nstal l throttl e body-to-i ntake mani fol d o-ri ng.
(4) I nstal l throttl e body to i ntake mani fol d.
(5) I nstal l 3 mounti ng bol ts. Ti ghten bol ts to 12
N·m (105 i n. l bs.) torque.
(6) I nstal l control cabl es.
(7) I nstal l el ectri cal connectors.
(8) I nstal l necessary vacuum l i nes.
(9) I nstal l ai r cl eaner duct at throttl e body.
4. 0L
A (factory adjusted) set screw i s used to mechani -
cal l y l i mi t the posi ti on of the throttl e body throttl e
pl ate. Never attempt to adjust the engine idle
speed using this screw. Al l i dl e speed functi ons are
control l ed by the Powertrai n Control Modul e (PCM).
(1) Cl ean mati ng surfaces of throttl e body and
i ntake mani fol d.
(2) I nstal l new throttl e body-to-i ntake mani fol d
gasket.
(3) I nstal l throttl e body to i ntake mani fol d.
(4) I nstal l four mounti ng bol ts. Ti ghten bol ts to 11
N·m (100 i n. l bs.) torque.
(5) I nstal l control cabl es.
(6) I nstal l el ectri cal connectors.
(7) I nstal l ai r cl eaner at throttl e body.
THROTTLE CONTROL CABLE
REMOVAL
2. 4L
CAUTION: Be careful not to damage or kink the
cable core wire (within the cable sheathing) while
servicing accelerator pedal or throttle cable.
(1) From i nsi de vehi cl e, hol d up accel erator pedal .
Remove pl asti c cabl e retai ner (cl i p) and throttl e cabl e
core wi re from upper end of pedal arm (Fi g. 27).
Pl asti c cabl e retai ner snaps i nto top of pedal arm.
(2) Remove cabl e core wi re at pedal arm.
(3) From i nsi de vehi cl e, pi nch both si des of cabl e
housi ng retai ner tabs (Fi g. 27) at dash panel .
Remove cabl e housi ng from dash panel and pul l i nto
engi ne compartment.
(4) Remove ai r box at throttl e body.
(5) Unsnap cabl e from dashpanel routi ng cl i p.
(6) Remove cabl e housi ng from dash panel and
pul l i nto engi ne compartment.
(7) Hol d throttl e i n wi de open posi ti on. Whi l e hel d
i n thi s posi ti on, sl i de throttl e cabl e pi n (Fi g. 28) from
throttl e body bel l crank.
Fig. 26 THROTTLE BODY AND SENSOR
LOCATIONS - 4.0L
1 - MOUNTING BOLTS (4)
2 - THROTTLE BODY
3 - IAC MOTOR
4 - ELEC. CONN.
5 - TPS
6 - MAP SENSOR
7 - ELEC. CONN.
8 - IAT SENSOR
9 - ELEC. CONN.
TJ FUEL INJECTION 14 - 37
THROTTLE BODY (Continued)
(8) Usi ng a pi ck or smal l screwdri ver, press rel ease
tab (Fi g. 28) to rel ease pl asti c cabl e mount from
bracket. Press on tab only enough to release cable
from bracket. If tab is pressed too much, it will be
broken.To remove throttl e cabl e from throttl e body
bracket, sl i de cabl e towards front of vehi cl e.
(9) Remove throttl e cabl e from vehi cl e.
4. 0L
CAUTION: Be careful not to damage or kink the
cable core wire (within the cable sheathing) while
servicing accelerator pedal or throttle cable.
(1) From i nsi de vehi cl e, hol d up accel erator pedal .
Remove pl asti c cabl e retai ner (cl i p) and throttl e cabl e
core wi re from upper end of accel erator pedal arm (Fi g.
29). Pl asti c cabl e retai ner (cl i p) snaps i nto pedal arm.
(2) Remove cabl e core wi re at pedal arm.
(3) From i nsi de vehi cl e, pi nch both si des of cabl e
housi ng retai ner tabs (Fi g. 29) at dash panel .
Remove cabl e housi ng from dash panel and pul l i nto
engi ne compartment.
Fig. 28 THROTTLE CABLE, PIN, RELEASE TAB -
2.4L
1 - MOUNTING BRACKET
2 - SPEED CONTROL CABLE
3 - THROTTLE CABLE
4 - RELEASE TAB
5 - CABLE PINS
6 - BELLCRANK
Fig. 29 ACCELERATOR PEDAL MOUNTING
1 - CABLE RETAINER
2 - SLOT
3 - MOUNTING STUDS (2)
4 - PEDAL/BRACKET ASSEMBLY
5 - MOUNTING STUDS
6 - RETAINER TABS
7 - CABLE
8 - CABLE STOP
Fig. 27 ACCELERATOR PEDAL MOUNTING
1 - CABLE RETAINER
2 - SLOT
3 - MOUNTING STUDS (2)
4 - PEDAL/BRACKET ASSEMBLY
5 - MOUNTING STUDS
6 - RETAINER TABS
7 - CABLE
8 - CABLE STOP
14 - 38 FUEL INJECTION TJ
THROTTLE CONTROL CABLE (Continued)
(4) Remove cabl e from cl i p gui des on engi ne cyl i n-
der head (val ve) cover (Fi g. 30).
(5) Remove throttl e cabl e bal l socket at throttl e
body by pushi ng bal l socket towards rear of vehi cl e
(bal l snaps off of throttl e body pi n) (Fi g. 31).
(6) Remove throttl e cabl e from throttl e body
mounti ng bracket by compressi ng rel ease tabs (Fi g.
31) and pushi ng cabl e through hol e i n bracket.
(7) Remove throttl e cabl e from vehi cl e.
INSTALLATION
2. 4L
(1) Sl i de accel erator cabl e pl asti c mount i nto throt-
tl e body mounti ng bracket. Conti nue sl i di ng unti l
rel ease tab i s al i gned to hol e i n mounti ng bracket.
(2) Hol d throttl e i n wi de open posi ti on. Whi l e hel d
i n thi s posi ti on, sl i de throttl e cabl e pi n i nto throttl e
body bel l crank.
(3) Push cabl e housi ng i nto rubber grommet and
through openi ng i n dash panel .
(4) Push other end of cabl e through openi ng i n
dash panel unti l retai ni ng tabs l ock i nto panel .
(5) From i nsi de vehi cl e, sl i de throttl e cabl e core
wi re i nto openi ng (sl ot) i n top of pedal arm.
(6) Push pl asti c cabl e retai ner (cl i p) i nto pedal arm
openi ng unti l i t snaps i n pl ace.
(7) I nstal l ai r box to throttl e body.
(8) Before starti ng engi ne, operate accel erator
pedal to check for any bi ndi ng.
4. 0L
(1) Sl i de throttl e cabl e through hol e i n throttl e
body bracket unti l retai ner tabs l ock i nto bracket.
Connect cabl e bal l end to throttl e body l i nkage bal l
(snaps on).
(2) Snap cabl e i nto cl i p gui des on engi ne cyl i nder
head (val ve) cover.
(3) Push other end of cabl e through openi ng i n
dash panel unti l retai ni ng tabs l ock i nto panel .
(4) From i nsi de dri vers compartment, sl i de throttl e
cabl e core wi re i nto openi ng i n top of accel erator
pedal arm. An i ndex tab i s l ocated on pedal arm.
Rotate and push cabl e retai ner (cl i p) i nto pedal arm
openi ng unti l i t snaps i n pl ace on i ndex tab.
(5) I nstal l ai r box to throttl e body.
(6) Before starti ng engi ne, operate accel erator
pedal to check for any bi ndi ng.
Fig. 30 THROTTLE CABLE ROUTING - 4.0L
1 - THROTTLE CABLE
2 - GUIDE
Fig. 31 THROTTLE CABLE AT THROTTLE BODY -
4.0L - TYPICAL
1 - ACCELERATOR CABLE
2 - OFF
3 - OFF
4 - THROTTLE BODY BELLCRANK
5 - SPEED CONTROL CABLE
6 - RELEASE TABS
7 - BRACKET
TJ FUEL INJECTION 14 - 39
THROTTLE CONTROL CABLE (Continued)
THROTTLE POSITION SENSOR
DESCRIPTION
The 3–wi re Throttl e Posi ti on Sensor (TPS) i s
mounted on the throttl e body and i s connected to the
throttl e bl ade.
OPERATION
The TPS i s a 3–wi re vari abl e resi stor that provi des
the Powertrai n Control Modul e (PCM) wi th an i nput
si gnal (vol tage) that represents the throttl e bl ade
posi ti on of the throttl e body. The sensor i s connected
to the throttl e bl ade shaft. As the posi ti on of the
throttl e bl ade changes, the resi stance (output vol t-
age) of the TPS changes.
The PCM suppl i es approxi matel y 5 vol ts to the
TPS. The TPS output vol tage (i nput si gnal to the
PCM) represents the throttl e bl ade posi ti on. The
PCM recei ves an i nput si gnal vol tage from the TPS.
Thi s wi l l vary i n an approxi mate range of from .26
vol ts at mi ni mum throttl e openi ng (i dl e), to 4.49 vol ts
at wi de open throttl e. Al ong wi th i nputs from other
sensors, the PCM uses the TPS i nput to determi ne
current engi ne operati ng condi ti ons. I n response to
engi ne operati ng condi ti ons, the PCM wi l l adjust fuel
i njector pul se wi dth and i gni ti on ti mi ng.
The PCM needs to i denti fy the acti ons and posi ti on
of the throttl e bl ade at al l ti mes. Thi s i nformati on i s
needed to assi st i n performi ng the fol l owi ng cal cul a-
ti ons:
• I gni ti on ti mi ng advance
• Fuel i njecti on pul se-wi dth
• I dl e (l earned val ue or mi ni mum TPS)
• Off-i dl e (0.06 vol t)
• Wi de Open Throttl e (WOT) open l oop (2.608
vol ts above l earned i dl e vol tage)
• Decel erati on fuel l ean out
• Fuel cutoff duri ng cranki ng at WOT (2.608 vol ts
above l earned i dl e vol tage)
• A/C WOT cutoff (certai n automati c transmi s-
si ons onl y)
REMOVAL
2. 4L
The Throttl e Posi ti on Sensor (TPS) i s mounted to
the throttl e body (Fi g. 32).
(1) Di sconnect TPS el ectri cal connector.
(2) Remove 2 TPS mounti ng screws.
(3) Remove TPS.
4. 0L
The TPS i s mounted to the throttl e body.
(1) Remove ai r cl eaner tube at throttl e body.
(2) Di sconnect TPS el ectri cal connector.
(3) Remove TPS mounti ng screws (Fi g. 33).
(4) Remove TPS.
Fig. 32 TPS/IAC MOTOR - 2.4L
1 - THROTTLE POSITION SENSOR (TPS)
2 - MOUNTING SCREWS
3 - IDLE AIR CONTROL MOTOR (IAC)
4 - MOUNTING SCREWS
Fig. 33 TPS MOUNTING SCREWS - 4.0L
1 - MOUNTING SCREWS
2 - TPS
14 - 40 FUEL INJECTION TJ
INSTALLATION
2. 4L
The throttl e shaft end of the throttl e body sl i des
i nto a socket i n the TPS. The TPS must be i nstal l ed
so that i t can be rotated a few degrees. (I f sensor wi l l
not rotate, i nstal l sensor wi th throttl e shaft on other
si de of socket tangs). The TPS wi l l be under sl i ght
tensi on when rotated.
(1) I nstal l TPS and retai ni ng screws.
(2) Ti ghten screws to 7 N·m (60 i n. l bs.) torque.
(3) Connect TPS el ectri cal connector to TPS.
(4) Manual l y operate throttl e (by hand) to check
for any TPS bi ndi ng before starti ng engi ne.
(5) I nstal l ai r cl eaner tube to throttl e body.
4. 0L
The throttl e shaft end of the throttl e body sl i des
i nto a socket i n the TPS (Fi g. 34). The TPS must be
i nstal l ed so that i t can be rotated a few degrees. (I f
the sensor wi l l not rotate, i nstal l the sensor wi th the
throttl e shaft on the other si de of the socket tangs).
The TPS wi l l be under sl i ght tensi on when rotated.
(1) I nstal l TPS and retai ni ng screws.
(2) Ti ghten screws to 7 N·m (60 i n. l bs.) torque.
(3) Connect TPS el ectri cal connector to TPS.
(4) Manual l y operate throttl e (by hand) to check
for any TPS bi ndi ng before starti ng engi ne.
(5) I nstal l ai r cl eaner tube to throttl e body.
Fig. 34 TPS INSTALLATION - 4.0L
1 - TANGS
2 - THROTTLE SHAFT
3 - THROTTLE BODY
4 - TPS
TJ FUEL INJECTION 14 - 41
THROTTLE POSITION SENSOR (Continued)
STEERING
TABLE OF CONTENTS
page page
STEERING
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - POWER
STEERING SYSTEM DIAGNOSIS CHARTS . . . 2
DIAGNOSIS AND TESTING - POWER
STEERING FLOW AND PRESSURE . . . . . . . . 4
COLUMN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
STEERING
DESCRIPTION
CAUTION: MOPARா ATF+4 is to be used in the
power steering system. No other power steering or
automatic transmission fluid is to be used in the
system. Damage may result to the power steering
pump and system if any other fluid is used, and do
not overfill.
The power steeri ng system has a hydraul i c pump.
The pump i s a constant fl ow rate and di spl acement
vane-type pump. The pump reservoi r on the 4.0L
engi ne i s mounted to the pump body (Fi g. 1)& (Fi g.
2). The 2.4L engi ne has a remote pump reservoi r
mounted to the fan shroud (Fi g. 3).
The steeri ng gear used i s a strai ght rati o reci rcu-
l ati ng bal l type gear. A ti l t and non-ti l t col umn pro-
vi de steeri ng i nput.
Fig. 1 POWER STEERING GEAR & PUMP - 4.0L
1 - POWER STEERING GEAR
2 - PRESSURE HOSE
3 - POWER STEERING RESERVOIR
4 - POWER STEERING PUMP
5 - RETURN HOSE
Fig. 2 RHD POWER STEERING HOSES
1 - PRESSURE HOSE
2 - RETURN HOSE
3 - MOUNTING BRACKETS
4 - STEERING GEAR
TJ STEERING 19 - 1
OPERATION
The gear acts as a rol l i ng thread between the
worm shaft and rack pi ston. The worm shaft i s sup-
ported by a thrust beari ng at the upper end. When
the worm shaft i s turned from i nput from the steer-
i ng col umn the rack pi ston moves. The rack pi ston
teeth mesh wi th the pi tman shaft. Turni ng the worm
shaft turns the pi tman shaft, whi ch turns the steer-
i ng l i nkage.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - POWER STEERING
SYSTEM DIAGNOSIS CHARTS
There i s some noi se i n al l power steeri ng systems. One of the most common i s a hi ssi ng sound evi dent at a
standsti l l parki ng. Or when the steeri ng wheel i s at the end of i t’s travel . Hi ss i s a hi gh frequency noi se si mi l ar
to that of a water tap bei ng cl osed sl owl y. The noi se i s present i n al l val ves that have a hi gh vel oci ty fl ui d passi ng
through an ori fi ce. There i s no rel ati onshi p between thi s noi se and steeri ng performance.
STEERING NOISE
CONDITION POSSIBLE CAUSES CORRECTION
OBJECTIONAL HISS OR
WHISTLE
1. Steering intermediate shaft to dash panel
seal.
1. Check and repair seal at dash
panel.
2. Noisy valve in power steering gear. 2. Replace steering gear.
RATTLE OR CLUNK 1. Gear mounting bolts loose. 1. Tighten bolts to specification.
2. Loose or damaged suspension
components/track bar.
2. Inspect and repair suspension.
3. Loose or damaged steering linkage. 3. Inspect and repair steering
linkage.
4. Internal gear noise. 4. Replace gear.
5. Pressure hose in contact with other
components.
5. Reposition hose.
Fig. 3 POWER STEERING GEAR & PUMP - 2.4L
1 - REMOTE RESERVOIR
2 - POWER STEERING PUMP
3 - PUMP MOUNT BRACKET
4 - MOUNTING BOLTS (3)
5 - PRESSURE SWITCH LOCATION
6 - PRESSURE OUTLET HOSE (GEAR TO PUMP)
7 - RETURN HOSE (RESERVOIR TO PUMP)
8 - CLAMPS
9 - STEERING GEAR
10 - INLET HOSE (RESERVOIR TO GEAR)
19 - 2 STEERING TJ
STEERING (Continued)
CONDITION POSSIBLE CAUSES CORRECTION
CHIRP OR SQUEAL 1. Loose belt. 1. Adjust or replace.
WHINE OR GROWL 1. Low fluid level. 1. Fill to proper level.
2. Pressure hose in contact with other
components.
2. Reposition hose.
3. Internal pump noise. 3. Replace pump.
4. Air in the system. 4. Perform pump initial operation.
SUCKING AIR SOUND 1. Loose return line clamp. 1. Replace clamp.
2. O-ring missing or damaged on hose
fitting.
2. Replace o-ring.
3. Low fluid level. 3. Fill to proper level.
4. Air leak between pump and reservoir. 4. Repair as necessary.
SCRUBBING OR
KNOCKING
1. Wrong tire size. 1. Verify tire size.
2. Wrong gear. 2. Verify gear.
BINDING AND STICKING
CONDITION POSSIBLE CAUSE CORRECTION
DIFFICULT TO TURN WHEEL
STICKS OR BINDS
1. Low fluid level. 1. Fill to proper level.
2. Tire pressure. 2. Adjust tire pressure.
3. Steering component. 3. Inspect and lube.
4. Loose belt. 4. Adjust or replace.
5. Low pump pressure. 5. Pressure test and replace if
necessary.
6. Column shaft coupler binding. 6. Replace coupler.
7. Steering gear worn or out of
adjustment.
7. Replace gear.
8. Ball joints binding. 8. Inspect and repair as necessary.
INSUFFICIENT ASST. OR POOR RETURN TO CENTER
CONDITION POSSIBLE CAUSE CORRECTION
HARD TURNING OR MOMENTARY
INCREASE IN TURNING EFFORT
1. Tire pressure. 1. Adjust tire pressure.
2. Low fluid level. 2. Fill to proper level.
3. Loose belt. 3. Adjust or replace.
4. Lack of lubrication. 4. Inspect and lubricate steering and
suspension compnents.
5. Low pump pressure. 5. Pressure test and repair as
necessary.
6. Internal gear leak. 6. Pressure and flow test, and
replace as necessary.
TJ STEERING 19 - 3
STEERING (Continued)
CONDITION POSSIBLE CAUSE CORRECTION
STEERING WHEEL
DOES NOT WANT TO RETURN TO
CENTER POSITION
1. Tire pressure. 1. Adjust tire pressure.
2. Wheel alignment. 2. Align front end.
3. Lack of lubrication. 3. Inspect and lubricate steering and
suspension compnents.
4. High friction in steering gear. 4. Test and adjust as necessary.
5. Ball joints binding. 5. Inspect and repair as necessary.
NOTE:
Some roads will cause a vehicle to drift, due to the
crown in the road.
LOOSE STEERING AND VEHICLE LEADS/DRIFTS
CONDITION POSSIBLE CAUSE CORRECTION
EXCESSIVE PLAY IN STEERING
WHEEL
1. Worn or loose suspension or
steering components.
1. Repair as necessary.
2. Worn or loose wheel bearings. 2. Repair as necessary.
3. Steering gear mounting. 3. Tighten gear mounting bolts to
specification.
4. Gear out of adjustment. 4. Adjust gear to specification.
5. Worn or loose steering coupler. 5. Repair as necessary.
VEHICLE PULLS TO ONE SIDE
DURING BRAKING
1. Tire Pressure. 1. Adjust tire pressure.
2. Air in brake hydraulics system. 2. Bleed brake system.
3. Worn brake components. 3. Repair as necessary.
VEHICLE LEADS OR DRIFTS
FROM STRAIGHT AHEAD
DIRECTION ON UNCROWNED
ROAD.
1. Tire pressure. 1. Adjust tire pressure.
2. Radial tire lead. 2. Cross front tires.
3. Brakes dragging. 3. Repair as necessary.
4. Wheel alignment. 4. Align vehicle.
5. Weak or broken spring. 5. Replace spring.
6. Loose or worn steering/
suspension components.
6. Repair as necessary.
7. Cross caster out of spec. 7. Adjust or replace axle as
necessary.
DIAGNOSIS AND TESTING - POWER STEERING
FLOW AND PRESSURE
The fol l owi ng procedure i s used to test the opera-
ti on of the power steeri ng system on the vehi cl e. Thi s
test wi l l provi de the gal l ons per mi nute (GPM) or
fl ow rate of the power steeri ng pump al ong wi th the
maxi mum rel i ef pressure. Perform test any ti me a
power steeri ng system probl em i s present. Thi s test
wi l l determi ne i f the power steeri ng pump or power
steeri ng gear i s not functi oni ng properl y. The fol l ow-
i ng pressure and fl ow test i s performed usi ng Power
Steeri ng Anal yzer Tool 6815 (Fi g. 4) and Adapter ki t
6893.
FLOW AND PRESSURE TEST
(1) Check the power steeri ng bel t to ensure i t i s i n
good condi ti on and adjusted properl y.
(2) Connect pressure gauge hose from the Power
Steeri ng Anal yzer to Tube 6865.
(3) Connect Adapter 6826 to Power Steeri ng Ana-
l yzer test val ve end.
19 - 4 STEERING TJ
STEERING (Continued)
(4) Di sconnect the hi gh pressure hose from the
power steeri ng pump.
(5) Connect Tube 6865 to the pump hose fi tti ng.
(6) Connect the power steeri ng hose from the
steeri ng gear to Adapter 6826.
(7) Open the test val ve compl etel y.
(8) Start engi ne and l et i dl e l ong enough to ci rcu-
l ate power steeri ng fl ui d through fl ow/pressure test
gauge.
(9) Shut off the engi ne and check the fl ui d l evel ,
add fl ui d as necessary. Start engi ne agai n and l et
i dl e.
(10) Gauge shoul d read bel ow 862 kPa (125 psi ), i f
above, i nspect the hoses for restri cti ons and repai r as
necessary. The i ni ti al pressure readi ng shoul d be i n
the range of 345-552 kPa (50-80 psi ).
(11) I ncrease the engi ne speed to 1500 RPM and
read the fl ow meter. The readi ng shoul d be 2.4 - 2.8
GPM, i f the readi ng i s bel ow thi s speci fi cati on the
pump shoul d be repl aced.
CAUTION: This next step involves testing maximum
pump pressure output and flow control valve oper-
ation. Do not leave test valve closed for more than
three seconds as the pump could be damaged.
(12) Cl ose val ve ful l y three ti mes for three seconds
and record hi ghest pressure i ndi cated each ti me. All
three readings must be above pump relief pres-
sure specifications and within 345 kPa (50 psi)
of each other.
• Pressures above speci fi cati ons but not wi thi n
345 kPa (50 psi ) of each other, repl ace pump.
• Pressures wi thi n 345 kPa (50 psi ) of each other
but bel ow speci fi cati ons, repl ace pump.
(13) Open the test val ve and turn the steeri ng
wheel to the extreme l eft and ri ght posi ti ons agai nst
the stops. Record the hi ghest pressure readi ng at
each posi ti on. Compare readi ngs to pump speci fi ca-
ti ons chart. I f pressure readi ngs are not wi thi n 50
psi . of each other, the gear i s l eaki ng i nternal l y and
must be repai red.
CAUTION: Do not force the pump to operate against
the stops for more than 2 to 4 seconds at a time
because, pump damage will result.
PUMP SPECIFICATIONS
ENGINE
RELIEF
PRESSURE ± 50
FLOW RATE
(GPM)
2.4L
9653 kPa (1400
psi)
1500 RPM 2.4 - 2.8
GPM
4.0L
9653 kPa (1400
psi)
Fig. 4 Power Steering Analyzer
1 - TUBE
2 - ADAPTER FITTINGS
3 - ANALYZER
4 - GAUGE HOSE
TJ STEERING 19 - 5
STEERING (Continued)
COLUMN
TABLE OF CONTENTS
page page
COLUMN
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 6
OPERATION - SERVICE PRECAUTIONS . . . . . . 6
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . 9
IGNITION SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 9
DIAGNOSIS AND TESTING - IGNITION
SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10
KEY-IN IGNITION SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 10
DIAGNOSIS AND TESTING - KEY-IN IGNITION
SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
KEY CYLINDER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11
STEERING WHEEL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12
COLUMN
DESCRIPTION
NOTE: The steering column on vehicles with an
automatic transmission may not be equipped with
an internal locking shaft that allows the ignition key
cylinder to be locked with the key. Alternative meth-
ods of locking the steering wheel for service will
have to be used.
The standard non-ti l t and ti l t steeri ng col umn has
been desi gned to be servi ced as an assembl y. The col -
umn i s connected to the steeri ng gear wi th an upper
and l ower shaft. The l ower shaft has a support bear-
i ng mounted to a bracket. The bracket mounts to the
frame rai l wi th two bol ts. These shafts and beari ng
are servi ceabl e. The key cyl i nder, swi tches, cl ock
spri ng, tri m shrouds and steeri ng wheel are servi ced
separatel y.
OPERATION - SERVICE PRECAUTIONS
Safety goggl es shoul d be worn at al l ti mes when
worki ng on steeri ng col umns.
To servi ce the steeri ng wheel , swi tches or ai rbag,
refer to El ectri cal - Restrai nts and fol l ow al l WARN-
I NGS and CAUTI ONS.
WARNING: THE AIRBAG SYSTEM IS A SENSITIVE,
COMPLEX ELECTRO-MECHANICAL UNIT. BEFORE
ATTEMPTING TO DIAGNOSE, REMOVE OR INSTALL
THE AIRBAG SYSTEM COMPONENTS YOU MUST
FIRST DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE. THEN WAIT TWO
MINUTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE. FAILURE TO DO SO COULD RESULT IN
ACCIDENTAL DEPLOYMENT OF THE AIRBAG AND
POSSIBLE PERSONAL INJURY. THE FASTENERS,
SCREWS, AND BOLTS, ORIGINALLY USED FOR
THE AIRBAG COMPONENTS, HAVE SPECIAL COAT-
INGS AND ARE SPECIFICALLY DESIGNED FOR THE
AIRBAG SYSTEM. THEY MUST NEVER BE
REPLACED WITH ANY SUBSTITUTES. ANYTIME A
NEW FASTENER IS NEEDED, REPLACE WITH THE
CORRECT FASTENERS PROVIDED IN THE SERVICE
PACKAGE OR FASTENERS LISTED IN THE PARTS
BOOKS.
REMOVAL
(1) Posi ti on front wheel s straight ahead.
(2) Remove and i sol ate the negati ve ground cabl e
from the battery.
(3) Remove the ai rbag, (Refer to 8 - ELECTRI CAL/
RESTRAI NTS/DRI VER AI RBAG - REMOVAL).
NOTE: If equipped with cruise control, disconnect
clock spring harness from the cruise switch har-
ness on the steering wheel.
(4) Remove the steeri ng wheel wi th an appropri ate
pul l er (Fi g. 1).
NOTE: Ensure the puller jaws are seated in the
pockets (Fig. 2) of the steering wheel armature.
(5) Turn i gni ti on cyl i nder to the on posi ti on and
remove cyl i nder by pressi ng rel ease through l ower
shroud access hol e (Fi g. 3) (Refer to 19 - STEERI NG/
COLUMN/LOCK CYLI NDER HOUSI NG -
REMOVAL).
19 - 6 COLUMN TJ
(6) Remove knee bl ocker cover and knee bl ocker,
(Refer to 23 - BODY/I NSTRUMENT PANEL/KNEE
BLOCKER - REMOVAL).
(7) Remove screws from the l ower col umn shroud
(Fi g. 4) and remove the shroud.
(8) Remove the steeri ng coupl er bol t and col umn
mounti ng nuts (Fi g. 5) then l ower col umn off the
mounti ng studs.
(9) Remove upper col umn shroud (Fi g. 4).
(10) Di sconnect and remove the wi ri ng harness
from the col umn (Fi g. 6).
NOTE: If vehicle is equipped with automatic trans-
mission, remove shifter interlock cable from the
column. (Refer to 21 - TRANSMISSION/TRANSAXLE/
AUTOMATIC - 30RH/GEAR SHIFT CABLE -
REMOVAL).
(11) Remove col umn.
Fig. 1 STEERING WHEEL PULLER
1 - PULLER C-3894-A
2 - STEERING WHEEL
Fig. 2 Steering Wheel Pockets
1 - STEERING WHEEL POCKETS
Fig. 3 LOCK CYLINDER RELEASE
1 - Lower Shroud
2 - Lock Cylinder Release Access Hole
3 - Pin Punch
Fig. 4 SHROUD REMOVAL/INSTALL
1 - Upper Shroud
2 - Lower Shroud
TJ COLUMN 19 - 7
COLUMN (Continued)
(12) Remove cl ock spri ng (Fi g. 7), swi tches, (SKI M
i f equi pped) (Refer to 8 - ELECTRI CAL/RE-
STRAI NTS/CLOCKSPRI NG - REMOVAL).
INSTALLATION
(1) Al i gn and i nstal l col umn i nto the steeri ng coupl er.
(2) I nstal l col umn harness and connect harness to
swi tches.
NOTE: If vehicle is equipped with automatic trans-
mission, install shifter interlock cable. (Refer to 21 -
TRANSMISSION/TRANSAXLE/AUTOMATIC - 30RH/
GEAR SHIFT CABLE - ADJUSTMENTS).
(3) I nstal l the upper col umn shroud.
(4) I nstal l the col umn onto the mounti ng studs.
CAUTION: Lower nuts must be installed and tight-
ened first then the upper nuts in order to prevent
damage to the capsules.
(5) I nstal l the l ower mounti ng nuts and ti ghten to
17 N·m (150 i n. l bs.).
(6) I nstal l the upper mounti ng nuts and ti ghten to
17 N·m (150 i n. l bs.).
(7) I nstal l the steeri ng col umn coupl er bol t and
ti ghten to 49 N·m (36 ft. l bs.).
(8) Center the cl ock spri ng (i f necessary) and
i nstal l i t on the col umn, (Refer to 8 - ELECTRI CAL/
RESTRAI NTS/CLOCKSPRI NG - I NSTALLATI ON).
(9) I nstal l the l ower col umn shroud and i nstal l
mounti ng screws.
(10) I nstal l the i gni ti on l ock cyl i nder. (Refer to 19 -
STEERI NG/COLUMN/LOCK CYLI NDER HOUSI NG
- I NSTALLATI ON).
(11) I nstal l the knee bl ocker and the knee bl ocker
cover, (Refer to 23 - BODY/I NSTRUMENT PANEL/
KNEE BLOCKER - I NSTALLATI ON).
NOTE: Do not reuse the old steering wheel bolt (a
new bolt must be used)
NOTE: If equipped with cruise control, connect
clock spring harness to cruise switch harness on
the steering wheel.
(12) I nstal l the steeri ng wheel and ti ghten bol t to
54 N·m (40 ft. l bs.).
(13) I nstal l the ai rbag, (Refer to 8 - ELECTRI CAL/
RESTRAI NTS/DRI VER AI RBAG - I NSTALLATI ON).
(14) I nstal l the negati ve battery termi nal .
Fig. 5 STEERING COLUMN MOUNTING
1 - Steering Column
2 - Mounting Holes
Fig. 6 WIRING HARNESS COLUMN
1 - Column Wiring Harness
2 - Multi-function Switch
3 - Ignition Switch
4 - Steering Column
Fig. 7 CLOCK SPRING
1 - Tilt Lever
2 - Ignition Switch
3 - Clockspring
4 - Steering Column
5 - SKIM
19 - 8 COLUMN TJ
COLUMN (Continued)
SPECIFICATIONS
TORQUE CHART
TORQUE SPECIFICATIONS
DESCRIPTION N·m Ft. Lbs. In. Lbs.
Tilt Steering Column
Steering Wheel Nut
54 40 —
Tilt Steering Column
Mounting Nuts
17 — 150
Tilt Steering Column
Coupler Bolt
49 36 —
Non-Tilt Steering Column
Steering Wheel Nut
54 40 —
Non-Tilt Steering Column
Mounting Nuts
17 — 150
Non-Tilt Steering Column
Coupler Bolt
49 36 —
IGNITION SWITCH
DESCRIPTION
The el ectri cal i gni ti on swi tch i s l ocated on the
steeri ng col umn. I t i s used as the mai n on/off swi tch-
i ng devi ce for most el ectri cal components. The
mechani cal key cyl i nder i s used to engage/di sengage
the el ectri cal i gni ti on swi tch.
DIAGNOSIS AND TESTING - IGNITION SWITCH
ELECTRICAL DIAGNOSIS
For i gni ti on swi tch el ectri cal schemati cs, Refer to
the appropri ate secti on for the component.
MECHANICAL DIAGNOSIS (KEY DIFFICULT TO
ROTATE)
Vehicles equipped with an automatic trans-
mission and a floor mounted shifter: a cabl e i s
used to connect the i nterl ock devi ce i n the steeri ng
col umn assembl y, to the transmi ssi on fl oor shi ft
l ever. Thi s i nterl ock system i s used to l ock the trans-
mi ssi on shi fter i n the PARK posi ti on when the key
cyl i nder i s rotated to any posi ti on. I f the i gni ti on key
i s di ffi cul t to rotate to or from any posi ti on, i t may
not be the faul t of the key cyl i nder or the steeri ng
col umn components. The brake transmi ssi on shi ft
i nterl ock cabl e may be out of adjustment. (Refer to
21 - TRANSMI SSI ON/TRANSAXLE/AUTOMATI C -
30RH/GEAR SHI FT CABLE - ADJUSTMENTS). The
i nterl ock system wi thi n the steeri ng col umn i s not
servi ceabl e. I f repai r i s necessary, the steeri ng col -
umn assembl y must be repl aced. (Refer to 19 -
STEERI NG/COLUMN - REMOVAL).
Vehicles equipped with a manual transmis-
sion and a floor mounted shifter: on certai n mod-
el s, a button i s l ocated on the steeri ng col umn behi nd
the i gni ti on key cyl i nder. The button must be manu-
al l y depressed to al l ow rotati on of the i gni ti on key
cyl i nder from the off to lock posi ti ons. I f i t i s di ffi -
cul t to rotate the key to any posi ti on, the l ever mech-
ani sm may be defecti ve. Thi s mechani sm i s not
servi ceabl e. I f repai r i s necessary, the steeri ng col -
umn assembl y must be repl aced.(Refer to 19 -
STEERI NG/COLUMN - REMOVAL).
REMOVAL
The i gni ti on key must be i n the key cyl i nder for
cyl i nder removal . The key cyl i nder must be removed
fi rst before removi ng i gni ti on swi tch.
(1) Remove key cyl i nder. (Refer to 19 - STEER-
I NG/COLUMN/LOCK CYLI NDER HOUSI NG -
REMOVAL).
(2) Remove l ower steeri ng col umn cover screws
and remove cover.
(3) Remove the mul ti -functi on swi tch.
(4) Di sconnect the el ectri cal connector at the rear
of the i gni ti on swi tch.
(5) Remove the i gni ti on swi tch mounti ng screw
(Fi g. 8). Use tamper proof torx bi t to remove the
screw.
(6) Pul l the i gni ti on swi tch strai ght out to remove
from the l ocki ng tabs (Fi g. 9)
TJ COLUMN 19 - 9
COLUMN (Continued)
INSTALLATION
The i gni ti on key must be i n the key cyl i nder for
cyl i nder i nstal l ati on. The key cyl i nder must be
al i gned wi th the i gni ti on swi tch for i nstal l ati on.
(1) Before i nstal l i ng i gni ti on swi tch, rotate the sl ot
i n the swi tch to the ON posi ti on (Fi g. 10).
(2) Connect the el ectri cal connector to rear of i gni -
ti on swi tch. Make sure that l ocki ng tab i s ful l y
seated i nto wi ri ng connector.
(3) Posi ti on the swi tch to the col umn and i nstal l
tamper proof screw. Ti ghten screw to 3 N·m (26 i n.
l bs.).
(4) Test the operati on of the l ock cyl i nder for
smooth rotati ng.
(5) I nstal l the mul ti -functi on swi tch.
(6) I nstal l steeri ng col umn l ower cover.
KEY-IN IGNITION SWITCH
DESCRIPTION
The key-i n i gni ti on swi tch i s i ntegral to the i gni -
ti on swi tch, whi ch i s mounted on the l eft si de of the
steeri ng col umn, opposi te the i gni ti on cyl i nder. I t
cl oses a path to ground for the i nstrument cl uster
chi me warni ng ci rcui try when the i gni ti on key i s
i nserted i n the i gni ti on cyl i nder and the dri ver door
jamb swi tch i s cl osed (dri ver door i s open). The
key-i n i gni ti on swi tch opens the ground path when
the key i s removed from the i gni ti on cyl i nder.
The key-i n i gni ti on swi tch cannot be repai red and,
i f faul ty or damaged, the enti re i gni ti on swi tch must
be repl aced. (Refer to 19 - STEERI NG/COLUMN/I G-
NI TI ON SWI TCH - REMOVAL).
DIAGNOSIS AND TESTING - KEY-IN IGNITION
SWITCH
For ci rcui t descri pti ons and di agrams, Refer to the
appropri ate secti ons on the i ndi vi dual components.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO ELECTRICAL - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Di sconnect and i sol ate the battery negati ve
cabl e. Remove the steeri ng col umn shrouds. Unpl ug
the key-i n i gni ti on swi tch wi re harness connector
from the i gni ti on swi tch.
Fig. 8 IGNITION SWITCH MOUNTING SCREW
1 - Tamper Proof Torx Screw
2 - Ignition Switch
Fig. 9 IGNITION SWITCH TABS
1 - Ignition Switch
2 - Locking Tabs
Fig. 10 IGNITION SWITCH ON POSITION
1 - Ignition Switch
2 - Rotate to On Position
19 - 10 COLUMN TJ
IGNITION SWITCH (Continued)
(2) Check for conti nui ty between the key-i n swi tch
sense ci rcui t and the l eft front door jamb swi tch
sense ci rcui t termi nal s of the key-i n i gni ti on swi tch.
There shoul d be conti nui ty wi th the key i n the i gni -
ti on cyl i nder, and no conti nui ty wi th the key removed
from the i gni ti on cyl i nder. I f OK, go to Step 3. I f not
OK, repl ace the faul ty i gni ti on swi tch assembl y.
(3) Check for conti nui ty between the l eft front door
jamb swi tch sense ci rcui t cavi ty of the key-i n i gni ti on
swi tch wi re harness connector and a good ground.
There shoul d be conti nui ty wi th the dri ver door open,
and no conti nui ty wi th the dri ver door cl osed. I f OK,
see the di agnosi s for I nstrument Cl uster i n thi s
group. I f not OK, repai r the ci rcui t to the dri ver door
jamb swi tch as requi red.
KEY CYLINDER
REMOVAL
The i gni ti on key must be i n the key cyl i nder for
cyl i nder removal . The key cyl i nder must be removed
fi rst before removi ng i gni ti on swi tch.
(1) I f equi pped wi th an automati c transmi ssi on,
pl ace shi fter i n PARK posi ti on.
(2) Rotate key to ON posi ti on.
(3) A rel ease tang i s l ocated on bottom of key cyl -
i nder (Fi g. 11).
(4) Posi ti on a smal l screwdri ver or pi n punch i nto
tang access hol e on bottom of steeri ng col umn l ower
cover (Fi g. 12).
(5) Push the pi n punch up whi l e pul l i ng key cyl i n-
der from steeri ng col umn.
INSTALLATION
The i gni ti on key must be i n the key cyl i nder for
cyl i nder i nstal l ati on.
(1) I nstal l the l ock cyl i nder i nto the housi ng usi ng
care to al i gn the end of the l ock cyl i nder wi th the
i gni ti on swi tch.
(2) Push the l ock cyl i nder i n unti l i t cl i cks.
(3) Rotate the key to the l ock posi ti on.
STEERING WHEEL
REMOVAL
(1) Di sabl e and remove the dri vers si de ai rbag.(Re-
fer to 8 - ELECTRI CAL/RESTRAI NTS/DRI VER AI R-
BAG - REMOVAL).
(2) Parti al l y remove the steeri ng wheel bol t and
l eave the bol t i n the col umn.
(3) I nstal l pul l er C-3894–A or equi val ent usi ng the
top of the bol t to push on. (Fi g. 13)
Fig. 11 KEY CYLINDER RELEASE TANG
1 - KEY CYLINDER
2 - RELEASE TANG
Fig. 12 KEY CYLINDER RELEASE HOLE
1 - Lower Cover
2 - Access Hole
3 - Pin Punch
TJ COLUMN 19 - 11
KEY-IN IGNITION SWITCH (Continued)
NOTE: Ensure the puller jaws are seated in the
pockets (Fig. 14) of the steering wheel armature.
(4) Remove the steeri ng wheel .
INSTALLATION
NOTE: Do not reuse the old steering wheel bolt (a
new bolt must be used)
(1) I nstal l steeri ng wheel to the col umn
NOTE: Be certain that the steering wheel mounting
bolt is tightened to the proper torque specification
to ensure proper clockspring operation.
(2) I nstal l the new steeri ng wheel bol t. Ti ghten the
bol t to 54 N·m (40 ft. l bs.).
(3) I nstal l the dri vers si de ai r bag. (Refer to 8 -
ELECTRI CAL/RESTRAI NTS/DRI VER AI RBAG -
I NSTALLATI ON).
Fig. 13 STEERING WHEEL PULLER
1 - PULLER C-3894-A
2 - STEERING WHEEL
Fig. 14 Steering Wheel Pockets
1 - STEERING WHEEL POCKETS
19 - 12 COLUMN TJ
STEERING WHEEL (Continued)
GEAR
TABLE OF CONTENTS
page page
GEAR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 13
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
DIAGNOSIS AND TESTING - POWER
STEERING GEAR LEAKAGE AREAS . . . . . . . 13
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . 15
SPECIFICATIONS
POWER STEERING GEAR . . . . . . . . . . . . . . 16
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . 16
SPECIAL TOOLS
POWER STEERING GEAR . . . . . . . . . . . . . . 16
GEAR
DESCRIPTION
CAUTION: MOPARா ATF+4 is to be used in the
power steering system. No other power steering or
automatic transmission fluid is to be used in the
system. Damage may result to the power steering
pump and system if any other fluid is used, and do
not overfill.
The power steeri ng system has a hydraul i c pump.
The pump i s a constant fl ow rate and di spl acement
vane-type pump. The pump reservoi r on the 4.0L
engi ne i s mounted to the pump body (Fi g. 1)& (Fi g.
2). The 2.4L engi ne has a remote pump reservoi r
mounted to the fan shroud (Fi g. 3).
The steeri ng gear used i s a strai ght rati o reci rcu-
l ati ng bal l type gear. A ti l t and non-ti l t col umn pro-
vi de steeri ng i nput.
OPERATION
The gear acts as a rol l i ng thread between the
worm shaft and rack pi ston. The worm shaft i s sup-
ported by a thrust beari ng at the upper end. When
the worm shaft i s turned the rack pi ston moves. The
rack pi ston teeth mesh wi th the pi tman shaft. Turn-
i ng the worm shaft turns the pi tman shaft, whi ch
turns the steeri ng l i nkage.
CAUTION: Components attached with a nut and cot-
ter pin must be torqued to specification. Then if the
slot in the nut does not line up with the cotter pin
hole, tighten nut until it is aligned. Never loosen the
nut to align the cotter pin hole.
DIAGNOSIS AND TESTING - POWER STEERING
GEAR LEAKAGE AREAS
NOTE: Do not service the Steering Gear, if the gear
is leaking it must be replaced with a new gear
assembly.
(1) Possi bl e power steeri ng gear l eakage areas.
(Fi g. 4).
REMOVAL
NOTE: The steering column on vehicles with an
automatic transmission may not be equipped with
an internal locking shaft that allows the ignition key
cylinder to be locked with the key. Alternative meth-
ods of locking the steering wheel for service will
have to be used.
Fig. 1 POWER STEERING GEAR & PUMP - 4.0L
1 - POWER STEERING GEAR
2 - PRESSURE HOSE
3 - POWER STEERING RESERVOIR
4 - POWER STEERING PUMP
5 - RETURN HOSE
TJ GEAR 19 - 13
(1) Pl ace the front wheel s i n the strai ght ahead
posi ti on wi th the steeri ng wheel centered and l ocked.
(2) Si phon out as much power steeri ng fl ui d as
possi bl e.
(3) Remove the bumper shi el d.
(4) Remove power steeri ng hoses/tubes from steer-
i ng gear.
(5) Remove the col umn coupl er shaft from the
gear.
(6) Remove pi tman arm from gear. (Refer to 19 -
STEERI NG/LI NKAGE/PI TMAN ARM - REMOVAL).
(7) Remove the steeri ng gear retai ni ng bol ts and
remove the gear (Fi g. 5).
INSTALLATION
(1) I nstal l steeri ng gear on the frame rai l and
ti ghten bol ts to 95 N·m (70 ft. l bs.)
(2) Al i gn and i nstal l the pi tman arm and ti ghten
nut to 251 N·m (185 ft. l bs.).
(3) Al i gn the col umn coupl er shaft to steeri ng gear.
I nstal l a new coupl er pi nch bol t and ti ghten to 49
N·m (36 ft. l bs.).
Fig. 2 RHD POWER STEERING HOSES
1 - PRESSURE HOSE
2 - RETURN HOSE
3 - MOUNTING BRACKETS
4 - STEERING GEAR
Fig. 3 POWER STEERING GEAR & PUMP - 2.4L
1 - REMOTE RESERVOIR
2 - POWER STEERING PUMP
3 - PUMP MOUNT BRACKET
4 - MOUNTING BOLTS (3)
5 - PRESSURE SWITCH LOCATION
6 - PRESSURE OUTLET HOSE (GEAR TO PUMP)
7 - RETURN HOSE (RESERVOIR TO PUMP)
8 - CLAMPS
9 - STEERING GEAR
10 - INLET HOSE (RESERVOIR TO GEAR)
Fig. 4 STEERING GEAR
1 - VALVE HOUSING O-RING
2 - ADJUSTER NUT
3 - POWER STEERING LINE FITTINGS
4 - INPUT SHAFT HOUSING GASKET
5 - INPUT SHAFT SEAL
6 - PITMAN SHAFT SEAL HOUSING / COVER O-RING
Fig. 5 STEERING GEAR REMOVAL/INSTALL
1 - STEERING GEAR
2 - FRAME MOUNT
19 - 14 GEAR TJ
GEAR (Continued)
(4) I nstal l power steeri ng hoses/tubes to steeri ng
gear and ti ghten to 28 N·m (21 ft. l bs.).
(5) I nstal l the bumper shi el d.
(6) Fi l l power steeri ng system to proper l evel ,
(Refer to 19 - STEERI NG/PUMP - STANDARD PRO-
CEDURE).
ADJUSTMENTS
CAUTION: Steering gear must be adjusted in the
proper order. If adjustments are not performed in
order, gear damage and improper steering response
may result.
NOTE: Adjusting the steering gear in the vehicle is
not recommended. Remove gear from the vehicle
and drain the fluid. Then mount gear in a vise to
perform adjustments.
WORM THRUST BEARING PRELOAD
NOTE: Off center torque (180 to 360 degrees from
gear center) = 0.4 to 0.8 Nm (3.5 in-lb to 7.0 in-lb)
This torque is set in the assembly plant and can’t
be adjusted in the field
OVER-CENTER ROTATING TORQUE
(1) Mount the gear careful l y i nto a vi se.
CAUTION: Do not overtighten the vise on the gear
case. This may affect the adjustment
(2) Rotate the i nput shaft wi th a crows foot socket
from stop to stop and count the number of turns.
(3) Starti ng at ei ther stop, turn the i nput shaft
back 1/2 the total number of turns. Thi s i s the center
of the gear travel .
(4) Loosen the adjuster pl ug l ocknut.
(5) Pl ace the torque wrench i n the verti cal posi ti on
on the i nput shaft. Rotate the wrench 50 degrees
each si de of the center and record the hi ghest rota-
ti onal torque i n thi s range (Fi g. 6). Thi s i s the Over-
Center Rotati ng Torque.
NOTE: The input shaft must rotate smoothly with-
out sticking or binding.
(6) The Over-Center Rotati ng Torque shoul d be
0.53-0.93 N·m (4.5 - 8 i n. l bs.) higher i n addi ti on to
the off center torque from above (Fi g. 6). than the
Prel oad Rotati ng Torque.
(7) I f an adjustment to the Over-Center Rotati ng
Torque i s necessary, fi rst l oosen the adjuster l ock
nut. Then turn the pi tman shaft adjuster screw back
(COUNTERCLOCKWI SE) i ncreases torque,
(CLOCKWI SE) reduces torque (Fi g. 7).
(8) Remeasure Over-Center Rotati ng Torque. I f
necessary turn the adjuster screw and repeat mea-
surement unti l correct Over-Center Rotati ng Torque
i s reached (Fi g. 7).
NOTE: To increase the Over-Center Rotating Torque
turn the screw COUNTERCLOCKWISE.
(9) Prevent the adjuster screw from turni ng whi l e
ti ghteni ng adjuster l ock nut (Fi g. 7). Ti ghten the
adjuster l ock nut to 65 N·m (48 ft. l bs.).
Fig. 6 OVER-CENTER TORQUE
1 - CROWSFOOT WRENCH
2 - INCH POUND TORQUE WRENCH
3 - STEERING GEAR
Fig. 7 OVER-CENTER ADJUSTMENT
1 - RATCHET WITH ADAPTER
2 - WRENCH
3 - CROWSFOOT WRENCH
4 - INCH POUND TORQUE WRENCH
5 - STEERING GEAR
6 - ALLEN HEAD SOCKET
TJ GEAR 19 - 15
GEAR (Continued)
SPECIFICATIONS
POWER STEERING GEAR
SPECIFICATIONS
DESCRIPTION SPECIFICATION
Steering Gear
Type
Recirculating Ball
Steering Gear
Gear Ratio
15:24
Worm Shaft Bearing
Preload
0.53–.93 N·m (3.5–8 in.
lbs.)
Pitman Shaft Over-
Center Drag
New Gear (under 400
miles)
.133 N·m (1.17 in. lbs.) +
Worm Shaft Preload
Pitman Shaft Over-
Center Drag
Used Gear (over 400
miles)
.133 N·m (1.17 in. lbs.) +
Worm Shaft Preload
TORQUE CHART
TORQUE SPECIFICATIONS
DESCRIPTION N·m Ft. Lbs. In. Lbs.
Power Steering Gear
Adjustment Screw Locknut
65 48 —
Power Steering Gear
Gear to Frame Bolts
95 70 —
Power Steering Gear
Pitman Shaft Nut
251 185 —
Power Steering Gear
Pressure Line
28 21 —
Power Steering Gear
Return Line
28 21 —
SPECIAL TOOLS
POWER STEERING GEAR
Remover, Pitman Arm C-4150A
19 - 16 GEAR TJ
GEAR (Continued)
LINKAGE
TABLE OF CONTENTS
page page
LINKAGE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 17
STANDARD PROCEDURE
STANDARD PROCEDURE - LUBRICATION . . 17
STANDARD PROCEDURE - STEERING
LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . 18
SPECIAL TOOLS
STEERING LINKAGE . . . . . . . . . . . . . . . . . . . 18
DAMPER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 18
DRAG LINK
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 19
PITMAN ARM
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 19
TIE ROD END
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 19
LINKAGE
DESCRIPTION
The steeri ng l i nkage consi sts of a pi tman arm,
drag l i nk, ti e rod, and steeri ng dampener (Fi g. 1).
Adjustment sl eeves are used on the ti e rod and drag
l i nk for toe and steeri ng wheel al i gnment.
The servi ce procedures and torque speci fi cati ons
are the same for LHD and RHD vehi cl es.
STANDARD PROCEDURE
STANDARD PROCEDURE - LUBRICATION
Peri odi c l ubri cati on of the steeri ng system compo-
nents i s requi red. Refer to Lubri cati on And Mai nte-
nance for the recommended mai ntenance schedul e.
The fol l owi ng components must be l ubri cated:
• Ti e rod ends
• Drag l i nk
STANDARD PROCEDURE - STEERING LINKAGE
The ti e rod end and bal l stud seal s shoul d be
i nspected duri ng al l oi l changes. I f a seal i s damaged,
i t shoul d be repl aced. Before i nstal l i ng a new seal ,
i nspect bal l stud at the throat openi ng. Check for
l ubri cant l oss, contami nati on, bal l stud wear or cor-
rosi on. I f these condi ti ons exi st, repl ace the ti e rod. A
repl acement seal can be i nstal l ed i f l ubri cant i s i n
good condi ti on. Otherwi se, a compl ete repl acement
bal l stud end shoul d be i nstal l ed.
CAUTION: If any steering components are replaced
or serviced an alignment must be performed, to
ensure the vehicle meets all alignment specifica-
tions.
CAUTION: Components attached with a nut and cot-
ter pin must be torqued to specification. Then if the
slot in the nut does not line up with the cotter pin
hole, tighten nut until it is aligned. Never loosen the
nut to align the cotter pin hole.
Fig. 1 Steering Linkage
1 - COTTER PIN
2 - NUT
3 - DAMPENER
4 - PITMAN ARM
5 - WASHER
6 - TIE ROD
7 - DRAG LINK
TJ LINKAGE 19 - 17
SPECIFICATIONS
TORQUE CHART
TORQUE SPECIFICATIONS
DESCRIPTION N·m Ft. Lbs. In. Lbs.
Pitman Arm
Shaft
251 185 —
Drag Link
Ball Studs
74 55 —
Drag Link
Clamp
49 36 —
Tie Rod Ends
Ball Studs
74 55 —
Tie Rod Ends
Clamp
27 20 —
Tie Rod
Ball Stud
88 65 —
Steering Damper
Frame
74 55 —
Steering Damper
Drag Link
74 55 —
SPECIAL TOOLS
STEERING LINKAGE
DAMPER
REMOVAL
(1) Pl ace the front wheel s i n a strai ght ahead posi -
ti on.
(2) Remove the steeri ng dampener retai ni ng nut
and bol t from the axl e bracket (Fi g. 1).
(3) Remove the cotter pi n and nut from the bal l
stud at the drag l i nk.
(4) Remove the steeri ng dampener bal l stud from
the drag l i nk usi ng C-3894-A pul l er.
INSTALLATION
(1) I nstal l the steeri ng dampener to the axl e
bracket and drag l i nk.
(2) I nstal l the steeri ng dampener bol t i n the axl e
bracket and ti ghten nut to 74 N·m (55 ft. l bs.).
(3) I nstal l the bal l stud nut at the drag l i nk and
ti ghten nut to 74 N·m (55 ft. l bs.). I nstal l a new cot-
ter pi n.
Puller C-3894–A
Remover Pitman C-4150A
19 - 18 LINKAGE TJ
LINKAGE (Continued)
DRAG LINK
REMOVAL
(1) Remove the cotter pi ns and nuts at the steer-
i ng knuckl e and drag l i nk (Fi g. 1).
(2) Remove the steeri ng dampener bal l stud from
the drag l i nk wi th a pul l er tool .
(3) Remove the drag l i nk from the steeri ng
knuckl e wi th a pul l er tool . Remove the same for ti e
rod and pi tman arm.
(4) I f necessary, l oosen the end cl amp bol ts and
remove the ti e rod end from the l i nk.
INSTALLATION
(1) I nstal l the drag l i nk adjustment sl eeve and ti e
rod end. Posi ti on cl amp bol ts (Fi g. 3).
(2) Posi ti on the drag l i nk at the steeri ng l i nkage.
I nstal l the drag l i nk to the steeri ng knuckl e nut. Do
the same for the ti e rod and pi tman arm.
(3) Ti ghten the nut at the steeri ng knuckl e to 47
N·m (35 ft. l bs.). Ti ghten the pi tman nut to 81 N·m
(60 ft. l bs.) and ti e rod bal l stud nut to 47 N·m (35 ft.
l bs.). I nstal l new cotter pi ns and bend end 60°.
(4) I nstal l the steeri ng dampener onto the drag
l i nk and ti ghten the nut to 74 N·m (55 ft. l bs.).
I nstal l a new cotter pi n and bend end 60°.
PITMAN ARM
REMOVAL
(1) Remove the cotter pi n and nut from the drag
l i nk at the pi tman arm.
(2) Remove the drag l i nk bal l stud from the pi t-
man arm wi th a pul l er.
(3) Remove the nut and washer from the steeri ng
gear shaft. Mark the pi tman shaft and pi tman arm
for i nstal l ati on reference. Remove the pi tman arm
from steeri ng gear wi th Pul l er C-4150A (Fi g. 2).
INSTALLATION
(1) Al i gn and i nstal l the pi tman arm on steeri ng
gear shaft.
(2) I nstal l the washer and nut on the shaft and
ti ghten the nut to 251 N·m (185 ft. l bs.).
(3) I nstal l drag l i nk bal l stud to pi tman arm.
I nstal l nut and ti ghten to 81 N·m (60 ft. l bs.). I nstal l
a new cotter pi n.
TIE ROD END
REMOVAL
(1) Remove the cotter pi ns and nuts at the steer-
i ng knuckl e and drag l i nk (Fi g. 1).
(2) Remove the bal l studs wi th pul l er tool
C-4150R.
(3) I f necessary, l oosen the end cl amp bol ts and
remove the ti e rod ends from the tube.
INSTALLATION
(1) I f necessary, i nstal l the ti e rod ends i n the
tube. Posi ti on the ti e rod cl amp (Fi g. 3) and ti ghten
to 27 N·m (20 ft. l bs.).
(2) I nstal l the ti e rod on the drag l i nk and steeri ng
knuckl e.
(3) Ti ghten the bal l stud nut on the steeri ng
knuckl e to 47 N·m (35 ft. l bs.). Ti ghten the bal l stud
nut to drag l i nk to 47 N·m (35 ft. l bs.) torque. I nstal l
new cotter pi ns.
Fig. 2 PITMAN ARM PULLER
1 - PITMAN ARM
2 - SPECIAL TOOL C-4150-A
3 - WRENCH
Fig. 3 Tie Rod
1 - TIE ROD CLAMP
2 - DRAG LINK CLAMPS
TJ LINKAGE 19 - 19
PUMP
TABLE OF CONTENTS
page page
PUMP
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 20
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
DIAGNOSIS AND TESTING - PUMP LEAKAGE . 20
STANDARD PROCEDURE - POWER
STEERING PUMP - INITIAL OPERATION . . . . 20
REMOVAL
REMOVAL - 4.0L . . . . . . . . . . . . . . . . . . . . . . 21
REMOVAL - 2.4L . . . . . . . . . . . . . . . . . . . . . . 21
INSTALLATION
INSTALLATION - 4.0L . . . . . . . . . . . . . . . . . . 21
INSTALLATION - 2.4L . . . . . . . . . . . . . . . . . . 22
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . 23
SPECIAL TOOLS
POWER STEERING PUMP . . . . . . . . . . . . . . 23
HOSES
DESCRIPTION
DESCRIPTION - PRESSURE LINE . . . . . . . . 24
DESCRIPTION - RETURN LINE . . . . . . . . . . . 24
OPERATION
OPERATION - PRESSURE LINE . . . . . . . . . . 24
OPERATION - RETURN LINE . . . . . . . . . . . . 24
FLUID
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 24
STANDARD PROCEDURE - POWER
STEERING FLUID LEVEL CHECKING . . . . . . 24
POWER STEERING PRESSURE SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 24
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 25
PULLEY
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 25
RESERVOIR
REMOVAL
REMOVAL - 4.0L . . . . . . . . . . . . . . . . . . . . . . 26
REMOVAL - 2.4L . . . . . . . . . . . . . . . . . . . . . . 26
INSTALLATION
INSTALLATION - 4.0L . . . . . . . . . . . . . . . . . . 26
INSTALLATION - 2.4L . . . . . . . . . . . . . . . . . . 26
PUMP
DESCRIPTION
Hydraul i c pressure for the power steeri ng system
i s provi ded by a bel t dri ven power steeri ng pump
(Fi g. 1). The pump shaft has a pressed-on hi gh
strength pl asti c dri ve pul l ey that i s bel t dri ven by
the crankshaft pul l ey. The reservoi r i s attached to
the pump body wi th spri ng cl i ps on the 4.0L engi ne.
A remote pump reservoi r i s used on the 2.4L engi ne
mounted to the fan shroud. The power steeri ng pump
i s connected to the steeri ng gear by the pressure and
return hoses.
OPERATION
The power steeri ng pump i s a constant fl ow rate
and di spl acement, vane-type pump. The pump i nter-
nal parts operate submerged i n fl ui d. The fl ow con-
trol ori fi ce i s part of the hi gh pressure l i ne fi tti ng.
The pressure rel i ef val ve i nsi de the fl ow control val ve
l i mi ts the pump pressure.
NOTE: Power steering pumps have different pres-
sure rates and are not interchangeable with other
pumps.
DIAGNOSIS AND TESTING - PUMP LEAKAGE
(1) Possi bl e areas of pump l eakage (Fi g. 2).
STANDARD PROCEDURE - POWER STEERING
PUMP - INITIAL OPERATION
WARNING: THE FLUID LEVEL SHOULD BE
CHECKED WITH ENGINE OFF TO PREVENT INJURY
FROM MOVING COMPONENTS.
CAUTION: MOPARா ATF+4 is to be used in the
power steering system. No other power steering or
automatic transmission fluid is to be used in the
system. Damage may result to the power steering
pump and system if any other fluid is used, and do
not overfill.
Wi pe fi l l er cap cl ean, then check the fl ui d l evel .
The di psti ck shoul d i ndi cate COLD when the fl ui d i s
at normal ambi ent temperature.
(1) Fi l l the pump fl ui d reservoi r to the proper l evel
and l et the fl ui d settl e for at l east two mi nutes.
(2) Start the engi ne and l et run for a few seconds
then turn engi ne off.
19 - 20 PUMP TJ
(3) Add fl ui d i f necessary. Repeat the above proce-
dure unti l the fl ui d l evel remai ns constant after run-
ni ng the engi ne.
(4) Rai se the front wheel s off the ground.
(5) Sl owl y turn the steeri ng wheel ri ght and l eft,
l i ghtl y contacti ng the wheel stops at l east 20 ti mes.
(6) Check the fl ui d l evel add i f necessary.
(7) Lower the vehi cl e, start the engi ne and turn
the steeri ng wheel sl owl y from l ock to l ock.
(8) Stop the engi ne and check the fl ui d l evel and
refi l l as requi red.
(9) I f the fl ui d i s extremel y foamy or mi l ky l ook-
i ng, al l ow the vehi cl e to stand a few mi nutes and
repeat the procedure.
CAUTION: Do not run a vehicle with foamy fluid for
an extended period. This may cause pump damage.
REMOVAL
REMOVAL - 4. 0L
(1) Remove serpenti ne dri ve bel t, (Refer to 7 -
COOLI NG/ACCESSORY DRI VE/DRI VE BELTS -
REMOVAL).
(2) Remove pressure and return hoses from pump
and drai n the pump.
(3) Loosen the pump bracket bol t at the engi ne
bl ock.
(4) Remove 3 pump mounti ng bol ts (Fi g. 3)
through pul l ey access hol es.
(5) Ti l t pump downward and remove from engi ne.
(6) Remove pul l ey from pump. (Refer to 19 -
STEERI NG/PUMP/PULLEY - REMOVAL).
REMOVAL - 2. 4L
(1) Remove serpenti ne dri ve bel t, (Refer to 7 -
COOLI NG/ACCESSORY DRI VE/DRI VE BELTS -
REMOVAL).
(2) Remove pressure and return hoses from pump
and drai n the pump.
(3) Remove 3 pump mounti ng bol ts (Fi g. 4)
through pul l ey access hol es.
(4) Loosen the 3 pump bracket bol ts.
(5) Ti l t pump downward and remove from engi ne.
(6) Remove pul l ey from pump. (Refer to 19 -
STEERI NG/PUMP/PULLEY - REMOVAL).
INSTALLATION
INSTALLATION - 4. 0L
(1) I nstal l pul l ey on pump. (Refer to 19 - STEER-
I NG/PUMP/PULLEY - I NSTALLATI ON).
(2) I nstal l pump on the engi ne mounti ng bracket.
(3) I nstal l 3 pump mounti ng bol ts and ti ghten to
27 N·m (20 ft. l bs.).
Fig. 1 Pump With Integral Reservoir
1 - CAP
2 - FLUID RESERVOIR (TYPICAL)
3 - HIGH-PRESSURE FITTING
4 - DRIVE PULLEY
5 - PUMP BODY
6 - RESERVOIR CLIP
Fig. 2 Power Steering Pump
TJ PUMP 19 - 21
PUMP (Continued)
(4) Ti ghten pump bracket bol t to 57 N·m (42 ft.
l bs.).
(5) I nstal l the pressure l i ne on the pump and
ti ghten to 28 N·m (21 ft. l bs.).
(6) I nstal l return hoses on pump.
(7) I nstal l dri ve bel t, (Refer to 7 - COOLI NG/AC-
CESSORY DRI VE/DRI VE BELTS - I NSTALLA-
TI ON).
(8) Add power steeri ng fl ui d, refer to Power Steer-
i ng Pump I ni ti al Operati on. (Refer to 19 - STEER-
I NG/PUMP - STANDARD PROCEDURE).
INSTALLATION - 2. 4L
(1) I nstal l pul l ey on pump. (Refer to 19 - STEER-
I NG/PUMP/PULLEY - I NSTALLATI ON).
(2) I nstal l pump on the engi ne mounti ng bracket.
(3) Ti ghten pump bracket bol ts to 47 N·m (35 ft.
l bs.).
(4) I nstal l 3 pump mounti ng bol ts and ti ghten to
27 N·m (20 ft. l bs.).
(5) I nstal l the pressure l i ne on the pump and
ti ghten to 28 N·m (21 ft. l bs.).
(6) I nstal l return hoses on pump.
(7) I nstal l dri ve bel t, (Refer to 7 - COOLI NG/AC-
CESSORY DRI VE/DRI VE BELTS - I NSTALLA-
TI ON).
(8) Add power steeri ng fl ui d, refer to Power Steer-
i ng Pump I ni ti al Operati on. (Refer to 19 - STEER-
I NG/PUMP - STANDARD PROCEDURE).
Fig. 3 Pump Mounting – 4.0L
1 - PUMP ASSEMBLY
2 - PUMP BRACKET
Fig. 4 POWER STEERING GEAR & PUMP - 2.4L
1 - REMOTE RESERVOIR
2 - POWER STEERING PUMP
3 - PUMP MOUNT BRACKET
4 - MOUNTING BOLTS (3)
5 - PRESSURE SWITCH LOCATION
6 - PRESSURE OUTLET HOSE (GEAR TO PUMP)
7 - RETURN HOSE (RESERVOIR TO PUMP)
8 - CLAMPS
9 - STEERING GEAR
10 - INLET HOSE (RESERVOIR TO GEAR)
19 - 22 PUMP TJ
PUMP (Continued)
SPECIFICATIONS
TORQUE CHART
TORQUE SPECIFICATIONS
DESCRIPTION N·m Ft. Lbs. In. Lbs.
Power Steering Pump
Bracket to Pump
28 21 —
Power Steering Pump
Bracket to 4.0L Engine
57 42 —
Power Steering Pump
Bracket to 2.4L Engine
28 21 —
Power Steering Pump
Flow Control Valve
75 55 —
Power Steering Pump
Pressure Line
28 21 —
SPECIAL TOOLS
POWER STEERING PUMP
Analyzer Set, Power Steering Flow/Pressure 6815
Adapters, Power Steering Flow/Pressure Tester
6893
Puller C-4333
Installer, Power Steering Pulley C-4063B
TJ PUMP 19 - 23
PUMP (Continued)
HOSES
DESCRIPTION
DESCRIPTION - PRESSURE LINE
The hose consi sts of two metal ends and rubber
center secti on that contai ns a tuni ng cabl e.
DESCRIPTION - RETURN LINE
Power steeri ng return l i ne i s a hose whi ch i s
cl amped at the pump and the gear.
OPERATION
OPERATION - PRESSURE LINE
Power steeri ng pressure l i ne, i s used to transfer
hi gh pressure power steeri ng fl ui d, from the power
steeri ng pump to the power steeri ng gear.
OPERATION - RETURN LINE
Power steeri ng return l i ne, i s used to transfer l ow
pressure power steeri ng fl ui d, from the power steer-
i ng gear to the power steeri ng pump.
FLUID
DESCRIPTION
The recommended fl ui d for the power steeri ng sys-
tem i s Mopar௡ ATF +4.
Mopar௡ ATF+4, when new i s red i n col or. The
ATF+4 i s dyed red so i t can be i denti fi ed from other
fl ui ds used i n the vehi cl e such as engi ne oi l or anti -
freeze. The red col or i s not permanent and i s not an
i ndi cator of fl ui d condi ti on, As the vehi cl e i s dri ven,
the ATF+4 wi l l begi n to l ook darker i n col or and may
eventual l y become brown. THIS IS NORMAL.
ATF+4 al so has a uni que odor that may change wi th
age. Consequentl y, odor and col or cannot be used to
i ndi cate the fl ui d condi ti on or the need for a fl ui d
change.
STANDARD PROCEDURE - POWER STEERING
FLUID LEVEL CHECKING
WARNING: FLUID LEVEL SHOULD BE CHECKED
WITH THE ENGINE OFF TO PREVENT PERSONAL
INJURY FROM MOVING PARTS.
CAUTION: MOPARா ATF+4 is to be used in the
power steering system. No other power steering or
automatic transmission fluid is to be used in the
system. Damage may result to the power steering
pump and system if any other fluid is used, and do
not overfill.
The power steeri ng fl ui d l evel can be vi ewed on the
di psti ck attached to the fi l l er cap. There are two
ranges l i sted on the di psti ck, COLD and HOT. Before
openi ng power steeri ng system, wi pe the reservoi r
fi l l er cap free of di rt and debri s. Remove the cap and
check the fl ui d l evel on i ts di psti ck. When the fl ui d i s
at normal ambi ent temperature, approxi matel y 21°C
to 27°C (70°F to 80°F), the fl ui d l evel shoul d read
between the mi ni mum and maxi mum area of the col d
range. When the fl ui d i s hot, fl ui d l evel i s al l owed to
read up to the hi ghest end of the HOT range. Onl y
add fl ui d when the vehi cl e i s col d.
Use only Mopar௡ ATF+4 Do not overfi l l the
power steeri ng system.
POWER STEERING PRESSURE
SWITCH
DESCRIPTION
A pressure sensi ng swi tch (Fi g. 5) i s i ncl uded i n
the power steeri ng system (mounted on the hi gh-
pressure l i ne). Thi s swi tch wi l l be used onl y on vehi -
cl es equi pped wi th a 2.4L engi ne and power steeri ng.
OPERATION
The power steeri ng pressure swi tch provi des an
i nput to the Powertrai n Control Modul e (PCM). Thi s
i nput i s provi ded duri ng peri ods of hi gh pump l oad
and l ow engi ne rpm; such as duri ng parki ng maneu-
vers. The PCM wi l l then i ncrease the i dl e speed
through the I dl e Ai r Control (I AC) motor. Thi s i s
done to prevent the engi ne from stal l i ng under the
i ncreased l oad.
Fig. 5 2.4L POWER STEERING PRESSURE SWITCH
1 - PRESSURE SWITCH
2 - PRESSURE HOSE
3 - POWER STEERING PUMP AND PULLEY ASSEMBLY
19 - 24 PUMP TJ
When steeri ng pump pressure exceeds 5860 kPa ±
690 kPa (850 psi ± 100 psi ), the normal l y cl osed
swi tch wi l l open and the PCM wi l l i ncrease the
engi ne i dl e speed. Thi s wi l l prevent the engi ne from
stal l i ng.
When pump pressure drops to approxi matel y 1379
kPa (200 psi ), the swi tch ci rcui t wi l l re-cl ose and
engi ne i dl e speed wi l l return to i ts previ ous setti ng.
REMOVAL
Thi s swi tch i s not used wi th 4.0L si x-cyl i nder
engi nes.
The power steeri ng pressure swi tch i s i nstal l ed i n
the power steeri ng hi gh-pressure hose (Fi g. 5).
(1) Di sconnect el ectri cal connector from power
steeri ng pressure swi tch.
(2) Pl ace a smal l contai ner or shop towel beneath
swi tch to col l ect any excess fl ui d.
(3) Remove swi tch. Use back-up wrench on power
steeri ng l i ne to prevent l i ne bendi ng.
INSTALLATION
Thi s swi tch i s not used wi th 4.0L si x-cyl i nder
engi nes.
(1) I nstal l power steeri ng swi tch i nto power steer-
i ng l i ne.
(2) Ti ghten to 14–22 N·m (124–195 i n. l bs.) torque.
(3) Connect el ectri cal connector to swi tch.
(4) Check power steeri ng fl ui d and add as neces-
sary.
(5) Start engi ne and agai n check power steeri ng
fl ui d. Add fl ui d i f necessary.
PULLEY
REMOVAL
CAUTION: On vehicles equipped with the 4.0L, Do
not reuse the old power steering pump pulley it is
not intended for reuse. A new pulley must be
installed if removed.
(1) Remove pump assembl y.
(2) Remove pul l ey from pump wi th Pul l er C-4333
or equi val ent pul l er (Fi g. 6).
INSTALLATION
NOTE: The pulley is marked front for installation.
CAUTION: On vehicles equipped with the 4.0L, Do
not reuse the old power steering pump pulley it is
not intended for reuse. A new pulley must be
installed if removed.
(1) Repl ace pul l ey i f bent, cracked, or l oose.
(2) I nstal l pul l ey on pump wi th I nstal l er C-4063-B
or equi val ent i nstal l er (Fi g. 7). The pul l ey must be
fl ush wi th the end of the shaft. Ensure the tool and
pul l ey are al i gned wi th the pump shaft.
(3) I nstal l pump assembl y.
(4) Wi th Serpenti ne Bel t, run engi ne unti l warm (5
mi n.) and note any bel t chi rp. I f chi rp exi sts, move
pul l ey outward approxi matel y 0.5 mm (0.020 i n.). I f
noi se i ncreases, press on 1.0 mm (0.040 i n.). Be
careful that pulley does not contact mounting
bolts.
Fig. 6 Pulley Removal
1 - POWER STEERING PUMP DRIVE PULLEY
2 - SPECIAL TOOL C-4333
Fig. 7 Pulley Installation
1- POWER STEERING PUMP DRIVE PULLEY
2 - SPECIAL TOOL C-4063-B
TJ PUMP 19 - 25
POWER STEERING PRESSURE SWITCH (Continued)
RESERVOIR
REMOVAL
REMOVAL - 4. 0L
(1) Remove power steeri ng pump. (Refer to 19 -
STEERI NG/PUMP - REMOVAL).
(2) Cl ean exteri or of pump.
(3) Cl amp the pump body i n a soft jaw vi ce.
(4) Pry up tab and sl i de the retai ni ng cl i ps off
(Fi g. 8).
NOTE: Use new retaining clips for installation.
(5) Remove fl ui d reservoi r from pump body.
Remove and di scard O-ri ng seal .
REMOVAL - 2. 4L
(1) Remove the pump return hoses from the reser-
voi r and drai n the reservoi r.
(2) Remove the push-i n fastener from the reservoi r
(Fi g. 9).
(3) Sl i de the reservoi r up out of the fan shroud
mount.
INSTALLATION
INSTALLATION - 4. 0L
(1) Lubri cate new O-ri ng Seal wi th Mopar Power
Steeri ng Fl ui d or equi val ent.
(2) I nstal l O-ri ng seal i n housi ng.
(3) I nstal l reservoi r onto housi ng.
(4) Sl i de and tap i n new reservoi r retai ner cl i ps
unti l tab l ocks to housi ng.
(5) I nstal l power steeri ng pump. (Refer to 19 -
STEERI NG/PUMP - I NSTALLATI ON).
(6) Add power steeri ng fl ui d, (Refer to 19 -
STEERI NG/PUMP - STANDARD PROCEDURE).
INSTALLATION - 2. 4L
(1) Sl i de reservoi r down onto the fan shroud
mount unti l i t cl i cks i n pl ace.
(2) I nstal l the push-i n fastener.
(3) I nstal l the hoses.
(4) Fi l l reservoi r to proper l evel , (Refer to 19 -
STEERI NG/PUMP - STANDARD PROCEDURE).
Fig. 8 Pump Reservoir Clips
1 - RESERVOIR
2 - RETAINING CLIPS
Fig. 9 POWER STEERING GEAR & PUMP - 2.4L
1 - REMOTE RESERVOIR
2 - POWER STEERING PUMP
3 - PUMP MOUNT BRACKET
4 - MOUNTING BOLTS (3)
5 - PRESSURE SWITCH LOCATION
6 - PRESSURE OUTLET HOSE (GEAR TO PUMP)
7 - RETURN HOSE (RESERVOIR TO PUMP)
8 - CLAMPS
9 - STEERING GEAR
10 - INLET HOSE (RESERVOIR TO GEAR)
19 - 26 PUMP TJ
TRANSMISSION AND TRANSFER CASE
TABLE OF CONTENTS
page page
MANUAL - NV1500 . . . . . . . . . . . . . . . . . . . . . . . . 1
MANUAL - NV3550 . . . . . . . . . . . . . . . . . . . . . . . 32
AUTOMATIC TRANSMISSION - 42RLE . . . . . . . . 70
TRANSFER CASE - NV231 . . . . . . . . . . . . . . . . 196
TRANSFER CASE - NV241 . . . . . . . . . . . . . . . . 231
MANUAL - NV1500
TABLE OF CONTENTS
page page
MANUAL - NV1500
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . 2
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 10
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 28
SPECIFICATIONS
MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . 30
MANUAL - NV1500
DESCRIPTION
The NV1500 i s a 5-speed, constant mesh, ful l y syn-
chroni zed manual transmi ssi on. The transmi ssi on i s
avai l abl e i n vehi cl es equi pped wi th a 2.4L engi ne.
The transmi ssi on gear case consi sts of two al umi -
num gear housi ngs and a detachabl e cl utch housi ng.
The mai nshaft i s supported by two seal ed bal l
beari ngs, and the countershaft i s supported by two
tapered rol l er beari ngs. The transmi ssi on gears al l
rotate on caged type needl e beari ngs. A rol l er beari ng
i s used between the i nput and output shaft.
The Transmi ssi on has a si ngl e shaft shi ft mecha-
ni sm wi th three shi ft forks al l mounted on the shaft.
The shaft i s supported i n the front and rear housi ngs
by bushi ngs. I nternal shi ft components consi st of the
forks, shaft, shi ft l ever socket, and detent compo-
nents.
The drai n pl ug i n on the bottom of the transmi s-
si on and fi l l pl ug i s on the si de.
OPERATION
The dri ver sel ects a parti cul ar gear by movi ng the
shi ft l ever to the desi red gear posi ti on. As the shi ft
l ever moves the sel ected shi ft rai l , the shi ft fork
attached to that rai l begi ns to move. The fork i s posi -
ti oned i n a groove i n the outer ci rcumference of the
synchroni zer sl eeve. As the shi ft fork moves the syn-
chroni zer sl eeve, the synchroni zer begi ns to speed-up
or sl ow down the sel ected gear (dependi ng on
whether we are up-shi fti ng or down-shi fti ng). The
synchroni zer does thi s by havi ng the synchroni zer
hub spl i ned to the mai nshaft, or the countershaft i n
some cases, and movi ng the bl ocker ri ng i nto contact
wi th the gear’s fri cti on cone. As the bl ocker ri ng and
fri cti on cone come together, the gear speed i s brought
up or down to the speed of the synchroni zer. As the
two speeds match, the spl i nes on the i nsi de of the
synchroni zer sl eeve become al i gned wi th the teeth on
the bl ocker ri ng and the fri cti on cone and eventual l y
wi l l sl i de over the teeth, l ocki ng the gear to the
mai nshaft, or countershaft, through the synchroni zer.
TJ TRANSMISSION AND TRANSFER CASE 21 - 1
DIAGNOSIS AND TESTING
LOW LUBRICANT LEVEL
A l ow transmi ssi on l ubri cant l evel i s general l y the
resul t of a l eak, i nadequate l ubri cant fi l l , or an i ncor-
rect l ubri cant l evel check.
Leaks can occur at the mati ng surfaces of the gear
case, i ntermedi ate pl ate and adaptor or extensi on
housi ng, or from the front/rear seal s. A suspected
l eak coul d al so be the resul t of an overfi l l condi ti on.
Leaks at the rear of the extensi on or adapter hous-
i ng wi l l be from the housi ng oi l seal s. Leaks at com-
ponent mati ng surfaces wi l l probabl y be the resul t of
i nadequate seal er, gaps i n the seal er, i ncorrect bol t
ti ghteni ng, or use of a non–recommended seal er.
A l eak at the front of the transmi ssi on wi l l be from
ei ther the front beari ng retai ner or retai ner seal .
Lubri cant may be seen dri ppi ng from the cl utch
housi ng after extended operati on. I f the l eak i s
severe, i t may al so contami nate the cl utch di sc caus-
i ng the di sc to sl i p, grab, and/or chatter.
A correct l ubri cant l evel check can onl y be made
when the vehi cl e i s l evel . Al so al l ow the l ubri cant to
settl e for a mi nute or so before checki ng. These rec-
ommendati ons wi l l ensure an accurate check and
avoi d an underfi l l or overfi l l condi ti on. Al ways check
the l ubri cant l evel after any addi ti on of fl ui d to avoi d
an i ncorrect l ubri cant l evel condi ti on.
HARD SHIFTING
Hard shi fti ng i s usual l y caused by a l ow l ubri cant
l evel , i mproper, or contami nated l ubri cants. The con-
sequence of usi ng non–recommended l ubri cants i s
noi se, excessi ve wear, i nternal bi nd, and hard shi ft-
i ng. Substanti al l ubri cant l eaks can resul t i n gear,
shi ft rai l , synchro, and beari ng damage. I f a l eak
goes undetected for an extended peri od, the fi rst i ndi -
cati ons of component damage are usual l y hard shi ft-
i ng and noi se.
Shi ft component damage, i ncorrect cl utch adjust-
ment, or a damaged cl utch pressure pl ate or di sc are
addi ti onal probabl e causes of i ncreased shi ft effort.
I ncorrect adjustment or a worn/damaged pressure
pl ate or di sc can cause i ncorrect rel ease. I f the cl utch
probl em i s advanced, gear cl ash duri ng shi fts can
resul t. Worn or damaged synchro ri ngs can cause
gear cl ash when shi fti ng i nto any forward gear. I n
some new or rebui l t transmi ssi ons, new synchro
ri ngs may tend to sti ck sl i ghtl y causi ng hard or noi sy
shi fts. I n most cases, thi s condi ti on wi l l decl i ne as
the ri ngs wear-i n.
TRANSMISSION NOISE
Most manual transmi ssi ons make some noi se dur-
i ng normal operati on. Rotati ng gears generate a mi l d
whi ne that i s audi bl e, but general l y onl y at extreme
speeds.
Severe, hi ghl y audi bl e transmi ssi on noi se i s gener-
al l y the i ni ti al i ndi cator of a l ubri cant probl em.
I nsuffi ci ent, i mproper, or contami nated l ubri cant wi l l
promote rapi d wear of gears, synchros, shi ft rai l s,
forks and beari ngs. The overheati ng caused by a
l ubri cant probl em, can al so l eads to gear and beari ng
damage.
REMOVAL
(1) Wi th vehi cl e i n neutral , posi ti on vehi cl e on
hoi st.
(2) Support engi ne wi th jack stand. Posi ti on wood
bl ock between jack and oi l pan to avoi d damagi ng
pan.
(3) Remove ski d pl ate/crossmember.
(4) Support transmi ssi on wi th a trans jack.
(5) Remove transmi ssi on mount from transmi ssi on
and exhaust.
(6) Remove propel l er shafts.
(7) Remove transfer case shi ft l i nkage and vent
hose.
(8) Remove wi ri ng connectors from transmi ssi on
and transfer case.
(9) Remove transfer case.
(10) Remove sl ave cyl i nder from cl utch housi ng.
(11) Remove starter.
(12) Remove transmi ssi on dust shi el d.
(13) Lower trans jack enough to remove shi ft
tower bol ts.
(14) Lower transmi ssi on jack and remove trans-
mi ssi on from under vehi cl e.
(15) Pul l transmi ssi on jack rearward (Fi g. 1) unti l
i nput shaft cl ears cl utch.
Fig. 1 TRANSMISSION ASSEMBLY
1 - CLUTCH HOUSING
2 - TRANSMISSION JACK
3 - TRANSMISSION
21 - 2 MANUAL - NV1500 TJ
MANUAL - NV1500 (Continued)
(16) Remove cl utch rel ease beari ng, rel ease fork
and retai ner cl i p (Fi g. 2).
(17) Remove cl utch housi ng from transmi ssi on.
DISASSEMBLY
FRONT HOUSING
(1) Shi ft transmi ssi on i nto Neutral .
(2) Remove drai n pl ug and drai n l ubri cant i nto a
contai ner.
(3) Remove backup l i ght swi tch (Fi g. 3).
(4) Remove shi ft tower bol ts and remove tower and
l ever assembl y (Fi g. 4).
(5) Remove shi ft shaft l ock bol t (Fi g. 5). Bol t
secures the shi ft shaft bushi ng and l ever.
Fig. 2 CLUTCH RELEASE BEARING
1 - FORK
2 - BEARING
3 - CLIP
Fig. 3 BACKUP LIGHT SWITCH
1 - BACKUP LAMP SWITCH
Fig. 4 SHIFT TOWER
1 - SHIFT TOWER AND LEVER ASSEMBLY
2 - SHIFT SOCKET
3 - SEAL
Fig. 5 SHIFT SHAFT BUSHING LOCK BOLT
1 - SHIFT SHAFT LOCK BOLT
2 - SHAFT SOCKET
TJ MANUAL - NV1500 21 - 3
MANUAL - NV1500 (Continued)
(6) Remove shi ft shaft detent pl ug wi th Remover
8117A (Fi g. 6).
(7) Remove shi ft shaft detent pl unger and spri ng
wi th a penci l magnet.
(8) Remove i nput shaft beari ng retai ner bol ts (Fi g.
7).
(9) Remove beari ng retai ner from i nput shaft wi th
a pry tool (Fi g. 8).
(10) Remove snap ri ng securi ng i nput shaft i n
front beari ng (Fi g. 9).
Fig. 6 DETENT PULLER
1 - REMOVER
2 - DETENT PLUG
Fig. 7 BEARING RETAINER BOLTS
1 - BOLTS (5)
2 - BEARING RETAINER
Fig. 8 INPUT SHAFT BEARING RETAINER
1 - BEARING RETAINER
2 - OIL FEED
Fig. 9 INPUT SHAFT SNAP RING
1 - INPUT SHAFT SNAP RING
2 - OIL FEED
21 - 4 MANUAL - NV1500 TJ
MANUAL - NV1500 (Continued)
(11) Remove front housi ng bol ts (Fi g. 10). Leave
one bol t i n pl ace unti l geartrai n i s ready to be
removed from case. Three bol ts at the rear of housi ng
are for the output shaft beari ng retai ner.
(12) Tap front housi ng off al i gnment dowel s wi th a
pl asti c mal l et and separate the housi ng.
(13) Remove i nput shaft beari ng (Fi g. 11).
(14) Note posi ti on of i nput shaft, shi ft shaft, forks,
and geartrai n components i n housi ng (Fi g. 12).
Fig. 10 HOUSING AND BEARING RETAINER BOL
1 - RETAINER BOLTS
2 - HOUSING BOLTS
3 - RETAINER BOLT
4 - HOUSING BOLT LOCATIONS
Fig. 11 INPUT SHAFT/COUNTERSHAFT BEARING
1 - COUNTERSHAFT FRONT BEARING RACE
2 - INPUT SHAFT BEARING
3 - FRONT HOUSING
Fig. 12 GEARTRAIN AND SHIFT COMPONENT
1 - SHIFT SHAFT
2 - BUSHING
3 - REAR HOUSING
4 - REVERSE IDLER AND SUPPORT
5 - OUTPUT SHAFT AND GEARS
6 - COUNTERSHAFT
7 - 1-2 FORK
8 - INPUT SHAFT
9 - 3-4 FORK
TJ MANUAL - NV1500 21 - 5
MANUAL - NV1500 (Continued)
SHIFT SHAFT, SHIFT FORKS AND REVERSE IDLER
(1) Dri ve out rol l pi n that secures shi ft bushi ng
and l ever to shi ft shaft wi th a hammer and punch
(Fi g. 13).
(2) Posi ti on shi ft socket off to the si de so rol l pi n
removal does not i nterfere wi th gears.
(3) Dri ve out shi ft socket rol l pi n wi th a hammer
and punch.
NOTE: Use proper size punch to prevent damage to
the shift shaft.
(4) Pul l shi ft shaft strai ght out of rear housi ng and
shi ft forks (Fi g. 14).
(5) Remove shi ft socket from rear housi ng (Fi g.
15).
(6) Remove l ever and bushi ng (Fi g. 16).
(7) Rotate 3-4 fork around synchro sl eeve unti l
fork cl ears shi ft arms on 1-2 and fi fth-reverse forks,
then remove 3-4 fork (Fi g. 17).
Fig. 13 SHIFT SHAFT LEVER & BUSHING ROLL PIN
1 - PIN PUNCH
2 - BUSHING AND LEVER
3 - SHIFT SHAFT
Fig. 14 SHIFT SHAFT
1 - SHIFT SHAFT
2 - 3-4 FORK
3 - SHAFT DETENT NOTCHES
Fig. 15 SHIFT SOCKET AND ROLL PIN
1 - SHAFT BORE
2 - ROLL PIN
3 - SHIFT SOCKET
Fig. 16 SHIFT SHAFT LEVER AND BUSHING
1 - SHAFT LEVER AND BUSHING
2 - 3-4 FORK
Fig. 17 3-4 SHIFT FORK
1 - 3-4 FORK
2 - 1-2 AND 5TH-REVERSE FORK ARMS
3 - 3-4 SYNCHRO SLEEVE
21 - 6 MANUAL - NV1500 TJ
MANUAL - NV1500 (Continued)
(8) Remove front reverse i dl er shaft support bol t
and l oosen rear bol t (Fi g. 18).
(9) Remove reverse i dl er shaft support by sl i di ng i t
strai ght out of housi ng.
(10) Remove rear reverse i dl er shaft bol t.
(11) Remove reverse i dl er shaft, i dl er gear, beari ng
and thrust washer (Fi g. 19).
GEARTRAIN
(1) Remove output shaft beari ng retai ner bol ts
(Fi g. 20).
(2) Hol d the geartrai n whi l e l i fti ng the rear hous-
i ng off (Fi g. 21).
GEARTRAIN
(1) Remove 1-2 and fi fth-reverse forks from syn-
chro sl eeves.
(2) Separate countershaft from mai nshaft.
(3) Separate i nput shaft from output shaft.
COUNTERSHAFT
(1) Remove countershaft front and rear beari ng
wi th Pul l er 8356.
(2) Remove rear beari ng race (i n rear housi ng)
wi th Beari ng Race Remover L-4454. I nstal l new race
wi th Dri ver C-4656 and Dri ver Handl e C-4171.
(3) Remove beari ng shi m cap from front housi ng
(bel ow i nput shaft beari ng retai ner). Remove shi m.
Dri ve race through and out of housi ng wi th Dri ver
C-4656 and Dri ver Handl e C-4171. I nstal l new race i nto
housi ng from outsi de. Do not drive all the way into
position. Tightening the shim cap will install the
race to the proper position. I nstal l shi m and shi m
cap and torque cap bol ts to 28.5 N·m (21 ft. l bs.).
Fig. 18 REVERSE IDLER SHAFT/SUPPORT BOLT
1 - SUPPORT BOLT
2 - SHAFT BOLT
Fig. 19 REVERSE IDLER ASSEMBLY
1 - SUPPORT
2 - BEARING
3 - WASHER
4 - GEAR
5 - SHAFT
Fig. 20 BEARING RETAINER BOLTS
1 - BEARING RETAINER BOLT
2 - REAR HOUSING
Fig. 21 REAR HOUSING
TJ MANUAL - NV1500 21 - 7
MANUAL - NV1500 (Continued)
OUTPUT SHAFT
NOTE: Synchronizer hubs and sleeves are different.
Remove synchronizer unit as an assembly to avoid
intermixing parts. Mark each synchro hub and
sleeve for assembly reference.
(1) Remove snap ri ng that secures 3-4 synchro hub
on output shaft.
(2) Remove 3-4 synchro assembl y, thi rd gear syn-
chro ri ng and thi rd gear wi th a shop press and Spl i t-
ter 1130. Posi ti on spl i tter between second and thi rd
gears.
(3) Remove thi rd gear needl e beari ng (Fi g. 22).
(4) Remove retai ni ng ri ng that secures two-pi ece
thrust washer on shaft.
(5) Remove two-pi ece thrust washer (Fi g. 23). Note
posi ti on of washer l ocati ng l ugs i n shaft notches for
i nstal l ati on reference.
(6) Remove second gear and needl e beari ng (Fi g.
24).
(7) Remove 2nd-3rd gear thrust washer l ocati ng
pi n.
(8) Remove second gear synchro ri ng and synchro
cone.
(9) Remove 1-2 synchro hub snap ri ng.
(10) Remove 1-2 synchro hub and sl eeve and fi rst
gear from output shaft wi th shop press and Spl i tter
1130 (Fi g. 25). Posi ti on spl i tter between fi rst and
reverse gears.
Fig. 22 THIRD GEAR NEEDLE BEARING
1 - THIRD GEAR NEEDLE BEARING
Fig. 23 TWO-PIECE THRUST WASH
1 - WASHER (2 HALVES)
2 - PIN RELIEF
3 - PIN
Fig. 24 SECOND GEAR AND NEEDLE BEARING
1 - SECOND GEAR
2 - SECOND GEAR NEEDLE BEARING
Fig. 25 1-2 SYNCHRO HUB AND SLEEVE
1 - 1-2 SYNCHRO HUB AND SLEEVE
2 - BEARING SPLITTER
21 - 8 MANUAL - NV1500 TJ
MANUAL - NV1500 (Continued)
(11) Remove fi rst gear needl e beari ng (Fi g. 26).
(12) Remove output shaft beari ng snap ri ng (Fi g.
27).
(13) Remove output shaft beari ng from shaft wi th
shop press and Spl i tter 1130. Posi ti on spl i tter
between beari ng and fi fth gear.
(14) Remove fi fth gear (Fi g. 28).
(15) Remove fi fth gear needl e beari ng. Spread
beari ng apart just enough to cl ear shoul der on output
shaft (Fi g. 29).
(16) Remove fi fth-reverse synchro hub snap ri ng
(Fi g. 30).
Fig. 26 FIRST GEAR NEEDLE BEARING
1 - FIRST GEAR NEEDLE BEARING
Fig. 27 OUTPUT SHAFT BEARING SNAP RING
1 - OUTPUT SHAFT BEARING
2 - BEARING SNAP RING
3 - SNAP RING PLIERS
Fig. 28 FIFTH GEAR
1 - FIFTH GEAR AND SYNCHRO RING
Fig. 29 FIFTH GEAR NEEDLE BEARING
1 - FIFTH GEAR NEEDLE BEARING
Fig. 30 FIFTH REVERSE SYNCHRO HUB SNAP
RING
1 - FIFTH-REVERSE SYNCHRO HUB AND SLEEVE
2 - SYNCHRO HUB SNAP RING
3 - SNAP RING PLIERS
TJ MANUAL - NV1500 21 - 9
MANUAL - NV1500 (Continued)
(17) Remove fi fth-reverse synchro hub and sl eeve
wi th shop press (Fi g. 31).
(18) Remove reverse gear and needl e beari ng (Fi g.
32).
CLEANING
Cl ean the gears, shafts, shi ft components and
transmi ssi on housi ngs wi th a standard parts cl ean-
i ng sol vent. Do not use aci d or corrosi ve base sol -
vents. Dry al l parts except beari ngs wi th compressed
ai r.
Cl ean the shaft beari ngs wi th a mi l d sol vent such
as Mopar௡ degreasi ng sol vent, Gunk, or si mi l ar sol -
vents. Do not dry the beari ngs wi th compressed ai r.
Al l ow the beari ngs to ei ther ai r dry, or wi pe them dry
wi th cl ean shop towel s.
INSPECTION
NOTE: Minor nicks on the surface can be smoothed
off with 320/420 grit emery cloth and final polished
with oil coated crocus cloth.
SHIFT LEVER ASSEMBLY
The shi ft l ever assembl y i s not servi ceabl e. Repl ace
the l ever and shi ft tower as an assembl y i f the tower,
l ever, l ever bal l or i nternal components are worn or
damaged.
SHIFT SHAFT AND FORKS
I nspect the shi ft fork i nterl ock arms and synchro
sl eeve contact surfaces (Fi g. 33). Repl ace any fork
exhi bi ti ng wear or damage i n these areas. Do not
attempt to sal vage shi ft forks.
Check condi ti on of the shi ft shaft detent pl unger
and spri ng. The pl unger shoul d be smooth and free of
ni cks or scores. Repl ace the pl unger and spri ng i f i n
doubt about condi ti on. Check condi ti on of detent
pl unger bushi ngs. Repl ace i f damaged.
I nspect the shi ft shaft, shi ft shaft bushi ng and
beari ng. The shaft l ever and the l ever bushi ng that
fi ts over the l ever. Repl ace the shaft i f bent, cracked
or severel y scored. Repl ace the shi ft shaft bushi ng or
beari ng i f damaged.
Repl ace the shaft l ever and bushi ng i f ei ther part
i s deformed or worn. Do not attempt to sal vage these
parts as shi ft fork bi ndi ng wi l l occur. Repl ace the rol l
pi n that secures the l ever to the shaft.
FRONT/REAR HOUSINGS AND BEARING
RETAINERS
Cl ean the gears, shafts, shi ft components and
transmi ssi on housi ngs wi th a standard parts cl ean-
i ng sol vent. Do not use aci d or corrosi ve base sol -
vents. Dry al l parts except beari ngs wi th compressed
ai r.
Cl ean the shaft beari ngs wi th a mi l d sol vent such
as Mopar degreasi ng sol vent, Gunk or si mi l ar sol -
vents. Do not dry the beari ngs wi th compressed ai r.
Al l ow the beari ngs to ei ther ai r dry or wi pe them dry
wi th cl ean shop towel s.
I nspect the housi ngs careful l y for cracks, stri pped
threads, scored mati ng surfaces, damaged beari ng
bores or worn dowel pi n hol es.
Fig. 31 FIFTH-REVERSE SYNCHRO HUB AND
SLEEVE
1 - PRESS
2 - FIFTH-REVERSE SYNCHRO HUB AND SLEEVE
3 - REVERSE GEAR
4 - OUTPUT SHAFT
Fig. 32 REVERSE GEAR AND NEEDLE BEARING
1 - REVERSE GEAR AND NEEDLE BEARING
21 - 10 MANUAL - NV1500 TJ
MANUAL - NV1500 (Continued)
NOTE: The front housing contains the countershaft
front bearing race. The rear housing contains the
countershaft rear bearing race. If a countershaft
bearing failure results, the bearing races must be
replaced also.
I nspect i nput shaft beari ng retai ner. Be sure the
rel ease beari ng sl i de surface of the retai ner i s i n
good condi ti on. Repl ace the retai ner seal i f necessary.
I nspect output shaft beari ng retai ner. Be sure the
U-shaped retai ner i s fl at and free of di storti on.
Repl ace the retai ner i f the threads are damaged or i f
the retai ner i s bent or cracked.
COUNTERSHAFT BEARINGS AND RACES
The countershaft beari ngs are standard tapered
rol l er beari ngs wi th matchi ng races. The races are
pressed i nto the front and rear housi ngs. I nspect
countershaft beari ngs and races for abnormal wear
or damage.
REVERSE IDLER COMPONENTS
I nspect i dl er gear, beari ng, shaft, thrust washer
and support for excessi ve wear or fai l ure (Fi g. 34).
Repl ace beari ng i f any of the needl e beari ng rol l ers
are worn, chi pped, cracked, fl at-spotted or bri nnel l ed.
Al so repl ace the beari ng i f the pl asti c beari ng cage i s
damaged or di storted.
Repl ace thrust washer, i f cracked, chi pped or worn.
Repl ace i dl er gear i f the teeth are chi pped, cracked or
worn thi n. Repl ace shaft i f worn, scored or the bol t
threads are damaged beyond repai r. Repl ace support
segment i f cracked or chi pped and repl ace the i dl er
attachi ng bol ts i f the threads are damaged.
Fig. 33 SHIFT FORKS AND SHAFT
1 - SHIFT SHAFT
2 - SHAFT LEVER
3 - SHAFT LEVER BUSHING
4 - 3-4 SHIFT FORK
5 - 1-2 SHIFT FORK
6 - FIFTH-REVERSE SHIFT FORK
Fig. 34 REVERSE IDLER ASSEMBLY
1 - SUPPORT
2 - BEARING
3 - WASHER
4 - GEAR
5 - SHAFT
TJ MANUAL - NV1500 21 - 11
MANUAL - NV1500 (Continued)
Shift Socket
I nspect shi ft socket for wear or damage. Repl ace
socket i f the rol l pi n or shi ft shaft bores are dam-
aged. Repl ace socket i f the bal l seat i s worn, or
cracked. Do not reuse the ori gi nal shi ft socket rol l
pi n. The socket rol l pi n i s approxi matel y i s approxi -
matel y 33 mm (1-1/4 i n.) l ong.
Output Shaft And Geartrain
I nspect al l gears for worn, cracked, chi pped or bro-
ken teeth. Check condi ti on of the beari ng bore i n
each gear. The bores shoul d be smooth and free of
surface damage. Di scol orati on of the gear bores i s a
normal occurrence and i s not a reason for repl ace-
ment. Repl ace gears onl y when tooth damage has
occurred or i f the bores are bri nnel l ed or severel y
scored.
I nspect shaft spl i nes and beari ngs surfaces.
Repl ace the shaft i f the spl i nes are damaged or bear-
i ng surfaces are deepl y scored, worn or bri nnel l ed.
ASSEMBLY
SYNCHRONIZER
NOTE: The easiest method of assembling each syn-
chro is to install the springs, struts and detent balls
one at a time.
(1) Sl i de the sl eeve part way onto the hub. Leave
enough room to i nstal l the spri ng i n the hub and the
strut i n the hub groove.
(2) I nstal l fi rst spri ng i n the hub and then i nstal l
a strut over the spri ng. Veri fy spri ng i s seated i n the
spri ng bore i n the strut.
(3) Sl i de the sl eeve onto the hub just far enough to
hol d the fi rst strut and spri ng i n pl ace.
(4) Pl ace detent bal l i n the top of the strut. Then
work the sl eeve over the bal l to hol d i t i n pl ace. Use
a smal l fl at bl ade screwdri ver to press the bal l i nto
pl ace whi l e movi ng the sl eeve over i t.
(5) Repeat procedure for the remai ni ng spri ngs,
struts and bal l s. Tape or rubber band each strut and
bal l temporari l y as they are i nstal l ed.
(6) Veri fy the three spri ngs, struts and detent bal l s
are al l i n pl ace (Fi g. 35).
OUTPUT SHAFT
NOTE: Lubricate shaft, gears and bearings with rec-
ommended lubricant and immerse each synchro
ring in lubricant before installation. Petroleum jelly
can be used to hold parts in place.
(1) I nstal l reverse gear needl e beari ng on shaft
(Fi g. 36). Sl i de beari ng up agai nst shoul der on output
shaft.
Fig. 35 ASSEMBLED SYNCHRO COMPONENTS
1 - SLEEVE
2 - HUB SHOULDER
3 - SPRING (3)
4 - STRUT (3)
5 - DETENT BALL (3)
6 - HUB
Fig. 36 REVERSE GEAR BEARING
1 - REVERSE GEAR BEARING
2 - SHOULDER
21 - 12 MANUAL - NV1500 TJ
MANUAL - NV1500 (Continued)
(2) I nstal l reverse gear over needl e beari ng (Fi g.
37).
(3) I nstal l sol i d brass synchro ri ng on reverse gear
(Fi g. 38).
NOTE: This synchro ring is different than all the
rest. The angle on the friction face is 9° versus the
6.5° of all the other synchro rings.
(4) Start fi fth-reverse synchro assembl y on output
shaft spl i nes by hand. Then seat synchro onto shaft
wi th shop press and Cup 6310-1 (Fi g. 39).
CAUTION: Fifth-reverse synchro hub and sleeve
can be installed backwards. One side of the sleeve
has double grooves and offset teeth. This side must
be installed away from reverse gear (towards 5th).
NOTE: The synchro hub is a press fit design. There
may be instances where the press is not necessary.
As long as there is a snug fit between the hub and
the shaft, the hub does not need to be replaced.
(5) I nstal l new fi fth-reverse hub snap ri ng (Fi g.
40) and veri fy snap ri ng i s seated i n the shaft groove.
NOTE: Install thickest snap ring that will fit in shaft
groove.
Fig. 37 REVERSE GEAR
1 - REVERSE GEAR
Fig. 38 REVERSE GEAR SYNCHRO RING
1 - REVERSE GEAR
2 - SYNCHRO RING (SOLID BRASS)
Fig. 39 FIFTH-REVERSE SYNCHRO ASSEMBLY
1 - SPACER
2 - PRESS RAM
3 - REVERSE GEAR
4 - FIFTH-REVERSE SYNCHRO ASSEMBLY
5 - CUP
6 - PRESS BLOCKS
7 - OUTPUT SHAFT
Fig. 40 FIFTH-REVERSE SYNCHRO HUB SNAP
RING
1 - FIFTH-REVERSE SYNCHRO ASSEMBLY
2 - SNAP RING
3 - PRESS BED
4 - PRESS BLOCKS
TJ MANUAL - NV1500 21 - 13
MANUAL - NV1500 (Continued)
(6) I nstal l fi fth gear synchro ri ng i n synchro hub
and sl eeve (Fi g. 41).
(7) I nstal l fi fth gear beari ng, spreadi ng beari ng
onl y enough to cl ear shoul der on output shaft (Fi g.
42). Veri fy beari ng i s seated.
(8) I nstal l fi fth gear on shaft and onto beari ng
(Fi g. 43).
(9) I nstal l output shaft beari ng.
(10) I nstal l output shaft beari ng snap ri ng, spread
snap ri ng onl y enough to i nstal l i t (Fi g. 44). Veri fy
snap ri ng i s seated i n shaft groove.
Fig. 41 FIFTH GEAR SYNCHRO RING
1 - FIFTH-SPEED SYNCHRO RING
2 - FIFTH-REVERSE SYNCHRO ASSEMBLY
Fig. 42 FIFTH GEAR BEARING
1 - SHAFT SHOULDER
2 - FIFTH GEAR BEARING
Fig. 43 FIFTH GEAR
1 - FIFTH GEAR
2 - BEARING
Fig. 44 OUTPUT SHAFT BEARING
1 - BEARING SNAP RING
2 - HEAVY DUTY SNAP RING PLIERS
21 - 14 MANUAL - NV1500 TJ
MANUAL - NV1500 (Continued)
(11) I nvert output shaft and set the shaft i n Cup
6310-1 so that fi fth gear i s seated on the tool (Fi g. 45).
(12) I nstal l fi rst gear beari ng on output shaft (Fi g.
45). Veri fy beari ng i s seated on shaft shoul der and i s
properl y joi ned.
(13) I nstal l synchro cone onto fi rst gear. Veri fy
synchro cone l ocati ng tabs are properl y l ocated to the
recesses i n fi rst gear.
(14) I nstal l fi rst gear on shaft and over beari ng
wi th beari ng synchro cone faci ng up (Fi g. 46).
(15) I nstal l fi rst gear synchro ri ng (Fi g. 47).
(16) Start 1-2 synchro assembl y on shaft by hand
(Fi g. 48). Be sure synchro sl eeve i s properl y posi -
ti oned.
CAUTION: The 1-2 synchro hub and sleeve can be
installed backwards. One side of the sleeve has a
groove and offset teeth. This side must be installed
towards 1st gear (away from 2nd gear).
NOTE: The synchro hub is a press fit design. There
may be instances where the press is not necessary.
As long as there is a snug fit between the hub and
the shaft, the hub does not need to be replaced.
Fig. 45 FIRST GEAR BEARING
1 - FIRST GEAR BEARING
2 - SHAFT SHOULDER
3 - CUP
4 - PRESS BLOCKS
Fig. 46 FIRST GEAR
1 - FIRST GEAR
2 - CUP
3 - BEARING
Fig. 47 FIRST GEAR SYNCHRO RING
1 - FIRST GEAR SYNCHRO RING
2 - CUP
3 - FIRST GEAR
Fig. 48 START 1-2 SYNCHRO ON SHAFT
1 - 1-2 SYNCHRO ASSEMBLY
2 - FIRST GEAR
3 - CUP
4 - SINGLE GROOVE SIDE OF SYNCHRO SLEEVE
TJ MANUAL - NV1500 21 - 15
MANUAL - NV1500 (Continued)
(17) Press 1-2 synchro onto output shaft wi th sui t-
abl e si ze pi pe and shop press (Fi g. 49).
CAUTION: Align synchro ring and sleeve as hub is
being pressed onto the shaft. The synchro ring can
be cracked if it becomes misaligned.
(18) I nstal l new 1-2 synchro hub snap ri ng (Fi g.
50) wi th the thi ckest snap ri ng that wi l l fi t i n shaft
groove. Veri fy snap ri ng i s seated i n shaft groove.
(19) I nstal l second gear synchro ri ng i n 1-2 syn-
chro hub and sl eeve (Fi g. 51). Veri fy synchro ri ng i s
seated i n sl eeve.
(20) I nstal l synchro cone i nto synchro ri ng.
Fig. 49 PRESS 1-2 SYNCHRO ASSEMBLY
1 - SUITABLE SIZE PIPE TOOL
2 - SYNCHRO RING
3 - CUP
4 - 1-2 SYNCHRO ASSEMBLY
5 - PRESS RAM
Fig. 50 1-2 SYNCHRO HUB SNAP RING
1 - 1-2 SYNCHRO
2 - CUP
3 - SYNCHRO SNAP RING
Fig. 51 SECOND GEAR SYNCHRO RING
1 - SECOND GEAR SYNCHRO RING
2 - 1-2 SYNCHRO
3 - CUP
21 - 16 MANUAL - NV1500 TJ
MANUAL - NV1500 (Continued)
(21) I nstal l second gear needl e beari ng on shaft
(Fi g. 52).
(22) I nstal l second gear onto shaft and beari ng
(Fi g. 53). Veri fy second gear i s seated on synchro
components.
(23) I nstal l thrust washer pi n to shaft and i nstal l
two-pi ece thrust washer (Fi g. 54). Veri fy washer
hal ves are seated i n shaft groove and pi n rel i efs are
posi ti oned at washer l ocati ng pi n.
(24) Seat retai ni ng ri ng around two-pi ece thrust
washer.
(25) I nstal l thi rd gear needl e beari ng on shaft (Fi g.
55).
Fig. 52 SECOND GEAR BEARING
1 - SECOND GEAR BEARING
2 - CUP
Fig. 53 SECOND GEAR
1 - CUP
2 - 1-2 SYNCHRO ASSEMBLY
3 - BEARING
4 - SECOND GEAR
Fig. 54 TWO-PIECE THRUST WASH
1 - WASHER (2 HALVES)
2 - PIN RELIEF
3 - PIN
Fig. 55 THIRD GEAR BEARING
1 - THIRD GEAR BEARING
TJ MANUAL - NV1500 21 - 17
MANUAL - NV1500 (Continued)
(26) I nstal l thi rd gear on shaft and beari ng (Fi g.
56).
(27) I nstal l thi rd speed synchro ri ng on thi rd gear
(Fi g. 57).
(28) Start 3-4 synchro hub on output shaft spl i nes
by hand (Fi g. 58).
CAUTION: The 3-4 synchro hub and sleeve can be
installed backwards. One side of the sleeve has two
grooves and offset teeth. This side must be
installed towards 3rd gear (away from 4th gear).
NOTE: The synchro hub is a press fit design. There
may be instances where the press is not necessary.
As long as there is a snug fit between the hub and
the shaft, the hub does not need to be replaced.
(29) Press 3-4 synchro assembl y onto output shaft
wi th shop press and sui tabl e si ze pi pe tool (Fi g. 59).
Press tool must be as cl ose to the hub center as pos-
si bl e but not contacti ng the shaft spl i nes.
Fig. 56 THIRD GEAR
1 - THIRD GEAR
2 - BEARING
Fig. 57 THIRD SPEED SYNCHRO RING
1 - THIRD SPEED SYNCHRO RING
2 - THIRD GEAR
Fig. 58 START 3-4 SYNCHRO HUB ON OUTPUT
SHAFT
1 - GROOVED SIDE OF SLEEVE (TO FRONT)
2 - 3-4 SYNCHRO ASSEMBLY
Fig. 59 3-4 SYNCHRO ASSEMBLY ON SHAFT
1 - PRESS RAM
2 - PIPE TOOL
3 - 3-4 SYNCHRO
4 - THIRD SPEED SYNCHRO RING
21 - 18 MANUAL - NV1500 TJ
MANUAL - NV1500 (Continued)
(30) I nstal l 3-4 synchro hub new snap ri ng (Fi g.
60) wi th thi ckest snap ri ng that wi l l fi t i n shaft
groove. Veri fy snap ri ng i s seated i n groove.
(31) Veri fy posi ti on of synchro sl eeves before pro-
ceedi ng (Fi g. 61).
Fig. 60 3-4 SYNCHRO HUB SNAP RING
1 - 3-4 SYNCHRO HUB SNAP RING
2 - HEAVY DUTY SNAP RING PLIERS
Fig. 61 SYNCHRO SLEEVE POSITION
1 - 2 GROOVES
2 - 1 GROOVE
3 - 2 GROOVES
4 - FOURTH GEAR
5 - THIRD GEAR
6 - SECOND GEAR
7 - FIRST GEAR
8 - REVERSE GEAR
9 - FIFTH GEAR
TJ MANUAL - NV1500 21 - 19
MANUAL - NV1500 (Continued)
GEARTRAIN
(1) I nstal l i nput shaft i nto Support Stand 8355
(Fi g. 62).
(2) I nstal l pi l ot beari ng i n i nput shaft (Fi g. 62).
(3) I nstal l fourth gear synchro ri ng on i nput shaft
(Fi g. 63).
(4) I nstal l assembl ed output shaft and geartrai n i n
i nput shaft (Fi g. 64). Rotate output shaft unti l the
3-4 synchro ri ng seats i n synchro hub and sl eeve.
Fig. 62 INPUT SHAFT AND PILOT BEARING
1 - PILOT BEARING
2 - INPUT SHAFT
3 - STAND
Fig. 63 FOURTH GEAR SYNCHRO RING ON INPUT
SHAFT
1 - FOURTH GEAR SYNCHRO RING
2 - INPUT SHAFT
3 - STAND
Fig. 64 MAINSHAFT ON SUPPORT STAND
1 - MAIN SHAFT
2 - SUPPORT STAND
21 - 20 MANUAL - NV1500 TJ
MANUAL - NV1500 (Continued)
(5) Sl i de countershaft i nto fi xture sl ot. Veri fy coun-
tershaft and output shaft gears are ful l y meshed
wi th the mai nshaft gears (Fi g. 65).
(6) Thread one Pi l ot Stud 8120 i n center or pas-
senger si de hol e of output shaft beari ng retai ner.
Then posi ti on retai ner on fi fth gear.
(7) Assembl e 1-2 and fi fth reverse-shi ft forks (Fi g.
66). Arm of fi fth-reverse fork goes through sl ot i n 1-2
fork.
(8) I nstal l assembl ed shi ft forks i n synchro sl eeves
(Fi g. 67). Veri fy forks are seated i n sl eeves.
Fig. 65 COUNTERSHAFT ON SUPPORT STAND
1 - COUNTER SHAFT
2 - MAIN SHAFT
3 - SUPPORT STAND
Fig. 66 1-2 AND FIFTH-REVERSE SHIFT FORKS
1 - FIFTH-REVERSE FORK ARM
2 - 1-2 FORK
3 - FIFTH-REVERSE FORK
Fig. 67 SHIFT FORKS AND SYNCHROS
1 - FIFTH REVERSE SHIFT FORK
2 - 1-2 SHIFT FORK
TJ MANUAL - NV1500 21 - 21
MANUAL - NV1500 (Continued)
REAR HOUSING
(1) Lubri cate countershaft rear beari ng race.
(2) I nstal l rear housi ng onto geartrai n (Fi g. 68).
Veri fy beari ng retai ner pi l ot stud i s i n correct bol t
hol e and countershaft and output shaft beari ngs are
al i gned i n housi ng and on countershaft.
(3) Seat rear housi ng on output shaft rear beari ng
and countershaft. Tap housi ng i nto pl ace wi th pl asti c
or rawhi de hammer.
(4) Appl y Mopar௡ Gasket Maker or equi val ent to
bol t threads, bol t shanks and under bol t heads (Fi g.
69).
(5) Start fi rst two bol ts i n retai ner (Fi g. 70). I t
may be necessary to move retai ner rearward (wi th
pi l ot stud) i n order to start bol ts.
(6) Remove Pi l ot Stud 8120 and i nstal l l ast
retai ner bol t (Fi g. 70).
(7) Ti ghten al l three retai ner bol ts to 22 N·m (16
ft. l bs.).
NOTE: All bolts except the reverse idler shaft bolts
have o-rings to seal the bolts to the transmission
case. Inspect the o-rings to ensure that they are in
good condition.
REVERSE IDLER
(1) Remove geartrai n and housi ng assembl y from
support stand wi th ai d of hel per.
(2) Assembl e shaft, gear and washer (wi thout
beari ng or support) and i nstal l i nto housi ng (Fi g. 71).
NOTE: The small shoulder on the reverse idler gear
goes toward the front of the transmission.
Fig. 68 REAR HOUSING
Fig. 69 RETAINER AND HOUSING BOLTS
1 - MOPAR GASKET MAKER
2 - RETAINER AND HOUSING BOLTS
3 - APPLY SEALER TO UNDERSIDE OF BOLT HEAD, SHANK
AND THREADS
Fig. 70 PILOT STUD AND RETAINER BOLTS
1 - BEARING RETAINER BOLT
2 - REAR HOUSING
Fig. 71 REVERSE IDLER ASSEMBLY
1 - SUPPORT
2 - BEARING
3 - WASHER
4 - GEAR
5 - SHAFT
21 - 22 MANUAL - NV1500 TJ
MANUAL - NV1500 (Continued)
(3) Appl y Mopar௡ Gasket Maker or equi val ent
seal er to undersi de of i dl er shaft and support bol t
heads, bol t shanks and bol t threads (Fi g. 69).
(4) Al i gn hol e i n housi ng wi th threaded hol e i n
shaft and start shaft rear bol t a few threads.
(5) I nstal l beari ng i nto posi ti on.
(6) I nstal l segment (Fi g. 71), al i gn housi ng hol e
wi th segment threaded hol e, and start support bol t a
few threads.
(7) Ti ghten l arge i dl er shaft bol t to 43 N·m (31.7
ft. l bs.). Ti ghten smal l i dl er shaft bol t to 22 N·m
(16.2 ft. l bs.).
CAUTION: Verify idler shaft and support segment
are properly seated and firmly in place while tight-
ening the shaft bolts. The segment, housing or
shaft threads can be damaged if the idler shaft is
allowed to shift out of position.
SHIFT SHAFT, SHAFT LEVER AND BUSHING AND SHIFT
SOCKET
(1) Veri fy al l synchro sl eeves are i n Neutral posi -
ti on (centered on hub).
CAUTION: Synchros must all be in Neutral position
to prevent damage to the housings, shift forks and
gears during installation of the two housings.
(2) I nstal l 3-4 shi ft fork i n synchro sl eeve (Fi g. 72).
Veri fy groove i n fork arm i s al i gned wi th grooves i n
1-2 and fi fth-reverse fork arms.
(3) Sl i de shi ft shaft through the shi ft forks (Fi g.
73).
(4) Assembl e shi ft shaft shi ft l ever and bushi ng
(Fi g. 74). Sl ot i n bushi ng must face up and rol l pi n
hol e for l ever to al i gn wi th hol e i n shaft.
Fig. 72 3-4 SHIFT FORK
1 - 3-4 FORK
2 - ALIGN GROOVES IN FORK ARMS
Fig. 73 SHIFT SHAFT
1 - SHIFT SHAFT
2 - 3-4 FORK
3 - SHAFT DETENT NOTCHES
Fig. 74 SHIFT SHAFT LEVER AND BUSHING
1 - SHAFT LEVER
2 - LEVER BUSHING
3 - BUSHING LOCK PIN SLOT
TJ MANUAL - NV1500 21 - 23
MANUAL - NV1500 (Continued)
(5) I nstal l assembl ed l ever and bushi ng on shi ft
shaft (Fi g. 75).
(6) Sl i de shi ft shaft through 1-2 and fi fth-reverse
fork and i nto shi ft l ever openi ng i n rear housi ng (Fi g.
76).
(7) Al i gn shi ft socket wi th shaft and sl i de shaft
through socket and i nto shi ft shaft beari ng i n rear
housi ng (Fi g. 77).
(8) Rotate shi ft shaft so detent notches i n shaft are
faci ng the TOP of the transmi ssi on housi ng.
CAUTION: Positioning of the shift shaft detent
notch is important. Both of the shaft roll pins can
be installed even when the shaft is 180° off. If this
occurs, transmission will have to be disassembled
to correct shaft alignment.
(9) Sel ect correct new rol l pi n for shi ft shaft l ever
(Fi g. 78). Shaft l ever rol l pi n i s approxi matel y 22 mm
(7/8 i n.) l ong. Shi ft socket rol l pi n i s approxi matel y
33 mm (1-1/4 i n.) l ong.
Fig. 75 SHIFT SHAFT LEVER AND BUSHING
1 - SHIFT SHAFT
2 - SHAFT LEVER AND BUSHING
3 - 3-4 FORK
Fig. 76 LEVER OPENING IN HOUSING
1 - SHIFT SHAFT
Fig. 77 SHIFT SOCKET AND SHAFT
1 - SHIFT SOCKET
2 - SHIFT SHAFT
Fig. 78 SHAFT LEVER AND SOCKET ROLL PINS
1 - SHAFT LEVER ROLL PIN
2 - SHIFT SOCKET ROLL PIN
21 - 24 MANUAL - NV1500 TJ
MANUAL - NV1500 (Continued)
(10) Al i gn rol l pi n hol es i n shi ft shaft, l ever and
bushi ng, then start rol l pi n i nto shaft l ever by hand
(Fi g. 79).
(11) Seat shaft l ever rol l pi n wi th pi n punch (Fi g.
80).
CAUTION: Shaft lever roll pin must be flush with
the surface of the lever. The lever bushing will bind
on the roll pin if the pin is not seated flush.
(12) Veri fy l ock pi n sl ot i n l ever bushi ng i s posi -
ti oned as shown (Fi g. 80).
(13) Al i gn rol l pi n hol es i n shi ft socket and shi ft
shaft. Then start rol l pi n i nto shi ft shaft by hand
(Fi g. 81).
(14) Seat rol l pi n i n shi ft socket wi th pi n punch.
Rol l pi n must be i nstal ed fl ush wi th socket (Fi g. 82).
(15) Veri fy notches i n shi ft fork arms are al i gned.
Fig. 79 STARTING ROLL PIN IN SHIFT SHAFT
LEVER
1 - SHAFT LEVER ROLL PIN
2 - LEVER AND BUSHING
Fig. 80 SEATING SHIFT SHAFT LEVER ROLL PIN
1 - BUSHING LOCK PIN SLOT
2 - SEAT ROLL PIN FLUSH WITH LEVER
Fig. 81 STARTING ROLL PIN IN SHIFT SOCKET
1 - ROLL PIN
2 - SHIFT SOCKET
3 - SHIFT SHAFT
Fig. 82 SEATING SHIFT SOCKET ROLL PIN
1 - PIN PUNCH
2 - SHIFT SOCKET
3 - SEAT ROLL PIN FLUSH
4 - SHIFT SOCKET
TJ MANUAL - NV1500 21 - 25
MANUAL - NV1500 (Continued)
FRONT HOUSING AND INPUT SHAFT BEARING RETAINER
(1) I f previ ousl y removed, i nstal l i nput shaft bear-
i ng i n front housi ng bore (Fi g. 83). I nstal l snap ri ng
and use pl asti c mal l et to seat beari ng. Beari ng goes
i n from front si de of housi ng onl y.
(2) Appl y smal l amount of petrol eum jel l y to shi ft
shaft bushi ng i n front housi ng (Fi g. 84).
(3) Appl y 1/8 i n. wi de bead of Mopar௡ Gasket
Maker or equi val ent to mati ng surfaces of front and
rear housi ngs (Fi g. 84).
(4) Have hel per hol d rear housi ng and geartrai n i n
upri ght posi ti on. Then i nstal l front housi ng on rear
housi ng and geartrai n.
(5) Work front housi ng downward onto geartrai n
unti l seated on rear housi ng.
CAUTION: If the front housing will not seat on the
rear housing, the shift components are not in Neu-
tral, or one or more components are misaligned. Do
not force the front housing into place.
(6) Pl ace transmi ssi on i n hori zontal posi ti on.
(7) Appl y Mopar௡ Gasket Maker or equi val ent to
housi ng attachi ng bol ts. Appl y seal er materi al seal er
to undersi de of bol t heads and to bol t shanks and
threads (Fi g. 85).
(8) I nstal l and start housi ng attachi ng bol ts by
hand (Fi g. 85). Then ti ghten bol ts to 34 N·m (25 ft.
l bs.).
(9) I nstal l shi ft shaft bushi ng l ock bol t (Fi g. 86).
Appl y Mopar௡ Gasket Maker or equi val ent to bol t
threads, shank and undersi de of bol t head before
i nstal l ati on.
CAUTION: If the lock bolt cannot be fully installed,
do not try to force it into place. Either the shift
shaft is not in Neutral, or the shaft bushing (or
lever) is misaligned.
(10) Remove countershaft beari ng shi m cap and
shi m. Attach a di al i ndi cator and move countershaft
front and back to measure shaft end pl ay. The
requi red countershaft pre-l oad 0.001-0.003 i nches.
Add thi s amount to the measured amount of counter-
shaft end-pl ay. Thi s gi ves the amount of shi ms nec-
essary to correctl y pre-l oad the front and rear
countershaft beari ngs.
Fig. 83 INPUT SHAFT AND COUNTERSHAFT
BEARING
1 - SHIFT SHAFT BUSHING
2 - INPUT SHAFT BEARING
3 - COUNTERSHAFT FRONT BEARING RACE
Fig. 84 SEALER TO FRONT/REAR HOUSING
1 - HOUSING FLANGE SURFACE
2 - MOPAR GASKET MAKER (OR LOCTITE 518)
Fig. 85 HOUSING ATTACHING BOLTS
1 - HOUSING ATTACHING BOLTS (APPLY SEALER
BEFOREHAND)
21 - 26 MANUAL - NV1500 TJ
MANUAL - NV1500 (Continued)
(11) I nstal l the sel ected shi ms and the shi m cap.
Ti ghten shi m cap bol ts to 29 N·m (21.4 ft. l bs.). Ver-
i fy the shi m sel ecti on by rotati ng the i nput shaft by
hand wi th the transmi ssi on i n neutral . The proper
torque requi red to rotate the i nput shaft and the
countershaft i s approxi matel y 5-7 i n.l bs.. The i nput
shaft shoul d therefore be easi l y rotated by hand. I f
the i nput shaft cannot be rotated by hand or i s not
smooth through several rotati ons, re-check the coun-
tershaft pre-l oad.
(12) Lubri cate then i nstal l shi ft shaft detent
pl unger i n housi ng bore. Verify plunger is fully
seated in detent notch in shift shaft.
NOTE: Lubricate plunger with Valvoline Dura blendா
Semi-Synthetic or Synthetic grease or equivalent.
(13) I nstal l detent pl ug i n end of I nstal l er 8123.
Posi ti on pl ug on detent spri ng and compress spri ng
unti l detent pl ug pi l ots i n detent pl unger bore. Dri ve
detent pl ug i nto transmi ssi on case unti l pl ug seats.
(14) I nstal l backup l i ght swi tch (Fi g. 87).
(15) I nstal l i nput shaft snap ri ng (Fi g. 88).
(16) I nstal l new oi l seal i n front beari ng retai ner
wi th I nstal l er 6448 (Fi g. 89).
(17) Appl y bead of Mopar௡ Si l i cone Seal er or
equi val ent to fl ange surface of front beari ng retai ner.
Fig. 86 SHIFT SHAFT BUSHING LOCK BOLT
1 - SHIFT SHAFT LOCK BOLT
2 - SHAFT SOCKET
Fig. 87 BACKUP LIGHT SWITCH
1 - BACKUP LAMP SWITCH
Fig. 88 INPUT SHAFT SNAP RING
1 - INPUT SHAFT SNAP RING
Fig. 89 BEARING RETAINER OIL SEAL
1 - INSTALLER
2 - FRONT BEARING RETAINER
TJ MANUAL - NV1500 21 - 27
MANUAL - NV1500 (Continued)
(18) Al i gn and i nstal l front beari ng retai ner over
i nput shaft and onto housi ng mounti ng surface (Fi g.
90). Al though retai ner i s one-way fi t on housi ng, be
sure bol t hol es are al i gned before seati ng retai ner.
NOTE: Be sure that no sealer gets into the oil feed
hole in the transmission case or bearing retainer.
(19) I nstal l and ti ghten beari ng retai ner bol ts to
29 N·m (21.4 ft. l bs.) (Fi g. 91).
SHIFT TOWER AND LEVER
(1) Appl y petrol eum jel l y to bal l end of shi ft l ever
and i nteri or of shi ft socket.
(2) Shi ft the transmi ssi on i nto thi rd gear.
(3) Al i gn and i nstal l shi ft tower and l ever assem-
bl y (Fi g. 92). Veri fy shi ft bal l i s seated i n socket and
offset i n the tower i s toward the passenger si de of
the vehi cl e before i nstal l i ng tower bol ts.
(4) I nstal l shi ft tower bol ts (Fi g. 93) and ti ghten
bol ts to 8.5 N·m (75.2 i n. l bs.).
(5) Fi l l transmi ssi on to bottom edge of fi l l pl ug
hol e wi th Mopar௡ Transmi ssi on.
(6) I nstal l and ti ghten fi l l pl ug to 34 N·m (25 ft.
l bs.).
(7) Check transmi ssi on vent. Be sure vent i s open
and not restri cted.
INSTALLATION
(1) I nstal l cl utch housi ng on transmi ssi on and
ti ghten housi ng bol ts to 46 N·m (34 ft. l bs.).
Fig. 90 INPUT SHAFT BEARING RETAINER
1 - BEARING RETAINER
2 - OIL FEED
Fig. 91 INPUT SHAFT BEARING RETAINER BOLTS
1 - BOLTS (5)
2 - BEARING RETAINER
Fig. 92 SHIFT TOWER
1 - SHIFT TOWER AND LEVER ASSEMBLY
2 - SHIFT SOCKET
3 - SEAL
Fig. 93 SHIFT TOWER BOLT
1 - SHIFT TOWER AND LEVER ASSEMBLY
21 - 28 MANUAL - NV1500 TJ
MANUAL - NV1500 (Continued)
(2) Lubri cate contact surfaces of rel ease fork pi vot
bal l stud and rel ease fork wi th hi gh temp grease.
(3) I nstal l rel ease beari ng, fork and retai ner cl i p.
(4) Posi ti on and secure transmi ssi on on transmi s-
si on jack.
(5) Li ghtl y l ubri cate pi l ot beari ng and transmi s-
si on i nput shaft spl i nes wi th Mopar hi gh temp
grease.
(6) Rai se transmi ssi on and al i gn transmi ssi on
i nput shaft and cl utch di sc spl i nes. Then sl i de trans-
mi ssi on i nto pl ace.
(7) I nstal l cl utch housi ng-to-engi ne bol ts and
ti ghten to 75 N·m (55 ft.l bs.) (Fi g. 94).
NOTE: Be sure the housing is properly seated on
engine block before tightening bolts.
(8) I nstal l shi ft tower and bol ts. Ti ghten bol ts to
11 N·m (8 ft.l bs.).
(9) I nstal l transmi ssi on mount and ti ghten bol ts to
54 N·m (40 ft. l bs.).
(10) I nstal l transfer case, shi ft l i nkage and vent
hose.
(11) I nstal l wi re connectors to transmi ssi on and
transfer case.
(12) I nstal l ski d pl ate/crossmember and ti ghten
bol ts to 41 N·m (31 ft. l bs.).
(13) Remove support stands from engi ne and
transmi ssi on.
(14) I nstal l propel l er shafts.
(15) I nstal l sl ave cyl i nder i n cl utch housi ng.
(16) I nstal l starter motor.
(17) I nstal l transmi ssi on dust shi el d.
SPECIFICATIONS
MANUAL
TORQUE SPECIFICATIONS
DESCRIPTION N·m Ft. Lbs. In. lbs.
Back up Lamp Switch 41 30 -
Coutershaft Bearing Shim Cap 41 30 -
Bearing Retainer - Front 41 30 -
Bearing Retainer - Rear 34 25 -
Drain/Fill Plug 34 25 -
Shift Shaft Lock Bolt 27 20 -
Idler Shaft Bolts - M8 27 20 -
Idler Shaft Bolts - M10 52 40 -
Shift Tower Bolts 11 8 100
Clutch Housing Bolts 46 34 -
Transmission Bolts 75 55 -
Skid Plate Bolts 41 31 -
Transmission mount bolts 54 40 -
Fig. 94 NV1500 TRANSMISSION
1 - TRANSMISSION
2 - CLUTCH ASSEMBLY
TJ MANUAL - NV1500 21 - 29
MANUAL - NV1500 (Continued)
SPECIAL TOOLS
INSTALLER C-4656
INSTALLER 8123
INSTALLER 6448
HANDLE C-4171
SUPPORT STAND 8355
REMOVER 8117A
REMOVER 8356
REMOVER L-4454
21 - 30 MANUAL - NV1500 TJ
MANUAL - NV1500 (Continued)
SPLITTER BEARING 1130
CUP 6310-1
STUD ALIGNMENT 8120
TJ MANUAL - NV1500 21 - 31
MANUAL - NV1500 (Continued)
MANUAL - NV3550
TABLE OF CONTENTS
page page
MANUAL - NV3550
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 32
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . 32
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 34
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 44
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 66
SPECIFICATIONS
MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . 67
VEHICLE SPEED SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 69
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 69
MANUAL - NV3550
DESCRIPTION
The NV3550 i s a medi um-duty, 5-speed, constant
mesh, ful l y synchroni zed manual transmi ssi on. The
transmi ssi on i s a four-wheel dri ve confi gurati ons.
The transmi ssi on gear case consi sts of two al umi -
num housi ngs. The cl utch housi ng i s a removabl e
component. I t i s not an i ntegral part of the transmi s-
si on front housi ng.
A combi nati on of rol l er and bal l beari ngs are used
to support the transmi ssi on shafts i n the two hous-
i ngs. The transmi ssi on gears al l rotate on caged type
needl e beari ngs. A rol l er beari ng i s used between the
i nput and output shaft.
The NV3550 has a si ngl e shaft shi ft mechani sm
wi th three shi ft forks al l mounted on the shaft. The
shaft i s supported i n the front and rear housi ngs by
bushi ngs and one l i near bal l beari ng. I nternal shi ft
components consi st of the forks, shaft, shi ft l ever
socket and detent components.
The transmi ssi on drai n pl ug i s l ocated on the bot-
tom and fi l l pl ug on the si de.
The NV3550 i denti fi cati on and part number bar
code tags (Fi g. 1) are l ocated on the top of the trans-
mi ssi on, forward of the shi ft tower.
OPERATION
The dri ver sel ects a parti cul ar gear by movi ng the
shi ft l ever to the desi red gear posi ti on. Thi s move-
ment moves the i nternal transmi ssi on shi ft compo-
nents to begi n the shi ft sequence. As the shi ft l ever
moves the sel ected shi ft rai l , the shi ft fork attached
to that rai l begi ns to move. The fork i s posi ti oned i n
a groove i n the outer ci rcumference of the synchro-
ni zer sl eeve. As the shi ft fork moves the synchroni zer
sl eeve, the synchroni zer begi ns to speed-up or sl ow
down the sel ected gear (dependi ng on whether we are
up-shi fti ng or down-shi fti ng). The synchroni zer does
thi s by havi ng the synchroni zer hub spl i ned to the
mai nshaft and movi ng the bl ocker ri ng i nto contact
wi th the gear’s fri cti on cone. As the bl ocker ri ng and
fri cti on cone come together, the gear speed i s brought
up or down to the speed of the synchroni zer. As the
two speeds match, the spl i nes on the i nsi de of the
synchroni zer sl eeve become al i gned wi th the teeth on
the bl ocker ri ng and the fri cti on cone and eventual l y
wi l l sl i de over the teeth, l ocki ng the gear to the
mai nshaft through the synchroni zer.
DIAGNOSIS AND TESTING
LOW LUBRICANT LEVEL
A l ow transmi ssi on l ubri cant l evel i s general l y the
resul t of a l eak, i nadequate l ubri cant fi l l or an i ncor-
rect l ubri cant l evel check.
Fig. 1 NV3550 Identification
1 - PART NUMBER TAG
2 - IDENTIFICATION TAG
3 - FRONT OF REAR HOUSING
21 - 32 MANUAL - NV3550 TJ
Leaks can occur at the mati ng surfaces of the gear
case and adaptor or from the front/rear seal s. A sus-
pected l eak coul d al so be the resul t of an overfi l l con-
di ti on.
Leaks at the rear of the extensi on or adapter hous-
i ng wi l l be from the housi ng oi l seal s. Leaks at com-
ponent mati ng surfaces wi l l probabl y be the resul t of
i nadequate seal er, gaps i n the seal er, i ncorrect bol t
ti ghteni ng, or use of a non-recommended seal er.
A l eak at the front of the transmi ssi on wi l l be from
ei ther the front beari ng retai ner or retai ner seal .
Lubri cant may be seen dri ppi ng from the cl utch
housi ng after extended operati on. I f the l eak i s
severe, i t may al so contami nate the cl utch di sc caus-
i ng the di sc to sl i p, grab, and/or chatter.
A correct l ubri cant l evel check can onl y be made
when the vehi cl e i s l evel . Al so al l ow the l ubri cant to
settl e for a mi nute or so before checki ng. These rec-
ommendati ons wi l l ensure an accurate check and
avoi d an underfi l l or overfi l l condi ti on. Al ways check
the l ubri cant l evel after any addi ti on of fl ui d to avoi d
an i ncorrect l ubri cant l evel condi ti on.
HARD SHIFTING
Hard shi fti ng i s usual l y caused by a l ow l ubri cant
l evel , i mproper, or contami nated l ubri cants. The con-
sequence of usi ng non–recommended l ubri cants i s
noi se, excessi ve wear, i nternal bi nd, and hard shi ft-
i ng. Substanti al l ubri cant l eaks can resul t i n gear,
shi ft rai l , synchro, and beari ng damage. I f a l eak
goes undetected for an extended peri od, the fi rst i ndi -
cati ons of component damage are usual l y hard shi ft-
i ng and noi se.
Shi ft component damage, i ncorrect cl utch adjust-
ment, or a damaged cl utch pressure pl ate or di sc are
addi ti onal probabl e causes of i ncreased shi ft effort.
I ncorrect adjustment or a worn/damaged pressure
pl ate or di sc can cause i ncorrect rel ease. I f the cl utch
probl em i s advanced, gear cl ash duri ng shi fts can
resul t. Worn or damaged synchro ri ngs can cause
gear cl ash when shi fti ng i nto any forward gear. I n
some new or rebui l t transmi ssi ons, new synchro
ri ngs may tend to sti ck sl i ghtl y causi ng hard or noi sy
shi fts. I n most cases, thi s condi ti on wi l l decl i ne as
the ri ngs wear-i n.
TRANSMISSION NOISE
Most manual transmi ssi ons make some noi se dur-
i ng normal operati on. Rotati ng gears generate a mi l d
whi ne that i s audi bl e, but general l y onl y at extreme
speeds.
Severe, hi ghl y audi bl e transmi ssi on noi se i s gener-
al l y the i ni ti al i ndi cator of a l ubri cant probl em.
I nsuffi ci ent, i mproper, or contami nated l ubri cant wi l l
promote rapi d wear of gears, synchros, shi ft rai l s,
forks and beari ngs. The overheati ng caused by a
l ubri cant probl em, can al so l ead to gear and beari ng
damage.
REMOVAL
(1) Shi ft transmi ssi on i nto fi rst or thi rd gear.
(2) Remove fl oor consol e and shi ft boot as neces-
sary to access the bottom of the shi ft l ever at the
shi ft tower attachment.
(3) Remove shi ft tower bol ts and remove shi ft
tower and shi ft l ever assembl y.
(4) Rai se and support vehi cl e on sui tabl e safety
stands.
(5) Support engi ne wi th adjustabl e jack stand.
Posi ti on wood bl ock between jack and oi l pan to
avoi d damagi ng pan.
(6) Remove ski d pl ate, i f equi pped.
(7) Remove crossmember.
(8) Di sconnect necessary exhaust system compo-
nents.
(9) Remove sl ave cyl i nder (Fi g. 2) from cl utch
housi ng.
(10) Remove propel l er shafts.
(11) Uncl i p wi re harnesses from transmi ssi on and
transfer case.
(12) Di sconnect transfer case shi ft l i nkage at
transfer case.
(13) Remove nuts attachi ng transfer case to trans-
mi ssi on.
(14) Remove transfer case.
Fig. 2 SLAVE CYLINDER
1 - CLUTCH SLAVE CYLINDER
TJ MANUAL - NV3550 21 - 33
MANUAL - NV3550 (Continued)
(15) Remove crankshaft posi ti on sensor (Fi g. 3).
CAUTION: The crankshaft position sensor must be
removed prior to transmission removal. Failure to
heed caution may result in damage.
(16) Support engi ne wi th adjustabl e jack stand.
Posi ti on wood bl ock between jack and oi l pan to
avoi d damagi ng pan.
(17) Support transmi ssi on wi th transmi ssi on jack.
(18) Secure transmi ssi on to jack wi th safety
chai ns.
(19) Di sconnect rear cushi on and bracket from
transmi ssi on.
(20) Remove rear crossmember.
(21) Remove cl utch housi ng-to-engi ne bol ts.
(22) Pul l transmi ssi on jack rearward unti l i nput
shaft cl ears cl utch. Then sl i de transmi ssi on out from
under vehi cl e.
(23) Remove cl utch rel ease beari ng, rel ease fork
and retai ner cl i p.
(24) Remove cl utch housi ng from transmi ssi on.
DISASSEMBLY
FRONT HOUSING
(1) Shi ft transmi ssi on i nto Neutral .
(2) Remove drai n pl ug and drai n l ubri cant.
(3) I nspect drai n pl ug magnet for debri s.
(4) Remove backup l i ght swi tch. Swi tch i s l ocated
on passenger si de of rear housi ng (Fi g. 4).
(5) Remove shi ft tower bol ts and remove tower and
l ever assembl y (Fi g. 5).
(6) Remove shi ft shaft l ock bol t (Fi g. 6) l ocated on
top of the housi ng just forward of shi ft tower.
Fig. 3 CRANKSHAFT POSITION SENSOR
1 - CRANKSHAFT POSITION SENSOR
2 - GROMMET
3 - MOUNTING BOLT(S)
4 - LEFT REAR OF ENGINE
5 - TRANSMISSION
Fig. 4 BACKUP LIGHT SWITCH
1 - BACKUP LIGHT SWITCH
Fig. 5 SHIFT TOWER
1 - SHIFT TOWER AND LEVER ASSEMBLY
2 - SHIFT SOCKET
3 - SEAL
Fig. 6 SHAFT LOCK BOLT
1 - SHIFT SHAFT LOCK BOLT
2 - SHAFT SOCKET
21 - 34 MANUAL - NV3550 TJ
MANUAL - NV3550 (Continued)
(7) Remove shi ft shaft detent pl ug wi th Remover
8117A. Attach the fi ngers of the remover to the
detent pl ug (Fi g. 7). Then push the cup down ti l l i t
contacts the trans. Ti ghten the nut (Fi g. 8) ti l l i t
pul l s the pl ug from the trans case.
(8) Remove shi ft shaft detent pl unger and spri ng.
Remove spri ng and pl unger wi th a penci l magnet.
(9) Remove bol ts attachi ng i nput shaft beari ng
retai ner to front housi ng and remove retai ner.
NOTE: Use pry tool to carefully lift retainer and
break sealer bead (Fig. 9).
(10) Remove beari ng retai ner from i nput shaft
(Fi g. 10).
(11) Remove snap ri ng that secures i nput shaft i n
front beari ng (Fi g. 11).
Fig. 7 DETENT PULLER
1 - REMOVER
2 - DETENT PLUG
Fig. 8 PULL DETENT PLUG
1 - NUT
2 - REMOVER
Fig. 9 BEARING RETAINER
1 - PRY TOOL
2 - BEARING RETAINER
Fig. 10 INPUT SHAFT BEARING RETAINER
1 - SHAFT BEARING
2 - BEARING RETAINER
3 - INPUT SHAFT
Fig. 11 INPUT SHAFT SNAP RING
1 - INPUT SHAFT SNAP RING
2 - OIL FEED
TJ MANUAL - NV3550 21 - 35
MANUAL - NV3550 (Continued)
(12) Remove bol ts that attach front housi ng to rear
housi ng.
(13) Separate front housi ng from rear housi ng
(Fi g. 12). Wi th a pl asti c mal l et tap the front housi ng
off the al i gnment dowel s.
(14) Remove and i nspect i nput shaft beari ng and
countershaft front beari ng (Fi g. 13).
(15) Remove screw from reverse bl ocker and
remove bl ocker (Fi g. 14) from case.
NOTE: The reverse blocker is only used on RHD
vehicles.
(16) Note the l ocati on of the i nput shaft, shi ft
shaft, shi ft forks and geartrai n (Fi g. 15).
Fig. 12 FRONT HOUSING
1 - FRONT HOUSING
2 - REAR HOUSING
3 - DOWELS (2)
4 - PLASTIC MALLET
Fig. 13 INPUT AND COUNTERSHAFT BEARING
RACE
1 - INPUT SHAFT BEARING
2 - FRONT HOUSING
3 - COUNTERSHAFT FRONT BEARING
Fig. 14 REVERSE BLOCKER (RHD)
1 - REVERSE BLOCKER
2 - SHIFTER SHAFT BUSHING
3 - VENT
Fig. 15 GEARTRAIN AND SHIFT COMPONENTS
1 - SHIFT SHAFT
2 - BUSHING
3 - REAR HOUSING
4 - REVERSE IDLER ANSD SUPPORT
5 - OUTPUT SHAFT AND GEARS
6 - COUNTERSHAFT
7 - 1-2 SHIFT FORK
8 - INPUT SHAFT
9 - 3-4 SHIFT FORK
21 - 36 MANUAL - NV3550 TJ
MANUAL - NV3550 (Continued)
SHIFT/FORK SHAFTS AND REVERSE IDLER
SEGMENT
(1) Unseat the rol l pi n that secures the shi ft
socket to the shi ft shaft wi th Remover 6858 as fol -
l ows:
(a) Posi ti on remover on the shi ft shaft. Center
the tool over the rol l pi n and veri fy that the tool
l egs are fi rml y seated on the shi ft socket (Fi g. 16).
(b) Ti l t the socket toward the si de of the case.
Thi s posi ti ons the rol l pi n at a sl i ght angl e to avoi d
trappi ng the pi n between the gear teeth.
(c) Ti ghten the tool to press the rol l pi n down-
ward and out of the shi ft socket (Fi g. 16).
NOTE: Press the roll pin just enough to clear the
shift shaft. Be careful not to push the pin into the
geartrain.
(2) Rotate l ever and bushi ng upward and out of
the shi ft forks and catch detent bal l and spri ng (Fi g.
17) as they exi t the shaft l ever.
NOTE: Place shop towel over shaft to contain
detent ball and spring.
(3) Wi th a hammer and punch dri ve out rol l pi n
that secures shi ft bushi ng and l ever to shi ft shaft
(Fi g. 18).
CAUTION: Use proper size punch to avoid bending
the shift shaft.
Fig. 16 SHIFT SOCKET ROLL PIN
1 - REMOVER
2 - SHIFT SOCKET
Fig. 17 DETENT SPRING AND BALL
1 - SHAFT LEVER
2 - SPRING AND BALL
3 - MAGNET
Fig. 18 SHIFT SHAFT LEVER AND BUSHING ROLL
PIN
1 - LEVER AND BUSHING
2 - SHIFT SHAFT
TJ MANUAL - NV3550 21 - 37
MANUAL - NV3550 (Continued)
(4) Pul l shi ft shaft strai ght (Fi g. 19) out of rear
housi ng.
(5) Remove shi ft socket from rear housi ng (Fi g.
20).
(6) Remove l ever and bushi ng (Fi g. 21).
(7) Rotate 3-4 fork around synchro sl eeve unti l
fork cl ears shi ft arms on 1-2 and fi fth-reverse forks,
then remove 3-4 fork (Fi g. 22).
Fig. 19 SHIFT SHAFT
1 - SHIFTER SHAFT
2 - SHIFTER SHAFT DETENT
3 - 3-4 SHIFT FORK
Fig. 20 SHIFT SOCKET AND ROLL PIN
1 - SHAFT BORE
2 - ROLL PIN
3 - SHIFT SOCKET
Fig. 21 SHIFT SHAFT LEVER AND BUSHING
1 - SHAFT LEVER AND BUSHING
2 - 3-4 FORK
Fig. 22 3-4 SHIFT FORK
1 - 3-4 FORK
2 - 1-2 AND 5TH-REVERSE FORK ARMS
3 - 3-4 SYNCHRO SLEEVE
21 - 38 MANUAL - NV3550 TJ
MANUAL - NV3550 (Continued)
(8) Remove the reverse i dl er shaft support bol t
(front bol t) (Fi g. 23).
(9) Loosen rear reverse i dl er shaft bol t (rear bol t)
(Fi g. 23).
(10) Remove reverse i dl er shaft support (Fi g. 24)
segment by sl i di ng i t strai ght out of housi ng.
(11) Support geartrai n and rear housi ng on Fi x-
ture 6747 as fol l ows:
(a) Adjust hei ght of reverse i dl er pedestal rod
unti l the reverse i dl e shaft bottoms i n Cup 8115.
(b) Posi ti on Adapters 6747-1A and 6747-2A on
Fi xture 6747.
(c) Sl i de fi xture tool onto i nput shaft, counter-
shaft and i dl er gear (Fi g. 25).
(d) Stand geartrai n and rear housi ng upri ght on
fi xture (Fi g. 26). Have hel per hol d fi xture tool i n
pl ace whi l e housi ng and geartrai n i s bei ng rotated
i nto upri ght posi ti on.
(12) Remove rear bol t hol di ng reverse i dl er shaft
i n housi ng.
Fig. 23 REVERSE IDLER SHAFT/SUPPORT BOLT
1 - SUPPORT BOLT
2 - SHAFT BOLT
Fig. 24 IDLER SHAFT SUPPORT
1 - IDLER SHAFT
2 - IDLER SHAFT SUPPORT
Fig. 25 FIXTURE ASSEMBLY
1 - FIXTURE
2 - ADAPTER 6747-1A
3 - CUP ADAPTER
4 - REVERSE IDLER PEDESTAL
5 - ADAPTER 6747-2A
Fig. 26 GEARTRAIN/HOUSING FIXTURE
1 - INPUT SHAFT
2 - COUNTERSHAFT
3 - FIXTURE
TJ MANUAL - NV3550 21 - 39
MANUAL - NV3550 (Continued)
REAR ADAPTER HOUSING
(1) Locate rear seal di mpl es (Fi g. 27). Wi th sl i de
hammer mounted screw, remove rear seal by i nsert-
i ng screw i nto one of the seal di mpl es (Fi g. 28).
(2) Remove rear beari ng snap ri ng from output
shaft wi th snap ri ng pl i ers (Fi g. 29).
(3) Li ft rear adapter housi ng upward and off
geartrai n (Fi g. 30).
(4) Remove beari ng retai ner bol ts and remove rear
beari ng retai ner and rear beari ng (Fi g. 31). I f needed
push or tap beari ng out of the housi ng wi th a ham-
mer.
(5) Exami ne condi ti on of beari ng bore, counter-
shaft rear beari ng race and i dl er shaft notch i n rear
housi ng. Repl ace housi ng i f race, bore or notch are
worn or damaged.
GEARTRAIN FROM FIXTURE
(1) Remove reverse i dl er gear assembl y from
assembl y fi xture cup.
(2) Remove 1-2 and fi fth-reverse forks from syn-
chro sl eeves.
(3) Sl i de countershaft out of fi xture tool .
(4) Li ft and remove output shaft and gears off
i nput shaft.
(5) Li ft and remove i nput shaft, pi l ot beari ng and
fourth gear synchro ri ng from assembl y fi xture tool .
OUTPUT SHAFT
NOTE: The synchronizer hubs and sleeves are dif-
ferent and must not be intermixed. Remove each
synchronizer unit as an assembly to avoid intermix-
ing parts. Reference mark or tag each synchro hub
and sleeve for correct assembly.
(1) Remove snap ri ng that secures 3-4 synchro hub
on output shaft.
Fig. 27 SEAL DIMPLES
1 - LOCATION OF DIMPLES
2 - SEAL FACE
Fig. 28 REAR SEAL
1 - SLIDE HAMMER
2 - REMOVER
3 - REAR SEAL
Fig. 29 REAR BEARING SNAP RING
1 - SNAP RING PLIERS
2 - REAR BEARING SNAP RING
3 - OUTPUT SHAFT
Fig. 30 REAR ADAPTER HOUSING
1 - REAR ADAPTER HOUSING
2 - OUTPUT SHAFT
21 - 40 MANUAL - NV3550 TJ
MANUAL - NV3550 (Continued)
(2) Remove 3-4 synchro assembl y, thi rd gear syn-
chro ri ng and thi rd gear wi th shop press and Beari ng
Spl i tter 1130. Posi ti on spl i tter between second and
thi rd gears.
(3) Remove thi rd gear needl e beari ng (Fi g. 32).
(4) Remove retai ni ng ri ng that secures two-pi ece
thrust washer on shaft (Fi g. 33). Use a smal l pry tool
to remove retai ni ng ri ng.
(5) Remove two-pi ece thrust washer (Fi g. 34). Note
posi ti on of washer l ocati ng l ugs i n shaft notches for
i nstal l ati on reference.
Fig. 31 REAR ADAPTER HOUSING COMPONENTS
1 - BEARING RETAINER
2 - RETAINER BOLTS (3)
3 - IDLER SHAFT NOTCH
4 - COUNTERSHAFT REAR BEARING RACE
5 - REAR BEARING
Fig. 32 THIRD GEAR NEEDLE BEARING
1 - THIRD GEAR NEEDLE BEARING
Fig. 33 THRUST WASHER
1 - PRY TOOL
2 - THRUST WASHER RETAINING RING
Fig. 34 TWO-PIECE THRUST WASHER
1 - SECOND GEAR
2 - THRUST WASHER (2-PIECE)
3 - WASHER LOCATING LUG
TJ MANUAL - NV3550 21 - 41
MANUAL - NV3550 (Continued)
(6) Remove second gear and needl e beari ng (Fi g.
35).
(7) Remove second gear synchro ri ng, synchro fri c-
ti on cone and synchro cone (Fi g. 36).
(8) Remove i nteri m ri ng.
(9) Remove 1-2 synchro hub snap ri ng.
(10) Remove 1-2 synchro hub and sl eeve and fi rst
gear from output shaft wi th press and Beari ng Spl i t-
ter 1130 (Fi g. 37). Posi ti on spl i tter between fi rst and
reverse gears.
(11) Remove fi rst gear needl e beari ng (Fi g. 38).
(12) Remove fi fth gear (Fi g. 39).
Fig. 35 SECOND GEAR AND NEEDLE BEARING
1 - SECOND GEAR
2 - SECOND GEAR NEEDLE BEARING
Fig. 36 SECOND GEAR SYNCHRO RING AND
CONES
1 - 1-2 SYNCHRO HUB AND SLEEVE
2 - INTERM RING
3 - SYNCHRO FRICTION CONE
4 - SYNCHRO CONE
5 - SYNCHRO RING
Fig. 37 HUB SLEEVE AND 1-2 SYNCHRO
1 - 1-2 SYNCHRO HUB AND SLEEVE
2 - SPLITTER
Fig. 38 FIRST GEAR NEEDLE BEARING
1 - FIRST GEAR NEEDLE BEARING
Fig. 39 FIFTH GEAR
1 - FIFTH GEAR AND SYNCHRO RING
21 - 42 MANUAL - NV3550 TJ
MANUAL - NV3550 (Continued)
(13) Remove fi fth gear needl e beari ng.
NOTE: Spread bearing apart just enough to clear
shoulder on output shaft (Fig. 40).
(14) Remove fi fth-reverse synchro hub snap ri ng
(Fi g. 41).
(15) Remove fi fth-reverse synchro hub and sl eeve
wi th a press (Fi g. 42).
(16) Remove reverse gear and needl e beari ng (Fi g.
43).
Fig. 40 FIFTH GEAR NEEDLE BEARING
1 - FIFTH GEAR NEEDLE BEARING
Fig. 41 FIFTH-REVERSE SYNCHRO HUB SNAP
RING
1 - FIFTH-REVERSE SYNCHRO HUB AND SLEEVE
2 - SYNCHRO HUB SNAP RING
3 - SNAP RING PLIERS
Fig. 42 FIFTH-REVERSE SYNCHRO HUB AND
SLEEVE
1 - PRESS
2 - FIFTH-REVERSE SYNCHRO HUB AND SLEEVE
3 - REVERSE GEAR
4 - OUTPUT SHAFT
Fig. 43 REVERSE GEAR AND NEEDLE BEARING
1 - REVERSE GEAR AND NEEDLE BEARING
TJ MANUAL - NV3550 21 - 43
MANUAL - NV3550 (Continued)
REVERSE IDLER
(1) Remove i dl er gear snap ri ngs (Fi g. 44).
(2) Remove thrust washer, wave washer, thrust
pl ate and i dl er gear from shaft.
(3) Remove i dl er gear needl e beari ng from shaft.
CLEANING
Cl ean the gears, shafts, shi ft components and trans-
mi ssi on housi ngs wi th a standard parts cl eani ng sol -
vent. Do not use aci d or corrosi ve base sol vents. Dry al l
parts except beari ngs wi th compressed ai r.
Cl ean the shaft beari ngs wi th a mi l d sol vent such
as Mopar௡ degreasi ng sol vent, Gunk, or si mi l ar sol -
vents. Do not dry the beari ngs wi th compressed ai r.
Al l ow the beari ngs to ei ther ai r dry, or wi pe them dry
wi th cl ean shop towel s.
INSPECTION
NOTE: Minor nicks on component surfaces can be
smoothed with 320/420 grit emery soaked in oil and
final polished with crocus cloth.
SHIFT LEVER ASSEMBLY
The shi ft l ever assembl y i s not servi ceabl e. Repl ace
the l ever and shi ft tower as an assembl y i f the tower,
l ever, l ever bal l , or i nternal components are worn, or
damaged.
SHIFT SHAFT AND FORKS
I nspect the shi ft fork i nterl ock arms and synchro
sl eeve contact surfaces (Fi g. 45). Repl ace any fork
exhi bi ti ng wear or damage i n these areas. Do not
attempt to sal vage shi ft forks.
Check condi ti on of the shi ft shaft detent pl unger
and spri ng. The pl unger shoul d be smooth and free of
ni cks, or scores. The pl unger spri ng shoul d be
strai ght and not col l apsed, or di storted. Repl ace the
pl unger and spri ng i f i n doubt about condi ti on. Check
condi ti on of detent pl unger bushi ngs. Repl ace i f dam-
aged.
I nspect the shi ft shaft, shi ft shaft bushi ng and
beari ng, the shaft l ever, and the l ever bushi ng that
fi ts over the l ever. Repl ace the shaft i f bent, cracked,
or severel y scored. Repl ace the shi ft shaft bushi ng or
beari ng i f damaged.
Repl ace the shaft l ever and bushi ng i f ei ther part
i s deformed, or worn. Do not attempt to sal vage these
parts as shi ft fork bi ndi ng wi l l occur. Repl ace the rol l
pi n that secures the l ever to the shaft.
FRONT/REAR HOUSINGS AND BEARING
RETAINERS
I nspect the housi ngs careful l y. Look for cracks,
stri pped threads, scored mati ng surfaces, damaged
beari ng bores, or worn dowel pi n hol es. Mi nor ni cks
on mati ng surfaces can be dressed off wi th a fi ne fi l e,
or emery cl oth.
NOTE: The front housing contains the countershaft
front bearing race. The rear housing contains the
countershaft rear bearing race. Be advised that
these components are NOT serviceable items. The
front housing will have to be replaced if the coun-
tershaft bearing race is loose, worn, or damaged.
The rear housing will have to be replaced if the
countershaft rear bearing race is loose, worn, or
damaged.
Fig. 44 REVERSE IDLER COMPONENTS
1 - SNAP RING
2 - FLAT WASHER
3 - WAVE WASHER
4 - THRUST WASHER
5 - REVERSE IDLER GEAR
6 - IDLER GEAR BEARING
7 - IDLER SHAFT
8 - THRUST WASHER
9 - SNAP RING
10 - THRUST WASHER LOCKBALLS
21 - 44 MANUAL - NV3550 TJ
MANUAL - NV3550 (Continued)
I nspect the i nput shaft beari ng retai ner. Be sure
the rel ease beari ng sl i de surface of the retai ner i s i n
good condi ti on. Repl ace the retai ner seal i f necessary.
I nspect the output shaft beari ng retai ner. Be sure
the U-shaped retai ner i s fl at and free of di storti on.
Repl ace the retai ner i f the threads are damaged, or i f
the retai ner i s bent, or cracked.
COUNTERSHAFT BEARINGS AND RACES
The countershaft beari ngs and races are machi ne
l apped duri ng manufacture to form matched sets.
The beari ngs and races shoul d not be i nterchanged.
NOTE: The bearing races are a permanent press fit
in the housings and are NOT serviceable. If a bear-
ing race becomes damaged, it will be necessary to
replace the front or rear housing as necessary. A
new countershaft bearing will be supplied with each
new housing for service use.
The countershaft beari ngs can be i nstal l ed back-
wards i f care i s not exerci sed. The beari ng rol l er cage
i s a di fferent di ameter on each si de. Be sure the
beari ng i s i nstal l ed so the l arge di ameter si de of the
cage i s faci ng the countershaft gear (Fi g. 46). The
smal l di ameter si de goes i n the beari ng race.
Fig. 45 SHIFT FORKS & SHAFT
1 - SHIFT SHAFT
2 - SHAFT LEVER
3 - SHAFT LEVER BUSHING
4 - 3-4 SHIFT FORK
5 - 1-2 SHIFT FORK
6 - FIFTH-REVERSE SHIFT FORK
Fig. 46 COUNTERSHAFT & BEARINGS
1 - COUNTERSHAFT
2 - BEARING CAGE
TJ MANUAL - NV3550 21 - 45
MANUAL - NV3550 (Continued)
REVERSE IDLER COMPONENTS
I nspect the i dl er gear, beari ng, shaft, thrust
washer, wave washer and thrust pl ate. Repl ace the
beari ng i f any of the needl e beari ng rol l ers are worn,
chi pped, cracked, fl at-spotted, or bri nnel l ed. Al so
repl ace the beari ng i f the pl asti c beari ng cage i s
damaged or di storted.
Repl ace the thrust washer, wave washer, or thrust
pl ate i f cracked, chi pped, or worn. Repl ace the i dl er
gear i f the teeth are chi pped, cracked or worn thi n.
Repl ace the shaft i f worn, scored, or the bol t threads
are damaged beyond repai r. Repl ace the support seg-
ment i f cracked, or chi pped and repl ace the i dl er
attachi ng bol ts i f the threads are damaged.
Shift Socket
I nspect the shi ft socket for wear or damage.
Repl ace the socket i f the rol l pi n, or shi ft shaft bores
are damaged. Repl ace the socket i f the bal l seat i s
worn, or cracked. Do not reuse the ori gi nal shi ft
socket rol l pi n. I nstal l a new pi n duri ng reassembl y.
The socket rol l pi n i s approxi matel y 33 mm (1-1/4
i n.) l ong.
Output Shaft And Geartrain
I nspect al l of the gears for worn, cracked, chi pped,
or broken teeth. Al so check condi ti on of the beari ng
bore i n each gear. The bores shoul d be smooth and
free of surface damage. Di scol orati on of the gear
bores i s a normal occurrence and i s not a reason for
repl acement. Repl ace gears onl y when tooth damage
has occurred, or i f the bores are bri nnel l ed or
severel y scored.
I nspect the shaft spl i nes and beari ngs surfaces.
Repl ace the shaft i f the spl i nes are damaged or bear-
i ng surfaces are deepl y scored, worn, or bri nnel l ed.
ASSEMBLY
Seal ers are used at al l case joi nts. Usea Mopar
Gasket Maker for al l case joi nts and Mopar si l i cone
seal er or equi val ent, for the i nput shaft beari ng
retai ner. Appl y these products as i ndi cated i n the
assembl y procedures.
CAUTION: The transmission shift components must
be in the Neutral position during assembly. This
prevents damage to the synchro and shift compo-
nents when the housings are installed.
SYNCHRONIZER
WARNING: WEAR SAFETY GLASSES WHILE
ASSEMBLING THE SYNCHRONIZER. A BALL
COULD JUMP OUT AND CAUSE INJURY.
To assembl e each synchro i nstal l the spri ngs,
struts and detent bal l s one at a ti me as fol l ows:
(1) Lubri cate synchroni zer components wi th Mopar
Manual Transmi ssi on l ubri cant or equi val ent.
(2) Sl i de the sl eeve part way onto the hub. Leave
enough room to i nstal l the spri ng i n the hub and the
strut i n the hub groove.
(3) I nstal l the fi rst spri ng i n the hub. Then i nstal l
a strut over the spri ng. Be sure the spri ng i s seated
i n the spri ng bore i n the strut.
(4) Sl i de the sl eeve onto the hub just far enough to
hol d the fi rst strut and spri ng i n pl ace.
(5) Pl ace the detent bal l i n the top of the strut.
Then careful l y work the sl eeve over the bal l to hol d
i t i n pl ace. Use a smal l fl at bl ade screwdri ver to
press the bal l i nto pl ace whi l e movi ng the sl eeve over
i t.
(6) Repeat the procedure for the remai ni ng
spri ngs, struts and bal l s. Tape or rubber band each
strut and bal l to temporari l y secure as they are
i nstal l ed.
(7) Veri fy synchro spri ngs, struts and detent bal l s
are al l i n pl ace (Fi g. 47).
OUTPUT SHAFT
NOTE: Lubricate all components with recommended
lubricant during assembly. Petroleum jelly can be
used to hold parts in place.
Fig. 47 SYNCHRONIZER COMPONENTS
1 - SLEEVE
2 - HUB SHOULDER
3 - SPRING (3)
4 - STRUT (3)
5 - DETENT BALL (3)
6 - HUB
21 - 46 MANUAL - NV3550 TJ
MANUAL - NV3550 (Continued)
(1) Lubri cate and i nstal l reverse gear needl e bear-
i ng on shaft (Fi g. 48). Sl i de beari ng up agai nst shoul -
der on output shaft.
(2) I nstal l reverse gear over needl e beari ng (Fi g.
49).
(3) I nstal l brass synchro ri ng on reverse gear (Fi g.
50).
(4) Assembl e fi fth-reverse synchro hub, sl eeve,
struts, spri ngs and detent bal l s, i f not previ ousl y
done.
CAUTION: One side of the hub has shoulders
around the hub bore, this side of the hub faces the
front of the shaft. One side of the sleeve is tapered.
The tapered side faces the front of the shaft.
(5) Start fi fth-reverse synchro assembl y on output
shaft spl i nes by hand. Then seat synchro onto shaft
wi th a press and Cup 6310-1 (Fi g. 51).
NOTE: Lugs on the synchro ring must be aligned
with the sleeve notches for installation.
Fig. 48 REVERSE GEAR BEARING
1 - REVERSE GEAR BEARING
2 - SHOULDER
Fig. 49 REVERSE GEAR
1 - REVERSE GEAR
Fig. 50 REVERSE SYNCHRO
1 - REVERSE GEAR
2 - SYNCHRO RING
Fig. 51 FIFTH-REVERSE SYNCHRO ASSEMBLY
1 - SPACER
2 - PRESS RAM
3 - REVERSE GEAR
4 - FIFTH-REVERSE SYNCHRO ASSEMBLY
5 - CUP
6 - PRESS BLOCKS
7 - OUTPUT SHAFT
TJ MANUAL - NV3550 21 - 47
MANUAL - NV3550 (Continued)
(6) I nstal l new fi fth-reverse hub snap ri ng (Fi g.
52) and veri fy the snap ri ng i s seated.
(7) I nstal l fi fth gear synchro ri ng i n synchro hub
and sl eeve (Fi g. 53).
(8) I nstal l fi fth gear beari ng, spreadi ng beari ng
onl y enough to cl ear shoul der on output shaft (Fi g.
54). Veri fy beari ng i s properl y seated.
(9) I nstal l fi fth gear on shaft and onto beari ng
(Fi g. 55).
Fig. 52 FIFTH/REVERSE SYNCHRO HUB SNAP RING
1 - FIFTH-REVERSE SYNCHRO ASSEMBLY
2 - SNAP RING
3 - PRESS BED
4 - PRESS BLOCKS
Fig. 53 FIFTH GEAR SYNCHRO RING
1 - FIFTH-SPEED SYNCHRO RING
2 - FIFTH-REVERSE SYNCHRO ASSEMBLY
Fig. 54 FIFTH GEAR BEARING
1 - SHAFT SHOULDER
2 - FIFTH GEAR BEARING
Fig. 55 FIFTH GEAR
1 - FIFTH GEAR
2 - BEARING
21 - 48 MANUAL - NV3550 TJ
MANUAL - NV3550 (Continued)
(10) I nvert output shaft and set the shaft i n Cup
6310-1 so that fi fth gear i s seated on the tool (Fi g.
56).
(11) I nstal l fi rst gear beari ng on output shaft (Fi g.
56). Veri fy beari ng i s seated on shaft shoul der and i s
properl y joi ned.
(12) I nstal l fi rst gear on shaft and over beari ng
wi th synchro cone faci ng up (Fi g. 57).
(13) I nstal l fi rst gear synchro ri ng (Fi g. 58).
(14) Assembl e 1-2 synchro hub sl eeve, spri ngs,
struts and detent bal l s.
CAUTION: The 1-2 synchro hub and sleeve can be
installed backwards. One side of the synchro sleeve
is marked First Gear Side. Verify this side of the
sleeve is facing first gear.
(15) Start 1-2 synchro assembl y on shaft by hand
(Fi g. 59). Veri fy synchro sl eeve i s properl y posi ti oned.
Fig. 56 FIRST GEAR BEARING
1 - FIRST GEAR BEARING
2 - SHAFT SHOULDER
3 - CUP
4 - PRESS BLOCKS
Fig. 57 FIRST GEAR
1 - FIRST GEAR
2 - CUP
3 - BEARING
Fig. 58 FIRST GEAR SYNCHRO RING
1 - FIRST GEAR SYNCHRO RING
2 - CUP
3 - FIRST GEAR
Fig. 59 STARTING 1-2 SYNCHRO
1 - 1–2 SYNCHRO ASSEMBLY
2 - CUP
3 - FIRST GEAR SIDE OF SYNCHRO SLEEVE
TJ MANUAL - NV3550 21 - 49
MANUAL - NV3550 (Continued)
(16) Press 1-2 synchro onto output shaft usi ng
sui tabl e si ze pi pe tool and shop press (Fi g. 60).
CAUTION: Align the synchro ring and sleeve as hub
the is being pressed onto the shaft. The synchro
ring can crack if not aligned.
(17) I nstal l i nterm ri ng.
(18) I nstal l new 1-2 synchro hub snap ri ng (Fi g.
61) and verfi y the snap ri ng i s seated.
(19) I nstal l second gear synchro ri ng i n 1-2 syn-
chro hub and sl eeve (Fi g. 62). Veri fy synchro ri ng i s
properl y seated.
(20) I nstal l synchro fri cti on cone and synchro cone
i n synchro ri ng.
(21) I nstal l second gear needl e beari ng on shaft
(Fi g. 63).
Fig. 60 PRESS 1-2 SYNCHRO
1 - SUITABLE SIZE PIPE TOOL
2 - SYNCHRO RING
3 - CUP
4 - 1-2 SYNCHRO ASSEMBLY
5 - PRESS RAM
Fig. 61 1-2 SYNCHRO HUB SNAP RING
1 - 1-2 SYNCHRO
2 - CUP
3 - SYNCHRO SNAP RING
Fig. 62 SECOND GEAR SYNCHRO RING
1 - SECOND GEAR SYNCHRO RING
2 - 1-2 SYNCHRO
3 - CUP
Fig. 63 SECOND GEAR BEARING
1 - SECOND GEAR BEARING
2 - CUP
21 - 50 MANUAL - NV3550 TJ
MANUAL - NV3550 (Continued)
(22) I nstal l second gear onto shaft and beari ng
(Fi g. 64). Veri fy second gear i s ful l y seated on syn-
chro components.
(23) I nstal l two-pi ece thrust washer (Fi g. 65).
Ensure washer hal ves are seated i n shaft groove and
that washer l ugs are seated i n shaft l ug bores.
NOTE: Dot or markings on the two-piece thrust
washer go toward 3rd gear.
(24) Start retai ni ng ri ng around two-pi ece thrust
washer (Fi g. 66). Ensure l ocati ng di mpl e i s between
the thrust washer hal ves.
Fig. 64 SECOND GEAR
1 - CUP
2 - 1-2 SYNCHRO ASSEMBLY
3 - BEARING
4 - SECOND GEAR
Fig. 65 TWO-PIECE THRUST WASH
1 - WASHER GROOVE IN SHAFT
2 - LUG BORE
3 - THRUST WASHER LUGS
4 - LUG BORE
5 - LUG
6 - WASHER HALF
Fig. 66 RETAINING RING
1 - THRUST WASHER RETAINING RING
2 - THRUST WASHER HALVES
3 - SECOND GEAR
4 - LOCATING DIMPLE
TJ MANUAL - NV3550 21 - 51
MANUAL - NV3550 (Continued)
(25) Seat thrust washer retai ni ng ri ng wi th pl asti c
mal l et (Fi g. 67).
(26) I nstal l thi rd gear needl e beari ng on shaft (Fi g.
68).
(27) I nstal l thi rd gear on shaft and beari ng (Fi g.
69).
(28) I nstal l thi rd speed synchro ri ng on thi rd gear
(Fi g. 70).
(29) Assembl e 3-4 synchro hub, sl eeve, spri ngs,
struts and detent bal l s.
(30) Start 3-4 synchro hub on output shaft spl i nes
by hand (Fi g. 71).
CAUTION: The 3-4 synchro hub and sleeve can be
installed backwards. One side of the sleeve has
grooves in it. This side of sleeve faces the front of
the shaft.
Fig. 67 THRUST RETAINER
1 - PLASTIC MALLET
2 - THRUST WASHER RETAINING RING
Fig. 68 THIRD GEAR BEARING
1 - THIRD GEAR BEARING
Fig. 69 THIRD GEAR
1 - THIRD GEAR
2 - BEARING
Fig. 70 THIRD SPEED SYNCHRO RING
1 - THIRD SPEED SYNCHRO RING
2 - THIRD GEAR
Fig. 71 3-4 SYNCHRO HUB ON OUTPUT SHAFT
1 - GROOVED SIDE OF SLEEVE (TO FRONT)
2 - 3-4 SYNCHRO ASSEMBLY
21 - 52 MANUAL - NV3550 TJ
MANUAL - NV3550 (Continued)
(31) Wi th the l ug on the ri ng al i gned wi th the sl ot
on the synchro, press 3-4 synchro assembl y onto out-
put shaft wi th shop press and sui tabl e si ze pi pe tool
(Fi g. 72).
NOTE: Place the pipe on hub as close to output
shaft as possible without contacting the shaft
splines.
(32) I nstal l new 3-4 synchro hub snap ri ng (Fi g.
73) and veri fy snap ri ng i s seated.
(33) Veri fy posi ti on of synchro sl eeves before pro-
ceedi ng wi th assembl y operati ons (Fi g. 74). Grooved
si de of 3-4 sl eeve shoul d be faci ng forward. Fi rst gear
si de of 1-2 sl eeve shoul d be faci ng fi rst gear. Tapered
si de of fi fth-reverse sl eeve shoul d be faci ng forward.
REVERSE IDLER ASSEMBLY
(1) Lubri cate i dl er components wi th Mopar Man-
ual Transmi ssi on l ubri cant or equi val ent.
(2) Sl i de i dl er gear beari ng on shaft (Fi g. 75).
Beari ng fi ts ei ther way on shaft.
(3) Sl i de gear onto shaft. Si de of gear wi th recess
goes to rear (Fi g. 75).
(4) Pl ace fi rst l ock bal l i n di mpl e at rear end of
i dl er shaft (Fi g. 75). Hol d bal l i n pl ace wi th petro-
l eum jel l y.
(5) Sl i de rear thrust washer onto shaft and over
l ock bal l (Fi g. 76).
(6) I nstal l snap ri ng i n groove at rear of shaft (Fi g.
76).
Fig. 72 3-4 SYNCHRO ON OUTPUT SHAFT
1 - PRESS RAM
2 - PIPE TOOL
3 - 3-4 SYNCHRO
4 - THIRD SPEED SYNCHRO RING
Fig. 73 3-4 SYNCHRO HUB SNAP RING
1 - 3-4 SYNCHRO HUB SNAP RING
2 - HEAVY DUTY SNAP RING PLIERS
TJ MANUAL - NV3550 21 - 53
MANUAL - NV3550 (Continued)
Fig. 74 SYNCHRO SLEEVE LOCATIONS
1 - DOUBLE GROOVE FORWARD
2 - GROOVE FORWARD
3 - FIRST GEAR SIDE MARKING TOWARD FIRST GEAR
4 - TAPER FORWARD
5 - GROOVE FORWARD
6 - 5TH-REV SYNCHRO SLEEVE
7 - 1-2 SYNCHRO SLEEVE
8 - 3-4 SYNCHRO SLEEVE
Fig. 75 IDLER GEAR AND BEARING
1 - IDLER GEAR
2 - BEARING
3 - LOCK BALL
4 - REAR OF SHAFT
Fig. 76 IDLER GEAR REAR THRUST WASHER
1 - LOCK BALL
2 - SNAP RING GROOVE
3 - THRUST WASHER
21 - 54 MANUAL - NV3550 TJ
MANUAL - NV3550 (Continued)
(7) I nstal l l ock bal l i n di mpl e at front of shaft.
Hol d bal l i n pl ace wi th petrol eum jel l y.
(8) I nstal l front thrust washer on shaft and sl i de
washer up agai nst gear and over l ock bal l (Fi g. 77).
(9) I nstal l wave washer, fl at washer and remai n-
i ng snap ri ng on i dl er shaft (Fi g. 77). Veri fy snap
ri ng i s seated.
SHIFT SHAFT AND BUSHINGS/BEARINGS
I nspect shi ft shaft bushi ng and beari ng for damage
and repl ace i f necessary.
(1) Locate a bol t that wi l l thread i nto the bushi ng
wi thout great effort.
(2) Thread the bol t i nto the bushi ng, al l owi ng the
bol t to make i ts own threads i n the bushi ng.
(3) Attach a sl i de hammer or sui tabl e pul l er to the
bol t and remove bushi ng.
(4) Use the short end of I nstal l er 8119 to i nstal l
the new bushi ng.
(5) The bushi ng i s correctl y i nstal l ed i f the bush-
i ng i s fl ush wi th the transmi ssi on case.
(6) To repl ace the beari ng l ocate a bol t that wi l l
thread i nto the beari ng wi thout great effort.
(7) Thread the bol t i nto the beari ng as much as
possi bl e.
(8) Attach a sl i de hammer or sui tabl e pul l er to the
bol t and remove the beari ng.
(9) Use the short end of I nstal l er 8119 to i nstal l
the new beari ng.
(10) The beari ng i s correctl y i nstal l ed i f the bear-
i ng i s fl ush wi th the transmi ssi on case.
DETENT PLUNGER BUSHING
I nspect detent pl unger bushi ngs for damage and
repl ace i f necessary.
NOTE: The detent plunger bushings are installed to
a specific depth. The space between the two bush-
ings when correctly installed contain an oil feed
hole. Do not attempt to install the bushings with
anything other than the specified tool or this oil
hole may become restricted.
(1) Usi ng the l ong end of I nstal l er 8119, dri ve the
detent bushi ngs through the outer case and i nto the
shi ft shaft bore.
(2) Remove the bushi ngs from the shi ft shaft bore.
(3) I nstal l a new detent pl unger bushi ng on the
l ong end of I nstal l er 8118.
(4) Start the bushi ng i n the detent pl unger bore i n
the case.
(5) Dri ve the bushi ng i nto the bore unti l the tool
contacts the transmi ssi on case.
(6) I nstal l a new detent pl unger bushi ng on the
short end of I nstal l er 8118.
(7) Start the bushi ng i n the detent pl unger bore i n
the case.
(8) Dri ve the bushi ng i nto the bore unti l the tool
contacts the transmi ssi on case.
Fig. 77 IDLER GEAR AND SHAFT ASSEMBLY
1 - REAR OF SHAFT
2 - GEAR
3 - THRUST WASHER AND BALL
4 - WAVE WASHER
5 - FLAT WASHER
6 - FRONT OF SHAFT
7 - SNAP RING
8 - SNAP RING
TJ MANUAL - NV3550 21 - 55
MANUAL - NV3550 (Continued)
GEARTRAIN ASSEMBLY
(1) I nstal l Adapter 6747-1A on i nput shaft hub of
Fi xture 6747 (Fi g. 78).
(2) I nstal l i nput shaft i n fi xture tool . Make sure
Adapter 6747-1A i s posi ti oned under shaft as shown
(Fi g. 79).
(3) I nstal l pi l ot beari ng i n i nput shaft (Fi g. 79).
NOTE: The side of the pilot bearing with the small
diameter goes toward the input shaft.
(4) I nstal l fourth gear synchro ri ng on i nput shaft
(Fi g. 80).
(5) Adjust hei ght of i dl er gear pedestal on assem-
bl y fi xture (Fi g. 81). Start wi th a basi c hei ght of 18.4
cm (7-1/4 i n.). Fi nal adjustment can be made after
gear i s posi ti oned on pedestal .
Fig. 78 ASSEMBLY FIXTURE
1 - ADAPTER 6747-2A (INSTALL ON COUNTERSHAFT FRONT
HUB)
2 - CUP ADAPTER 8115
3 - ADAPTER 6747-A
4 - FIXTURE 6747
Fig. 79 PILOT BEARING AND INPUT SHAFT
1 - PILOT BEARING
2 - INPUT SHAFT
Fig. 80 FOURTH GEAR SYNCHRO
1 - FOURTH GEAR SYNCHRO RING
2 - INPUT SHAFT
Fig. 81 IDLER PEDESTAL BASIC HEIGHT
1 - REVERSE IDLER PEDESTAL
21 - 56 MANUAL - NV3550 TJ
MANUAL - NV3550 (Continued)
(6) I nstal l assembl ed output shaft and geartrai n i n
i nput shaft (Fi g. 82). Careful l y rotate output shaft
unti l the 3-4 synchro ri ng seats i n synchro hub and
sl eeve.
(7) I nstal l Adapter 6747-2A on front beari ng hub of
countershaft. The adapter has a shoul der on one si de
that goes towards the countershaft.
(8) Sl i de countershaft (and adapter) i nto fi xture
sl ot. Veri fy countershaft and output shaft gears are
ful l y meshed wi th the mai nshaft gears (Fi g. 83).
(9) Check al i gnment of countershaft and output
shaft gear teeth. Note that gears may not al i gn per-
fectl y. A di fference i n hei ght of 1.57 to 3.18 mm (1/16
to 1/8 i n.) wi l l probabl y exi st. Thi s di fference wi l l not
i nterfere wi th assembl y.
(10) Posi ti on reverse i dl er i n support cup of assem-
bl y fi xture (Fi g. 84). Ensure i dl er gear i s properl y
meshed and al i gned wi th shaft gear teeth and that
bol t hol es are faci ng out and not toward geartrai n.
Adjust pedestal up or down i f necessary. Al so be sure
that short end of i dl er shaft i s faci ng up as shown.
Fig. 83 COUNTERSHAFT ON FIXTURE
1 - OUTPUT SHAFT AND GEARTRAIN
2 - COUNTERSHAFT (SLIDE INTO PLACE ON FIXTURE TOOL)
Fig. 84 REVERSE IDLER ASSEMBLY POSITION
1 - OUTPUT SHAFT AND GEARTRAIN
2 - COUNTERSHAFT
3 - REVERSE IDLER ASSEMBLY
4 - TOOL PEDESTAL
Fig. 82 OUTPUT SHAFT AND GEARTRAIN
1 - OUTPUT SHAFT AND GEARTRAIN
2 - INPUT SHAFT
3 - FIXTURE 6747
TJ MANUAL - NV3550 21 - 57
MANUAL - NV3550 (Continued)
(11) Assembl e 1-2 and fi fth reverse-shi ft forks (Fi g.
85). Arm of fi fth-reverse fork goes through sl ot i n 1-2
fork.
(12) I nstal l assembl ed shi ft forks i n synchro
sl eeves (Fi g. 86). Veri fy forks are properl y seated i n
sl eeves.
ADAPTER HOUSING
(1) I nstal l rear beari ng i n adapter housi ng. Use
wood hammer handl e or wood dowel to tap beari ng
i nto pl ace.
(2) Posi ti on rear beari ng retai ner i n adapter hous-
i ng (Fi g. 87).
(3) Appl y Mopar Gasket Maker or equi val ent, to
threads, bol t shanks and under hex heads of beari ng
retai ner bol ts.
(4) Appl y l i beral quanti ty of petrol eum jel l y to
countershaft rear beari ng and beari ng race.
(5) I nstal l countershaft rear beari ng i n beari ng
race (Fi g. 87).
CAUTION: Be sure the large diameter side of the
roller retainer faces the countershaft and the small
diameter side faces the race and housing.
(6) Appl y extra petrol eum jel l y to hol d counter-
shaft rear beari ng i n pl ace when housi ng i s i nstal l ed.
(7) Appl y l i ght coat of petrol eum jel l y to shi ft shaft
bushi ng/beari ng i n adapter housi ng.
(8) I nstal l adapter housi ng on geartrai n.
Fig. 85 1-2 AND FIFTH-REVERSE
1 - FIFTH-REVERSE FORK ARM
2 - 1-2 FORK
3 - FIFTH-REVERSE FORK
Fig. 86 SHIFT FORKS IN SYNCHRO
1 - SYNCHRO SLEEVES
2 - FORK ARMS
3 - SHIFT FORKS
Fig. 87 ADAPTER HOUSING
1 - BEARING RETAINER
2 - RETAINER BOLT
3 - IDLER SHAFT NOTCH
4 - COUNTERSHAFT BEARING RACE
5 - REAR BEARING
21 - 58 MANUAL - NV3550 TJ
MANUAL - NV3550 (Continued)
(9) I nstal l rear beari ng snap ri ng on output shaft
(Fi g. 88).
(10) Lubri cate l i p of new rear seal (Fi g. 89) wi th
Mopar Door Ease or transmi ssi on fl ui d.
(11) I nstal l new rear seal i n adapter housi ng bore
wi th I nstal l er C-3860-A. Veri fy seal i s seated i n hous-
i ng bore (Fi g. 89).
(12) Sl i de reverse i dl er shaft support strai ght i nto
the housi ng.
(13) I nstal l reverse i dl er shaft support bol t and
i dl er shaft bol t (Fi g. 90). Ti ghten bol ts to 19-25 N·m
(14-18 ft. l bs.).
SHIFT SHAFT, SHAFT LEVER AND BUSHING AND
SHIFT SOCKET
(1) Veri fy that al l synchro sl eeves are i n Neutral
posi ti on (centered on hub).
CAUTION: The transmission synchros must all be
in Neutral position for assembly. Otherwise the
housings, shift forks and gears can be damaged
during installation of the two housings.
(2) I nstal l 3-4 shi ft fork i n synchro sl eeve (Fi g. 91).
Veri fy that groove i n fork arm i s al i gned wi th grooves
i n 1-2 and fi fth-reverse fork arms as shown.
Fig. 88 REAR BEARING SNAP RING
1 - SNAP RING PLIERS
2 - SNAP RING
3 - OUTPUT SHAFT
Fig. 89 REAR SEAL
1 - REAR SEAL
2 - SEAL LIP
3 - OUTPUT SHAFT
Fig. 90 REVERSE IDLER SHAFT/SUPPORT BOLT
1 - SUPPORT BOLT
2 - SHAFT BOLT
Fig. 91 3-4 SHIFT FORK
1 - 3-4 FORK
2 - ALIGN GROOVES IN FORK ARMS
TJ MANUAL - NV3550 21 - 59
MANUAL - NV3550 (Continued)
(3) Sl i de the end of shi ft shaft wi th shaft detent
notches through 3-4 shi ft fork.
(4) Assembl e shi ft shaft shi ft l ever and bushi ng
(Fi g. 92). Be sure sl ot i n bushi ng i s faci ng up and rol l
pi n hol e for l ever i s al i gned wi th hol e i n shaft.
(5) I nstal l assembl ed l ever and bushi ng on shi ft
shaft (Fi g. 93).
(6) Sl i de shi ft shaft through shi ft forks (Fi g. 94)
and i nto shi ft l ever openi ng i n rear housi ng (Fi g. 95).
Fig. 92 LEVER AND BUSHING
1 - SHAFT LEVER
2 - LEVER BUSHING
3 - BUSHING LOCK PIN SLOT
Fig. 93 LEVER AND BUSHING ASSENBLY
1 - SHIFT SHAFT
2 - SHAFT LEVER AND BUSHING
3 - 3-4 FORK
Fig. 94 SHIFT SHAFT
1 - SHIFT SHAFT
2 - 3-4 SHIFT FORK
Fig. 95 SHAFT IN LEVER OPENING
1 - SHIFT SHAFT
21 - 60 MANUAL - NV3550 TJ
MANUAL - NV3550 (Continued)
(7) Al i gn shi ft socket wi th shaft and sl i de shaft
through socket and i nto shi ft shaft beari ng i n rear
housi ng (Fi g. 96).
(8) Rotate shi ft shaft so detent notches i n shaft are
faci ng the TOP of the transmi ssi on housi ng.
CAUTION: Positioning of the shift shaft detent
notch is important. Both of the shaft roll pins can
be installed even when the shaft is 180° off. If this
occurs, the transmission will have to be disassem-
bled again to correct shaft alignment.
(9) Sel ect correct new rol l pi n for shi ft shaft l ever
(Fi g. 97). Shaft l ever rol l pi n i s approxi matel y 22 mm
(7/8 i n.) l ong. Shi ft socket rol l pi n i s approxi matel y
33 mm (1-1/4 i n.) l ong.
(10) Al i gn rol l pi n hol es i n shi ft shaft, l ever and
bushi ng. Then start rol l pi n i nto shaft l ever by hand
(Fi g. 98).
(11) Seat shaft l ever rol l pi n wi th pi n punch (Fi g.
99).
CAUTION: The shaft lever roll pin must be flush
with the surface of the lever. The lever bushing will
bind on the roll pin if the pin is not seated flush.
(12) Veri fy that l ock pi n sl ot i n l ever bushi ng i s
posi ti oned as shown (Fi g. 99).
Fig. 96 SHIFT SOCKET
1 - SHIFT SOCKET
2 - SHIFT SHAFT
Fig. 97 ROLL PIN IDENTIFICATION
1 - SHAFT LEVER ROLL PIN
2 - SHIFT SOCKET ROLL PIN
Fig. 98 ROLL PIN IN SHIFT SHAFT
1 - SHAFT LEVER ROLL PIN 22 mm (7/8 in.)
2 - LEVER AND BUSHING
Fig. 99 SHIFT SHAFT LEVER ROLL
1 - BUSHING LOCK PIN SLOT
2 - ROLL PIN FLUSH WITH LEVER
TJ MANUAL - NV3550 21 - 61
MANUAL - NV3550 (Continued)
(13) Al i gn rol l pi n hol es i n shi ft socket and shi ft
shaft. Then start rol l pi n i nto shi ft shaft by hand
(Fi g. 100).
(14) Seat rol l pi n i n shi ft socket wi th pi n punch.
Rol l pi n must be fl ush wi th socket (Fi g. 101).
(15) Veri fy that notches i n shi ft fork arms are
al i gned (Fi g. 102). Real i gn arms i f necessary.
(16) Rotate shi ft l ever and bushi ng downward to
expose detent bore i n the l ever.
(17) I nstal l detent spri ng then the bal l i nto the
detent bore (Fi g. 103) and hol d the bal l i n the l ever.
Then rotate the l ever upward i nto the fork arm
notches.
NOTE: Verify detent ball is seated in the fork arms
before proceeding.
Fig. 100 ROLL PIN IN SHIFT SOCKET
1 - ROLL PIN 33 mm (1 1/4 in.)
2 - SHIFT SOCKET
3 - SHIFT SHAFT
Fig. 101 SEATING SHIFT SOCKET ROLL PIN
1 - PIN PUNCH
2 - SHIFT SOCKET
3 - SEAT ROLL PIN FLUSH
4 - SHIFT SOCKET
Fig. 102 SHIFT LEVER POSITION
1 - SHIFT FORK ARMS
2 - DETENT BORE
Fig. 103 DETENT SPRING AND BALL
1 - SHAFT LEVER
2 - SPRING AND BALL
3 - MAGNET
21 - 62 MANUAL - NV3550 TJ
MANUAL - NV3550 (Continued)
FRONT HOUSING AND INPUT SHAFT BEARING
RETAINER
(1) I nstal l reverse bl ocker, retai nter and retai ner
bol t i n front housi ng.
(2) I f previ ousl y removed, i nput shaft beari ng i n
front housi ng (Fi g. 104). I nstal l snap ri ng and use
pl asti c mal l et to seat beari ng. Beari ng goes i n from
front si de of housi ng onl y.
(3) Appl y l i beral quanti ty of petrol eum jel l y to
countershaft front beari ng. Then i nsert beari ng i n
front housi ng race (Fi g. 104). Large di ameter si de of
beari ng cage goes toward countershaft (Fi g. 105).
Smal l di ameter si de goes toward beari ng race i n
housi ng.
(4) Reach i nto countershaft front beari ng wi th fi n-
ger, and push each beari ng rol l er outward agai nst
race. Then appl y extra petrol eum jel l y to hol d rol l ers
i n pl ace. Thi s avoi ds havi ng rol l ers becomi ng di s-
pl aced duri ng housi ng i nstal l ati on.
(5) Appl y smal l amount of petrol eum jel l y to shi ft
shaft bushi ng i n front housi ng.
(6) Appl y 1/8 i n. wi de bead of Mopar Gasket
Maker or equi val ent, to mati ng surfaces of front and
rear housi ngs (Fi g. 106).
Fig. 104 INPUT SHAFT AND COUNTERSHAFT
FRONT BEARING
1 - INPUT SHAFT BEARING
2 - COUNTERSHAFT FRONT BEARING
3 - SHIFT SHAFT BUSHING
Fig. 105 COUNTERSHAFT FRONT BEARING
1 - BEARING RACE
2 - PETROLEUM JELLY
3 - COUNTERSHAFT FRONT BEARING
Fig. 106 SEAL FRONT/REAR HOUSINGS
1 - HOUSING FLANGE SURFACE
2 - GASKET MAKER
TJ MANUAL - NV3550 21 - 63
MANUAL - NV3550 (Continued)
(7) Have hel per hol d rear housi ng and geartrai n i n
upri ght posi ti on. Then i nstal l front housi ng on rear
housi ng and geartrai n.
(8) Work front housi ng downward onto geartrai n
unti l seated on rear housi ng.
CAUTION: If the front housing will not seat on the
rear housing, either the shift components are not in
Neutral, or one or more components are mis-
aligned. Do not force the front housing into place.
This will only result in damaged components.
(9) Tap rear housi ng al i gnment dowel s back i nto
pl ace wi th hammer and pi n punch. Both dowel s
shoul d be fl ush fi t i n each housi ng. Have hel per hol d
transmi ssi on upri ght whi l e dowel s are tapped back
i nto pl ace.
(10) Pl ace transmi ssi on i n hori zontal posi ti on.
(11) Appl y Mopar Gasket Maker or equi val ent to
housi ng attachi ng bol ts. Appl y seal er materi al seal er
to undersi de of bol t heads and to bol t shanks and
threads (Fi g. 107).
(12) I nstal l and start housi ng attachi ng bol ts by
hand (Fi g. 107). Then ti ghten bol ts to 34 N·m (25 ft.
l bs.).
(13) I nstal l shi ft shaft bushi ng l ock bol t (Fi g. 108).
Appl y Mopar Gasket Maker or equi val ent, to bol t
threads, shank and undersi de of bol t head before
i nstal l ati on.
NOTE: This is a special bolt and can not be substi-
tuted with any other bolt.
CAUTION: If the lock bolt cannot be fully installed,
do not try to force it into place. Either the shift
shaft is not in Neutral or the shaft bushing (or
lever) is misaligned.
(14) Lubri cate then i nstal l shi ft shaft detent
pl unger i n housi ng bore. Lubri cate pl unger wi th Val -
vol i ne Dura Bl end௡ semi -syntheti c/syntheti c grease
or equi val ent. Verify plunger is fully seated in
detent notch in shift shaft.
(15) I nstal l detent spri ng i nsi de pl unger.
(16) I nstal l pl ug on detent spri ng and compress
spri ng. Then dri ve detent pl ug wi th I nstal l er 8123
i nto transmi ssi on case unti l pl ug seats.
(17) I nstal l backup l i ght swi tch (Fi g. 109).
Fig. 107 HOUSING BOLTS
1 - HOUSING BOLTS
Fig. 108 SHAFT LOCK BOLT
1 - SHIFT SHAFT LOCK BOLT
2 - SHAFT SOCKET
Fig. 109 BACKUP LIGHT SWITCH
1 - BACKUP LIGHT SWITCH
21 - 64 MANUAL - NV3550 TJ
MANUAL - NV3550 (Continued)
(18) I nstal l i nput shaft snap ri ng (Fi g. 110).
(19) I nstal l new oi l seal i n front beari ng retai ner
wi th I nstal l er 6448 (Fi g. 111).
(20) Appl y bead of Mopar si l i cone seal er or equi v-
al ent to fl ange surface of front beari ng retai ner (Fi g.
112).
(21) Al i gn and i nstal l front beari ng retai ner over
i nput shaft and onto housi ng mounti ng surface (Fi g.
113). Al though retai ner i s one-way fi t on housi ng, be
sure bol t hol es are al i gned before seati ng retai ner.
NOTE: Ensure no sealer gets in the transmission
case oil feed hole and slot in bearing retainer is
aligned with oil feed hole.
(22) I nstal l and ti ghten beari ng retai ner bol ts to
9-14 N·m (7-10 ft. l bs.) (Fi g. 114).
Fig. 110 SHAFT SNAP RING - TYPICAL
1 - INPUT SHAFT SNAP RING
Fig. 111 OIL SEAL IN FRONT BEARING RETAINER
1 - INSTALLER
2 - FRONT BEARING RETAINER
Fig. 112 SEAL BEARING RETAINER AND HOUSING
1 - APPLY SEALER BEAD
2 - INPUT SHAFT BEARING RETAINER
Fig. 113 INPUT SHAFT BEARING RETAINER
1 - INPUT SHAFT
2 - OIL FEED
3 - BEARING RETAINER
Fig. 114 BEARING RETAINER BOLTS
1 - RETAINER
2 - BOLTS
TJ MANUAL - NV3550 21 - 65
MANUAL - NV3550 (Continued)
SHIFT TOWER AND LEVER
(1) Appl y petrol eum jel l y to bal l end of shi ft l ever
and i nteri or of shi ft socket.
(2) Shi ft the transmi ssi on i nto thi rd gear.
(3) Al i gn and i nstal l shi ft tower and l ever assem-
bl y (Fi g. 115). Be sure shi ft bal l i s seated i n socket
and the offset i n the tower i s toward the passenger
si de of the vehi cl e before i nstal l i ng tower bol ts.
(4) I nstal l shi ft tower bol ts (Fi g. 116). Ti ghten
bol ts to 8.5 N·m (75.2 i n. l bs.).
(5) Fi l l transmi ssi on to bottom edge of fi l l pl ug
hol e wi th Mopar Transmi ssi on Lubri cant.
(6) I nstal l and ti ghten fi l l pl ug to 34 N·m (25 ft.
l bs.).
(7) Check transmi ssi on vent. Be sure vent i s open
and not restri cted.
INSTALLATION
(1) I nstal l cl utch housi ng on transmi ssi on and
ti ghten housi ng bol ts to 46 N·m (34 ft. l bs.).
(2) Lubri cate contact surfaces of rel ease fork pi vot
bal l stud and rel ease fork wi th hi gh temp grease.
(3) I nstal l rel ease beari ng, fork and retai ner cl i p.
(4) Posi ti on and secure transmi ssi on on transmi s-
si on jack.
(5) Li ghtl y l ubri cate pi l ot beari ng and transmi s-
si on i nput shaft spl i nes wi th Mopar hi gh temp
grease.
(6) Rai se transmi ssi on and al i gn transmi ssi on
i nput shaft and cl utch di sc spl i nes. Then sl i de trans-
mi ssi on i nto pl ace.
(7) I nstal l and ti ghten cl utch housi ng-to-engi ne
bol ts (Fi g. 117) to:Be sure the housing is properly
seated on engine block before tightening bolts.
• Ti ghten 3/8” di ameter bol ts to 37 N·m (27 ft.l bs.)
• Ti ghten 7/16” di ameter bol ts to 58 N·m (43
ft.l bs.)
• Ti ghten M12 bol ts to 75 N·m (55 ft.l bs.)
(8) Be sure transmi ssi on i s i n fi rst or thi rd gear.
(9) I nstal l crossmember and ti ghten crossmember-
to-frame bol ts to 41 N·m (31 ft. l bs.).
(10) I nstal l fasteners to hol d rear cushi on and
bracket to transmi ssi on. Then ti ghten transmi ssi on-
to-rear support bol ts/nuts to 54 N·m (40 ft. l bs.).
(11) Remove support stands from engi ne and
transmi ssi on.
(12) I nstal l and connect crankshaft posi ti on sensor.
(13) I nstal l transfer case.
(14) I nstal l propel l er shafts.
(15) I nstal l sl ave cyl i nder i n cl utch housi ng.
Fig. 115 SHIFT TOWER
1 - SHIFT TOWER
2 - SHIFT SOCKET
3 - SEALING SURFACE
Fig. 116 SHIFT TOWER BOLTS
1 - SHIFT TOWER AND LEVER ASSEMBLY
Fig. 117 NV3550 TRANSMISSION
1 - TRANSMISSION
2 - CLUTCH ASSEMBLY
21 - 66 MANUAL - NV3550 TJ
MANUAL - NV3550 (Continued)
(16) I nstal l ski d pl ate, i f equi pped and ti ghten
bol ts to 42 N·m (31 ft. l bs.). Ti ghten stud nuts to 17
N·m (150 i n. l bs.).
(17) Fi l l transmi ssi on and transfer case i f
equi pped, wi th recommended l ubri cants. Refer to the
Lubri cant Recommendati on secti ons of the appropri -
ate component for correct fl ui d.
(18) I nstal l nuts on two M6X1.0 bol ts and thread
the bol ts i nto the threaded hol es at the base of the
shi ft l ever.
(19) Ti ghten the nuts equal l y unti l the shi ft l ever
wi l l sl i de over the shi ft tower stub shaft.
(20) I nstal l the fl oor consol e and shi ft boot.
SPECIFICATIONS
MANUAL
TORQUE SPECIFICATIONS
DESCRIPTION N·m Ft. Lbs. In. Lbs.
Clutch Housing Bolts 54-61 40-45 -
Crossmember To Frame Bolts 61-75 44-55 -
Crossmember To Insulator Nuts 54-61 40-45 -
Drain/Fill Plug 9-27 14-20 -
Front To Rear Housing Bolts 30-35 22-26 -
Front Bearing Retainer Bolts 9-14 7-8 80-124
Idler Shaft Bolts 19-25 14-18 -
Rear Bearing Retainer Bolts 30-35 22-26 -
Shift Tower Bolts 7-10 5-7 62-88
Slave Cylinder Nuts 23 17 -
Transfer Case Nuts 47 35 -
U-Joint Clamp Bolts 19 14 -
SPECIAL TOOLS
REMOVER/INSTALLER 6858
FIXTURE 6747
ADAPTER 6747-1A
ADAPTER 6747-2A
TJ MANUAL - NV3550 21 - 67
MANUAL - NV3550 (Continued)
CUP 8115
SPLITTER 1130
TUBE 6310-1
INSTALLER 8118
REMOVER/INSTALLER 8119
PIN ALIGNMENT 8120
REMOVER 8117A
INSTALLER 8123
INSTALLER 6448
21 - 68 MANUAL - NV3550 TJ
MANUAL - NV3550 (Continued)
VEHICLE SPEED SENSOR
DESCRIPTION
The 3-wi re Vehi cl e Speed Sensor (VSS) i s l ocated
on the speedometer pi ni on gear adapter. I f equi pped
wi th 4WD, thi s adapter i s l ocated on the extensi on
housi ng of the transfer case (dri vers si de). I f
equi pped wi th 2WD, thi s adapter i s l ocated on the
l eft si de of the transmi ssi on extensi on housi ng.
OPERATION
The VSS i s a 3-ci rcui t (3–wi re), magneti c, hal l -ef-
fect sensor.
The 3 ci rcui ts are:
• A 5-vol t power suppl y from the Powertrai n Con-
trol Modul e (PCM).
• A ground i s provi ded for the sensor though a
l ow-noi se sensor return ci rcui t i n the PCM.
• An i nput to the PCM i s used to determi ne vehi -
cl e speed and di stance travel ed.
The speed sensor generates 8 pul ses per sensor
revol uti on. These si gnal s, i n conjuncti on wi th a
cl osed throttl e si gnal from the throttl e posi ti on sen-
sor, i ndi cate a cl osed throttl e decel erati on to the
PCM. When the vehi cl e i s stopped at i dl e, a cl osed
throttl e si gnal i s recei ved by the PCM (but a speed
sensor si gnal i s not recei ved).
Under decel erati on condi ti ons, the PCM adjusts the
I dl e Ai r Control (I AC) motor to mai ntai n a desi red MAP
val ue. Under i dl e condi ti ons, the PCM adjusts the I AC
motor to mai ntai n a desi red engi ne speed.
REMOVAL
The Vehi cl e Speed Sensor (VSS) i s l ocated on the
speedometer pi ni on gear adapter. I f equi pped wi th
4WD, thi s adapter i s l ocated on the transfer case
extensi on (l eft si de) (Fi g. 118). I f equi pped wi th 2WD,
thi s adapter i s l ocated on the extensi on housi ng of
the transmi ssi on (l eft si de).
(1) Rai se and support vehi cl e.
(2) Di sconnect el ectri cal connector from sensor by
pushi ng sl i de tab (Fi g. 118). After sl i de tab has been
posi ti oned, push i n on secondary rel ease l ock (Fi g. 118)
on si de of connector and pul l connector from sensor.
(3) Remove sensor mounti ng bol t (Fi g. 119).
(4) Remove sensor (pul l strai ght out) from speed-
ometer pi ni on gear adapter (Fi g. 119). Do not remove
gear adapter from transmi ssi on.
INSTALLATION
(1) Cl ean i nsi de of speedometer pi ni on gear
adapter before i nstal l i ng speed sensor.
(2) I nstal l sensor i nto speedometer gear adapter
and i nstal l mounti ng bol t. Before ti ghteni ng bol t, ver-
i fy speed sensor i s ful l y seated (mounted fl ush) to
speedometer pi ni on gear adapter.
(3) Ti ghten sensor mounti ng bol t to 2.2 N·m (20 i n.
l bs.) torque.
(4) Connect el ectri cal connector to sensor.
Fig. 118 VSS Location
1 - SENSOR ELECTRICAL CONNECTOR
2 - SLIDE TAB
3 - 4WD TRANSFER CASE EXTENSION
4 - VEHICLE SPEED SENSOR
5 - RELEASE LOCK
Fig. 119 VSS Removal/Installation
1 - ELECTRICAL CONNECTOR
2 - SENSOR MOUNTING BOLT
3 - O-RING
4 - SPEEDOMETER PINION GEAR
5 - SPEEDOMETER PINION GEAR ADAPTER
6 - O-RING
7 - VEHICLE SPEED SENSOR
TJ MANUAL - NV3550 21 - 69
AUTOMATIC TRANSMISSION - 42RLE
TABLE OF CONTENTS
page page
AUTOMATIC TRANSMISSION - 42RLE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 72
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - AUTOMATIC
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . 79
DIAGNOSIS AND TESTING - ROAD TEST . . . 79
DIAGNOSIS AND TESTING - HYDRAULIC
PRESSURE TESTS . . . . . . . . . . . . . . . . . . . . 80
DIAGNOSIS AND TESTING - CLUTCH AIR
PRESSURE TESTS . . . . . . . . . . . . . . . . . . . . 82
DIAGNOSIS AND TESTING - FLUID
LEAKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
STANDARD PROCEDURE - ALUMINUM
THREAD REPAIR . . . . . . . . . . . . . . . . . . . . . . 84
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 86
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 117
SCHEMATICS AND DIAGRAMS - 42RLE
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . 120
SPECIFICATIONS
42RLE AUTOMATIC TRANSMISSION . . . . . . 133
SPECIAL TOOLS
42RLE AUTOMATIC TRANSMISSION . . . . . . 135
ACCUMULATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 138
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 138
ADAPTER HOUSING SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 138
BEARINGS
ADJUSTMENTS
BEARING ADJUSTMENT PROCEDURES . . . 139
BRAKE TRANSMISSION SHIFT INTERLOCK
MECHANISM
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 139
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 140
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 140
ADJUSTMENTS
ADJUSTMENT - BRAKE TRANSMISSION
SHIFT INTERLOCK CABLE . . . . . . . . . . . . . 140
DRIVING CLUTCHES
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 142
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 142
FLUID AND FILTER
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - CAUSES OF
BURNT FLUID . . . . . . . . . . . . . . . . . . . . . . . 142
DIAGNOSIS AND TESTING - EFFECTS OF
INCORRECT FLUID LEVEL . . . . . . . . . . . . . 142
DIAGNOSIS AND TESTING - FLUID
CONTAMINATION . . . . . . . . . . . . . . . . . . . . 143
STANDARD PROCEDURE
STANDARD PROCEDURE - FLUID LEVEL
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
STANDARD PROCEDURE - FLUID/FILTER
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
STANDARD PROCEDURE - TRANSMISSION
FILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
GEARSHIFT CABLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 145
HOLDING CLUTCHES
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 146
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 146
INPUT CLUTCH ASSEMBLY
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 146
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
INPUT SPEED SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 163
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 163
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 164
OIL PUMP
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 164
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 164
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 164
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
OUTPUT SPEED SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 166
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 166
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 166
OVERDRIVE SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 167
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 167
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 167
PLANETARY GEARTRAIN
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 167
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 168
SEAL - OIL PUMP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 168
SHIFT MECHANISM
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 168
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 168
21 - 70 AUTOMATIC TRANSMISSION - 42RLE TJ
DIAGNOSIS AND TESTING - SHIFT
MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . 168
ADJUSTMENTS - SHIFT MECHANISM . . . . . . 168
SOLENOID
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 169
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 170
SOLENOID/PRESSURE SWITCH ASSY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 170
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 170
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 171
TORQUE CONVERTER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 172
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 176
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 177
TRANSMISSION CONTROL RELAY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 178
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 178
TRANSMISSION RANGE SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 178
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 178
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 179
TRANSMISSION TEMPERATURE SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 179
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 180
VALVE BODY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 180
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 180
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 185
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 195
TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 71
AUTOMATIC TRANSMISSION -
42RLE
DESCRIPTION
F
i
g
.
1
4
2
R
L
E
A
u
t
o
m
a
t
i
c
T
r
a
n
s
m
i
s
s
i
o
n
21 - 72 AUTOMATIC TRANSMISSION - 42RLE TJ
The 42RLE (Fi g. 1) i s a four-speed transmi ssi on
that i s a conventi onal hydraul i c/mechani cal assembl y
control l ed wi th adapti ve el ectroni c control s and mon-
i tors. The hydraul i c system of the transmi ssi on con-
si sts of the transmi ssi on fl ui d, fl ui d passages,
hydraul i c val ves, and vari ous l i ne pressure control
components. An i nput cl utch assembl y whi ch houses
the underdri ve, overdri ve, and reverse cl utches i s
used. I t al so uti l i zes separate hol di ng cl utches: 2nd/
4th gear and Low/Reverse. The pri mary mechani cal
components of the transmi ssi on consi st of the fol l ow-
i ng:
• Three mul ti pl e di sc i nput cl utches
• Two mul ti pl e di sc hol di ng cl utches
• Four hydraul i c accumul ators
• Two pl anetary gear sets
• Hydraul i c oi l pump
• Val ve body
• Sol enoi d/Pressure swi tch assembl y
Control of the transmi ssi on i s accompl i shed by
ful l y adapti ve el ectroni cs. Opti mum shi ft schedul i ng
i s accompl i shed through conti nuous real -ti me sensor
feedback i nformati on provi ded to the Transmi ssi on
Control Modul e (TCM) porti on of the Powertrai n
Control Modul e (PCM).
The TCM i s the heart of the el ectroni c control sys-
tem and rel i es on i nformati on from vari ous di rect
and i ndi rect i nputs (sensors, swi tches, etc.) to deter-
mi ne dri ver demand and vehi cl e operati ng condi -
ti ons. Wi th thi s i nformati on, the TCM can cal cul ate
and perform ti mel y and qual i ty shi fts through vari -
ous output or control devi ces (sol enoi d pack, trans-
mi ssi on control rel ay, etc.).
The TCM al so performs certai n sel f-di agnosti c
functi ons and provi des comprehensi ve i nformati on
(sensor data, DTC’s, etc.) whi ch i s hel pful i n proper
di agnosi s and repai r. Thi s i nformati on can be vi ewed
wi th the DRB௡ scan tool .
TRANSMISSION IDENTIFICATION
The 42RLE transmi ssi on can be i denti fi ed by a
barcode l abel that i s affi xed to the upper l eft area of
the bel l housi ng.
The l abel contai ns a seri es of di gi ts that can be
transl ated i nto useful i nformati on such as transmi s-
si on part number, date of manufacture, manufactur-
i ng ori gi n, assembl y l i ne i denti fi er, bui l d sequence
number, etc. Refer to (Fi g. 2) for i denti fi cati on l abel
breakdown.
I f the tag i s not l egi bl e or i s mi ssi ng, the “PK”
number, whi ch i s stamped i nto the l eft rear fl ange of
the transmi ssi on case, can be referred to for i denti fi -
cati on. The enti re part number, bui l d code, and
sequence number are stamped i nto the fl ange.
OPERATION
The 42RLE transmi ssi on rati os are:
First 2.84 : 1
Second 1.57 : 1
Third 1.00 : 1
Overdrive 0.69 : 1
Reverse 2.21 : 1
1 - DRIVEPLATE 6 - REVERSE CLUTCH 11 - STUB SHAFT
2 - TORQUE CONVERTER 7 - FRONT PLANET CARRIER 12 - LOW/REVERSE CLUTCH
3 - INPUT SHAFT 8 - REAR PLANET CARRIER 13 - 2/4 CLUTCH
4 - UNDERDRIVE CLUTCH 9 - OUTPUT SHAFT 14 - OIL PUMP
5 - OVERDRIVE CLUTCH 10 - SNAP RING
Fig. 2 Identification Label Breakdown
1 - T=TRACEABILITY
2 - SUPPLIER CODE (PK=KOKOMO)
3 - COMPONENT CODE (TK=KOKOMO TRANSMISSION)
4 - BUILD DAY (350=DEC. 15)
5 - BUILD YEAR (1=2001)
6 - ASSEMBLY LINE CODE
7 - BUILD SEQUENCE NUMBER
8 - LAST THREE OF P/N
9 - CHANGE LEVEL
10 - TRANSMISSION PART NUMBER
11 - P=PART NUMBER
TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 73
AUTOMATIC TRANSMISSION - 42RLE (Continued)
FIRST GEAR POWERFLOW
I n fi rst gear range, torque i nput i s through the
underdri ve cl utch to the underdri ve hub assembl y
(Fi g. 3). The underdri ve hub i s spl i ned to the rear
sun gear. When the underdri ve cl utch i s appl i ed, i t
rotates the underdri ve hub and rear sun gear. The
L/R cl utch i s appl i ed to hol d the front carri er/rear
annul us assembl y. The rear sun gear dri ves the rear
pl anetary pi ni on gears. The rear pl anetary pi ni on
gears are forced to wal k around the i nsi de of the sta-
ti onary rear annul us gear. The pi ni ons are pi nned to
the rear carri er and cause the rear carri er assembl y
to rotate as they wal k around the annul us gear. Thi s
provi des the torque output for fi rst gear. The other
pl anetary gearset components are freewheel i ng. The
fi rst gear rati o i s 2.84:1.
Fig. 3 First Gear Powerflow
1 - UNDERDRIVE CLUTCH APPLIED (Turns Rear Sun) 2 - LOW-REVERSE CLUTCH APPLIED (Holds Rear Annulus/Front Carrier)
21 - 74 AUTOMATIC TRANSMISSION - 42RLE TJ
AUTOMATIC TRANSMISSION - 42RLE (Continued)
SECOND GEAR POWERFLOW
Second gear i s achi eved by havi ng both pl anetary
gear sets contri bute to torque mul ti pl i cati on (Fi g. 4).
As i n fi rst gear, torque i nput i s through the under-
dri ve cl utch to the rear sun gear. The 2/4 cl utch i s
appl i ed to hol d the front sun gear stati onary. The
rotati ng rear sun gear turns the rear pl anetary pi n-
i ons. The rear pi ni ons rotate the rear annul us/front
carri er assembl y. The pi ni ons of the front carri er
wal k around the stati onary front sun gear. Thi s
transmi ts torque to the front annul us/rear carri er
assembl y, whi ch provi des output torque and a gear
rati o of 1.57:1.
Fig. 4 Second Gear Powerflow
1 - UNDERDRIVE CLUTCH APPLIED (Turns Rear Sun)
2 - 2-4 CLUTCH APPLIED (Holds Front Sun)
TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 75
AUTOMATIC TRANSMISSION - 42RLE (Continued)
THIRD GEAR POWERFLOW
I n thi rd gear, two i nput cl utches are appl i ed to pro-
vi de torque i nput: the underdri ve cl utch and over-
dri ve cl utch (Fi g. 5). The underdri ve cl utch rotates
the rear sun gear, whi l e the overdri ve cl utch rotates
the front carri er/rear annul us assembl y. The resul t i s
two components (rear sun gear and rear annul us
gear) rotati ng at the same speed and i n the same
di recti on. Thi s effecti vel y l ocks the enti re pl anetary
gearset together and i s rotated as one uni t. The gear
rati o i n thi rd i s 1:1.
Fig. 5 Third Gear Powerflow
1 - UNDERDRIVE CLUTCH APPLIED (Turns Rear Sun) 2 - OVERDRIVE CLUTCH APPLIED (Turns Front Carrier/Rear Annulus)
21 - 76 AUTOMATIC TRANSMISSION - 42RLE TJ
AUTOMATIC TRANSMISSION - 42RLE (Continued)
FOURTH GEAR POWERFLOW
I n fourth gear i nput torque i s through the over-
dri ve cl utch whi ch dri ves the front carri er (Fi g. 6).
The 2/4 cl utch i s appl i ed to hol d the front sun gear.
As the overdri ve cl utch rotates the front carri er, i t
causes the pi ni ons of the front carri er to wal k around
the stati onary front sun gear. Thi s causes the front
carri er pi ni ons to turn the front annul us/rear carri er
assembl y whi ch provi des output torque. I n fourth
gear, transmi ssi on output speed i s more than engi ne
i nput speed. Thi s si tuati on i s cal l ed overdri ve and
the gear rati o i s 0.69:1.
Fig. 6 Fourth Gear Powerflow
1 - OVERDRIVE CLUTCH APPLIED (Turns Rear Sun) 2 - 2-4 CLUTCH APPLIED (Holds Front Sun)
TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 77
AUTOMATIC TRANSMISSION - 42RLE (Continued)
REVERSE GEAR POWERFLOW
I n reverse, i nput power i s through the reverse
cl utch (Fi g. 7). When appl i ed, the reverse cl utch
dri ves the front sun gear through the overdri ve hub
and shaft. The L/R cl utch i s appl i ed to hol d the front
carri er/rear annul us assembl y stati onary. The front
carri er i s bei ng hel d by the L/R cl utch so the pi ni ons
are forced to rotate the front annul us/rear carri er
assembl y i n the reverse di recti on. Output torque i s
provi ded, i n reverse, wi th a gear rati o of 2.21:1.
Fig. 7 Reverse Gear Powerflow
1 - LOW-REVERSE CLUTCH APPLIED (Holds Rear Annulus Front Carrier) 2 - REVERSE CLUTCH APPLIED (Turns Front Sun)
21 - 78 AUTOMATIC TRANSMISSION - 42RLE TJ
AUTOMATIC TRANSMISSION - 42RLE (Continued)
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - AUTOMATIC
TRANSMISSION
CAUTION: Before attempting any repair on the
42RLE Four Speed Automatic Transmission, always
check for proper shift linkage adjustment. Also
check for diagnostic trouble codes with the DRBா
scan tool and the 42RLE Transmission Diagnostic
Procedure Manual.
42RLE automati c transmi ssi on mal functi ons may
be caused by these general condi ti ons:
• Poor engi ne performance
• I mproper adjustments
• Hydraul i c mal functi ons
• Mechani cal mal functi ons
• El ectroni c mal functi ons
When di agnosi ng a probl em al ways begi n wi th
recordi ng the compl ai nt. The compl ai nt shoul d be
defi ned as speci fi c as possi bl e. I ncl ude the fol l owi ng
checks:
• Temperature at occurrence (col d, hot, both)
• Dynami c condi ti ons (accel erati on, decel erati on,
upshi ft, corneri ng)
• El ements i n use when condi ti on occurs (what
gear i s transmi ssi on i n duri ng condi ti on)
• Road and weather condi ti ons
• Any other useful di agnosti c i nformati on.
After noti ng al l condi ti ons, check the easi l y acces-
si bl e vari abl es:
• Fl ui d l evel and condi ti on
• Shi ft l i nkage adjustment
• Di agnosti c troubl e code i nspecti on
Then perform a road test to determi ne i f the prob-
l em has been corrected or that more di agnosi s i s nec-
essary. I f the probl em exi sts after the prel i mi nary
tests and correcti ons are compl eted, hydraul i c pres-
sure checks shoul d be performed.
DIAGNOSIS AND TESTING - ROAD TEST
Pri or to performi ng a road test, veri fy that the
fl ui d l evel , fl ui d condi ti on, and l i nkage adjustment
have been approved.
Duri ng the road test, the transmi ssi on shoul d be
operated i n each posi ti on to check for sl i ppi ng and
any vari ati on i n shi fti ng.
I f the vehi cl e operates properl y at hi ghway speeds,
but has poor accel erati on, the converter stator over-
runni ng cl utch may be sl i ppi ng. I f accel erati on i s nor-
mal , but hi gh throttl e openi ng i s needed to mai ntai n
hi ghway speeds, the converter stator cl utch may
have sei zed. Both of these stator defects requi re
repl acement of the torque converter and thorough
transmi ssi on cl eani ng.
Sl i ppi ng cl utches can be i sol ated by compari ng the
“El ements i n Use” chart wi th cl utch operati on
encountered on a road test. Thi s chart i denti fi es
whi ch cl utches are appl i ed at each posi ti on of the
sel ector l ever.
A sl i ppi ng cl utch may al so set a DTC and can be
determi ned by operati ng the transmi ssi on i n al l
sel ector posi ti ons.
TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 79
AUTOMATIC TRANSMISSION - 42RLE (Continued)
ELEMENTS IN USE AT EACH POSITION OF SELECTOR LEVER
Shift Lever Position
INPUT CLUTCHES HOLDING CLUTCHES
Underdrive Overdrive Reverse 2/4 Low/Reverse
P - PARK X
R - REVERSE X X
N - NEUTRAL X
OD - OVERDRIVE
First X X
Second X X
Direct X X
Overdrive X X
D - DRIVE*
First X X
Second X X
Direct X X
L - LOW*
First X X
Second X X
Direct X X
* Vehicle upshift and downshift speeds are increased when in these selector positions.
The process of el i mi nati on can be used to detect
any uni t whi ch sl i ps and to confi rm proper operati on
of good uni ts. Road test anal ysi s can di agnose sl i p-
pi ng uni ts, but the cause of the mal functi on cannot
be determi ned. Practi cal l y any condi ti on can be
caused by l eaki ng hydraul i c ci rcui ts or sti cki ng
val ves.
DIAGNOSIS AND TESTING - HYDRAULIC
PRESSURE TESTS
Pressure testi ng i s a very i mportant step i n the
di agnosti c procedure. These tests usual l y reveal the
cause of most transmi ssi on probl ems.
Before performi ng pressure tests, be certai n that
fl ui d l evel and condi ti on, and shi ft cabl e adjustments
have been checked and approved. Fl ui d must be at
operati ng temperature (150 to 200 degrees F.).
I nstal l an engi ne tachometer, rai se vehi cl e on hoi st
whi ch al l ows the wheel s to turn, and posi ti on
tachometer so i t can be read.
Usi ng speci al adapters L-4559, attach 300 psi
gauge(s) C-3293SP to the port(s) requi red for test
bei ng conducted.
Test port l ocati ons are shown i n (Fi g. 8).
Fig. 8 Pressure Taps
1 - TORQUE CONVERTER CLUTCH OFF
2 - REVERSE
3 - LOW/REVERSE
4 - 2/4
5 - UNDERDRIVE
6 - TORQUE CONVERTER CLUTCH ON
7 - OVERDRIVE
21 - 80 AUTOMATIC TRANSMISSION - 42RLE TJ
AUTOMATIC TRANSMISSION - 42RLE (Continued)
TEST ONE-SELECTOR IN L (1st Gear)
NOTE: This test checks pump output, pressure reg-
ulation and condition of the low/reverse clutch
hydraulic circuit and shift schedule.
(1) Attach pressure gauge to the l ow/reverse cl utch
tap.
(2) Move sel ector l ever to the L posi ti on.
(3) Al l ow vehi cl e wheel s to turn and i ncrease
throttl e openi ng to achi eve an i ndi cated vehi cl e speed
to 20 mph.
(4) Low/reverse cl utch pressure shoul d read 115 to
145 psi .
TEST TWO-SELECTOR IN DRIVE (Second Gear)
NOTE: This test checks the underdrive clutch
hydraulic circuit as well as the shift schedule.
(1) Attach gauge to the underdri ve cl utch tap.
(2) Move sel ector l ever to the 3 posi ti on.
(3) Al l ow vehi cl e wheel s to turn and i ncrease
throttl e openi ng to achi eve an i ndi cated vehi cl e speed
of 30 mph.
(4) I n second gear the underdri ve cl utch pressure
shoul d read 110 to 145 psi .
TEST TWO A–SELECTOR IN OD (Fourth Gear)
NOTE: This test checks the underdrive clutch
hydraulic circuit as well as the shift schedule.
(1) Attach gauge to the underdri ve cl utch tap.
(2) Move sel ector l ever to the OD posi ti on.
(3) Al l ow wheel s to rotate freel y and i ncrease
throttl e openi ng to achi eve an i ndi cated speed of 40
mph.
(4) Underdri ve cl utch pressure shoul d read bel ow
5 psi . I f not, than ei ther the sol enoi d assembl y or
control l er i s at faul t.
TEST THREE-SELECTOR IN OVERDRIVE (Third and
Second Gear)
NOTE: This test checks the overdrive clutch
hydraulic circuit as well as the shift schedule.
(1) Attach gauge to the overdri ve cl utch tap.
(2) Move sel ector l ever to the OD posi ti on.
(3) Al l ow vehi cl e wheel s to turn and i ncrease
throttl e openi ng to achi eve an i ndi cated vehi cl e speed
of 20 mph.
(4) Overdri ve cl utch pressure shoul d read 74 to 95
psi .
(5) Move sel ector l ever to the 3 posi ti on and
i ncrease i ndi cated vehi cl e speed to 30 mph.
(6) The vehi cl e shoul d be i n second gear and over-
dri ve cl utch pressure shoul d be l ess than 5 psi .
TEST FOUR-SELECTOR IN OD (Fourth Gear)
NOTE: This test checks the 2/4 clutch hydraulic cir-
cuit.
(1) Attach gauge to the 2/4 cl utch tap.
(2) Move sel ector l ever to the OD posi ti on.
(3) Al l ow vehi cl e front wheel s to turn and i ncrease
throttl e openi ng to achi eve an i ndi cated vehi cl e speed
of 30 mph. Vehi cl e shoul d be i n fourth gear.
(4) The 2/4 cl utch pressure shoul d read 75 to 95
psi .
TEST FIVE-SELECTOR IN OVERDRIVE (Fourth
Gear, CC on)
NOTE: These tests check the torque converter
clutch hydraulic circuit.
(1) Attach gauge to the torque converter cl utch off
pressure tap.
(2) Move sel ector l ever to the overdri ve posi ti on.
(3) Al l ow vehi cl e wheel s to turn and i ncrease
throttl e openi ng to achi eve an i ndi cated vehi cl e speed
of 50 mph. Vehi cl e shoul d be i n 4th gear, CC on.
CAUTION: Both wheels must turn at the same
speed.
(4) Torque converter cl utch off pressure shoul d be
l ess than 5 psi .
(5) Now attach the gauge to the torque converter
cl utch on pressure tap.
(6) Move sel ector to the overdri ve posi ti on.
(7) Al l ow vehi cl e wheel s to turn and i ncrease
throttl e openi ng to achi eve an i ndi cated vehi cl e speed
of 50 mph.
(8) Veri fy the torque converter cl utch i s appl i ed
mode usi ng the RPM di spl ay of the DRB scan tool .
(9) Torque converter cl utch on pressure shoul d be
60-90 psi .
TEST SIX-SELECTOR IN REVERSE
NOTE: This test checks the reverse clutch hydraulic
circuit.
(1) Attach gauge to the reverse and l ow/reverse
cl utch tap.
(2) Move sel ector l ever to the reverse posi ti on.
(3) Read reverse cl utch pressure wi th output sta-
ti onary (foot on brake) and throttl e opened to achi eve
1500 rpm.
(4) Reverse and l ow/reverse cl utch pressure shoul d
read 165 to 235 psi .
TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 81
AUTOMATIC TRANSMISSION - 42RLE (Continued)
TEST RESULT INDICATIONS
(1) I f proper l i ne pressure i s found i n any one test,
the pump and pressure regul ator are worki ng prop-
erl y.
(2) Low pressure i n al l posi ti ons i ndi cates a defec-
ti ve pump, a cl ogged fi l ter, or a stuck pressure regu-
l ator val ve.
(3) Cl utch ci rcui t l eaks are i ndi cated i f pressures
do not fal l wi thi n the speci fi ed pressure range.
(4) I f the overdri ve cl utch pressure i s greater than
5 psi i n Step 6 of Test Three, a worn reacti on shaft
seal ri ng or a defecti ve sol enoi d assembl y i s i ndi -
cated.
(5) I f the underdri ve cl utch pressure i s greater
than 5 psi i n Step 4 of Test Two-A, a defecti ve sol e-
noi d/pressure swi tch assembl y or control l er i s the
cause.
ALL PRESSURE SPECIFICATIONS ARE PSI (ON HOIST, WITH WHEELS FREE TO TURN)
Gear
Selector
Position
Actual Gear PRESSURE TAPS
Under-
drive
Clutch
Over-
drive
Clutch
Reverse
Clutch
Torque
Converter
Clutch
Off
Torque
Converter
Clutch
On
2/4
Clutch
Low/
Reverse
Clutch
PARK - 0 mph * PARK 0-2 0-5 0-2 60-110 45-100 0-2 115-145
REVERSE - 0 mph * REVERSE 0-2 0-7 165-235 50-100 35-85 0-2 165-235
NEUTRAL - 0 mph * NEUTRAL 0-2 0-5 0-2 60-110 45-100 0-2 115-145
Low - 20 mph # FIRST 110-145 0-5 0-2 60-110 45-100 0-2 115-145
Third - 30 mph # SECOND 110-145 0-5 0-2 60-110 45-100 115-145 0-2
Third - 45 mph # DIRECT 75-95 75-95 0-2 60-90 45-80 0-2 0-2
OD - 30 mph # OVERDRIVE 0-2 75-95 0-2 60-90 45-80 75-95 0-2
OD - 50 mph # OVERDRIVE
WITH TCC
0-2 75-95 0-2 0-5 60-95 75-95 0-2
* Engine Speed at 1500 rpm
# CAUTION: Both wheels must be turning at same speed.
DIAGNOSIS AND TESTING - CLUTCH AIR
PRESSURE TESTS
I noperati ve cl utches can be l ocated by substi tuti ng
ai r pressure for fl ui d pressure. The cl utches may be
tested by appl yi ng ai r pressure to thei r respecti ve
passages after the val ve body has been removed. Use
Speci al Tool 6599-1 and 6599-2 to perform test (Fi g.
9).
To make ai r pressure tests, proceed as fol l ows:
NOTE: The compressed air supply must be free of
all dirt and moisture. Use a pressure of 30 psi.
Remove oi l pan and val ve body. See Val ve body
recondi ti on.
Appl y ai r pressure to the hol es i n the speci al tool ,
one at a ti me.
Li sten for the cl utch to appl y. I t wi l l gi ve a sl i ght
thud sound. I f a l arge amount of ai r i s heard escap-
i ng, the transmi ssi on must be removed from vehi cl e,
di sassembl ed and al l seal s i nspected.
Fig. 9 Air Pressure Test Plate
1 - AIR PRESSURE TEST PLATES
2 - 2/4 CLUTCH RETAINER HOLE
21 - 82 AUTOMATIC TRANSMISSION - 42RLE TJ
AUTOMATIC TRANSMISSION - 42RLE (Continued)
OVERDRIVE CLUTCH
Appl y ai r pressure to the overdri ve cl utch appl y
passage and watch for the push/pul l pi ston to move
forward. The pi ston shoul d return to i ts starti ng
posi ti on when the ai r pressure i s removed.
UNDERDRIVE CLUTCH
Because thi s cl utch pi ston cannot be seen, i ts oper-
ati on i s checked by functi on. Ai r pressure i s appl i ed
to the l ow/reverse or the 2/4 cl utches. Thi s l ocks the
output shaft. Use a pi ece of rubber hose wrapped
around the i nput shaft and a pai r of cl amp-on pl i ers
to turn the i nput shaft. Next appl y ai r pressure to
the underdri ve cl utch (Fi g. 10). The i nput shaft
shoul d not rotate wi th hand torque. Rel ease the ai r
pressure and confi rm that the i nput shaft wi l l rotate.
REVERSE CLUTCH
Appl y ai r pressure to the reverse cl utch appl y pas-
sage and watch for the push/pul l pi ston to move rear-
ward. The pi ston shoul d return to i ts starti ng
posi ti on when the ai r pressure i s removed.
2/4 CLUTCH
Appl y ai r pressure to the feed hol e l ocated on the
2/4 cl utch retai ner. Look i n the area where the 2/4
pi ston contacts the fi rst separator pl ate and watch
careful l y for the 2/4 pi ston to move rearward. The
pi ston shoul d return to i ts ori gi nal posi ti on after the
ai r pressure i s removed.
LOW/REVERSE CLUTCH
Appl y ai r pressure to the l ow/reverse cl utch feed
hol e passage. Look i n the area where the l ow/reverse
pi ston contacts the fi rst separator pl ate. Watch care-
ful l y for the pi ston to move forward. The pi ston
shoul d return to i ts ori gi nal posi ti on after the ai r
pressure i s removed.
DIAGNOSIS AND TESTING - FLUID LEAKAGE
FLUID LEAKAGE - TORQUE CONVERTER HOUSING
AREA
When di agnosi ng converter housi ng fl ui d l eaks,
three acti ons must be taken before repai r:
(1) Veri fy proper transmi ssi on fl ui d l evel .
(2) Veri fy that the l eak ori gi nates from the con-
verter housi ng area and i s transmi ssi on fl ui d.
(3) Determi ne the true source of the l eak.
Fl ui d l eakage at or around the torque converter
area may ori gi nate from an engi ne oi l l eak (Fi g. 11).
The area shoul d be exami ned cl osel y. Factory fi l l
fl ui d i s red and, therefore, can be di sti ngui shed from
engi ne oi l .
Some suspected converter housi ng fl ui d l eaks may
not be l eaks at al l . They may onl y be the resul t of
resi dual fl ui d i n the converter housi ng, or excess
fl ui d spi l l ed duri ng factory fi l l , or fi l l after repai r.
Converter housi ng l eaks have several potenti al
sources. Through careful observati on, a l eak source
can be i denti fi ed before removi ng the transmi ssi on
for repai r.
Pump seal l eaks tend to move al ong the dri ve hub
and onto the rear of the converter (Fi g. 11). Pump
o-ri ng or pump body l eaks fol l ow the same path as a
seal l eak. Pump attachi ng bol t l eaks are general l y
deposi ted on the i nsi de of the converter housi ng and
not on the converter i tsel f. Pump seal or gasket l eaks
usual l y travel down the i nsi de of the converter hous-
i ng (Fi g. 11).
Fig. 10 Testing Underdrive Clutch
1 - AIR PRESSURE TEST PLATE 6599–1
2 - AIR NOZZLE
Fig. 11 Converter Housing Leak Paths
1 - PUMP SEAL
2 - PUMP VENT
3 - PUMP BOLT
4 - PUMP GASKET
5 - CONVERTER HOUSING
6 - CONVERTER
7 - REAR MAIN SEAL LEAK
TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 83
AUTOMATIC TRANSMISSION - 42RLE (Continued)
TORQUE CONVERTER LEAKAGE
Possi bl e sources of torque converter l eakage are:
• Torque converter wel d l eaks at the outsi de di am-
eter wel d (Fi g. 12).
• Torque converter hub wel d (Fi g. 12).
STANDARD PROCEDURE - ALUMINUM
THREAD REPAIR
Damaged or worn threads i n the al umi num trans-
mi ssi on case and val ve body can be repai red by the
use of Hel i -Coi l s, or equi val ent. Thi s repai r consi sts
of dri l l i ng out the worn-out damaged threads. Then
tap the hol e wi th a speci al Hel i -Coi l tap, or equi va-
l ent, and i nstal l i ng a Hel i -Coi l i nsert, or equi val ent,
i nto the hol e. Thi s bri ngs the hol e back to i ts ori gi nal
thread si ze.
Hel i -Coi l , or equi val ent, tool s and i nserts are
readi l y avai l abl e from most automoti ve parts suppl i -
ers.
REMOVAL
(1) Di sconnect battery negati ve cabl e.
(2) Rai se and support vehi cl e.
(3) Di sconnect and l ower or remove necessary
exhaust components.
(4) Remove engi ne-to-transmi ssi on bendi ng braces
or engi ne col l ar.
(5) Remove starter motor. (Refer to 8 - ELECTRI -
CAL/STARTI NG/STARTER MOTOR - REMOVAL)
(6) On 4.0L engi ne equi pped vehi cl es, di sconnect
and remove crankshaft posi ti on sensor (Fi g. 13).
Retai n sensor attachi ng bol t.
CAUTION: The crankshaft position sensor can be
damaged during transmission removal (or installa-
tion) if the sensor is left in place. To avoid damage,
remove the sensor before removing the transmis-
sion.
(7) I f transmi ssi on i s bei ng removed for overhaul ,
remove transmi ssi on oi l pan, drai n fl ui d and rei nstal l
pan. (Refer to 21 - TRANSMI SSI ON/AUTOMATI C -
42RLE/FLUI D - STANDARD PROCEDURE)
(8) Remove torque converter access cover.
(9) Rotate crankshaft i n cl ockwi se di recti on unti l
converter bol ts are accessi bl e. Then remove bol ts one
at a ti me. Rotate crankshaft wi th socket wrench on
dampener bol t.
(10) Mark propel l er shaft and axl e yokes for
assembl y al i gnment. Then di sconnect and remove
propel l er shafts. (Refer to 3 - DI FFERENTI AL &
DRI VELI NE/PROPELLER SHAFT/PROPELLER
SHAFT - REMOVAL)
Fig. 12 Converter Leak Points - Typical
1 - OUTSIDE DIAMETER WELD
2 - TORQUE CONVERTER HUB WELD
3 - STARTER RING GEAR
4 - LUG
Fig. 13 Crankshaft Position Sensor
1 - CRANKSHAFT POSITION SENSOR
2 - MOUNTING BOLT
3 - ELECTRICAL CONNECTOR
4 - TRANSMISSION BELLHOUSING
21 - 84 AUTOMATIC TRANSMISSION - 42RLE TJ
AUTOMATIC TRANSMISSION - 42RLE (Continued)
(11) Di sconnect wi res from the i nput and output
speed sensors (Fi g. 14).
(12) Di sconnect wi res from the transmi ssi on range
sensor (Fi g. 14) and the sol enoi d/pressure swi tch
assembl y (Fi g. 15).
(13) Di sconnect gearshi ft cabl e from transmi ssi on
manual val ve l ever.
(14) Di sconnect shi ft rod from transfer case shi ft
l ever or remove shi ft l ever from transfer case.
(15) Support rear of engi ne wi th safety stand or
jack.
(16) Rai se transmi ssi on sl i ghtl y wi th servi ce jack
to rel i eve l oad on ski d pl ate and transmi ssi on sup-
port.
(17) Remove bol ts securi ng rear support (Fi g. 16)
and cushi on to transmi ssi on and ski d pl ate. Rai se
transmi ssi on sl i ghtl y, sl i de exhaust hanger arm from
bracket and remove rear support.
(18) Remove bol ts attachi ng ski d pl ate (Fi g. 16) to
frame and remove ski d pl ate. (Refer to 13 - FRAME
& BUMPERS/FRAME/TRANSFER CASE SKI D
PLATE - REMOVAL)
(19) Di sconnect transfer case vent hose.
(20) Remove transfer case. (Refer to 21 - TRANS-
MI SSI ON/TRANSFER CASE - REMOVAL)
(21) Remove fi l l tube bracket bol ts and pul l tube
out of transmi ssi on. Retai n fi l l tube seal . Remove the
bol t attachi ng transfer case vent tube to converter
housi ng.
(22) Di sconnect fl ui d cool er l i nes at transmi ssi on.
(23) Remove al l converter housi ng bol ts.
(24) Careful l y work transmi ssi on and torque con-
verter assembl y rearward off engi ne bl ock dowel s.
(25) Hol d torque converter i n pl ace duri ng trans-
mi ssi on removal .
(26) Lower transmi ssi on and remove assembl y
from under the vehi cl e.
(27) To remove torque converter, careful l y sl i de
torque converter out of the transmi ssi on.
Fig. 14 Input and Output Speed Sensors and
Transmission Range Sensor
1 - INPUT SPEED SENSOR
2 - OUTPUT SPEED SENSOR
3 - TRANSMISSION RANGE SENSOR
Fig. 15 Solenoid/Pressure Switch Assembly
1 - SOLENOID/PRESSURE SWITCH ASSEMBLY CONNECTOR
Fig. 16 Transmission Mount - Automatic
Transmission
1 - TRANSMISSION SUPPORT BRACKET
2 - AUTOMATIC TRANSMISSION
3 - SKID PLATE
4 - FRAME
5 - TRANSMISSION MOUNT SUPPORT BRACKET
6 - CUSHION
TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 85
AUTOMATIC TRANSMISSION - 42RLE (Continued)
DISASSEMBLY
NOTE: If the transmission is being reconditioned
(clutch/seal replacement) or replaced, it is neces-
sary to perform the Quick Learn Procedure using
the DRBIIIா Scan Tool (Refer to 8 - ELECTRICAL/
ELECTRONIC CONTROL MODULES/TRANSMISSION
CONTROL MODULE - STANDARD PROCEDURE).
Before di sassembl i ng transmi ssi on, move the shi ft
l ever cl ockwi se as far as i t wi l l go and then remove
the shi ft l ever.
NOTE: Tag all clutch pack assemblies, as they are
removed, for reassembly identification.
CAUTION: Do not intermix clutch discs or plates as
the unit might then fail.
(1) Remove the torque converter from the trans-
mi ssi on i nput shaft (Fi g. 17).
(2) Measure i nput shaft end pl ay usi ng Tool 8266.
Set up Tool 8266 and a di al i ndi cator as shown i n
(Fi g. 18). Move i nput shaft i n and out to obtai n end
pl ay readi ng. End pl ay speci fi cati ons are 0.13 to 0.64
mm (0.005 to 0.025 i nch). Record i ndi cator readi ng
for reference when reassembl i ng the transmi ssi on. I f
endpl ay exceeds the speci fi ed range, the #4 thrust
pl ate needs to be i nspected and changed i f necessary.
NOTE: The four bolts along the bottom of the
adapter housing have a sealing patch applied from
the factory. Note the locations of these bolts and
seperate these bolts for reuse.
(3) Remove the bol ts (Fi g. 19) that hol d the
adapter housi ng onto the transmi ssi on case.
Fig. 19 Remove Adapter Housing Bolts
1 - TRANSMISSION CASE
2 - ADAPTER HOUSING
3 - BOLTS
Fig. 17 Remove Torque Converter
1 - TORQUE CONVERTER
2 - TRANSMISSION
3 - INPUT SHAFT
Fig. 18 Measure Input Shaft End Play Using Tool
8266 - Typical
1 - TOOL 8266-8
2 - TOOL 8266-2
3 - TOOL C-3339
21 - 86 AUTOMATIC TRANSMISSION - 42RLE TJ
AUTOMATIC TRANSMISSION - 42RLE (Continued)
(4) Remove the adapter (Fi g. 21) housi ng from the
transmi ssi on case. There are two pry sl ots (Fi g. 20)
l ocated near the bottom corners of the housi ng for
separati ng the housi ng from the transmi ssi on case.
(5) I nspect the l ube tube grommet (Fi g. 20) for
damage. I f the grommet l i p i s damaged, i t wi l l need
to be repl aced.
(6) Usi ng a Sl i de Hammer C-3752 (Fi g. 22),
remove the 4X4 stub shaft (Fi g. 23) from the trans-
mi ssi on output shaft. I nspect the ci r-cl i p on the shaft
for damage and repl ace the cl i p i f necessary.
Fig. 20 Lube Tube Grommet
1 - HOUSING
2 - LUBE TUBE
3 - GROMMET
4 - PRY SLOTS
Fig. 21 Remove Adapter Housing
1 - TRANSMISSION CASE
2 - ADAPTER HOUSING
Fig. 22 Remove the 4X4 Stub shaft Using C-3752
1 - 4X4 STUB SHAFT
2 - PULLER C-3752
Fig. 23 Remove 4X4 Stub Shaft
1 - STUB SHAFT
2 - OUTPUT SHAFT
TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 87
AUTOMATIC TRANSMISSION - 42RLE (Continued)
(7) Remove the i nput speed sensor bol t (Fi g. 24).
(8) Remove the output speed sensor bol t (Fi g. 25).
NOTE: The speed sensor bolts have a sealing patch
applied from the factory. Seperate these bolts for
reuse.
(9) Remove the i nput and output speed sensors
(Fi g. 26). I denti fy the speed sensors for re-i nstal l a-
ti on si nce they are not i nterchangeabl e.
NOTE: One of the oil pan bolts has a sealing patch
applied from the factory. Seperate this bolt for
reuse.
(10) Remove the transmi ssi on oi l pan bol ts (Fi g.
27).
Fig. 27 Remove Transmission Oil Pan Bolts
1 - TRANSMISSION OIL PAN
2 - BOLTS
Fig. 24 Remove Input Speed Sensor Bolt
1 - INPUT SPEED SENSOR
2 - TRANSMISSION CASE
Fig. 25 Remove Output Speed Sensor Bolt
1 - OUTPUT SPEED SENSOR
2 - TRANSMISSION CASE
Fig. 26 Remove Output Speed Sensor
1 - OUTPUT SPEED SENSOR
2 - TRANSMISSION CASE
21 - 88 AUTOMATIC TRANSMISSION - 42RLE TJ
AUTOMATIC TRANSMISSION - 42RLE (Continued)
(11) Remove the transmi ssi on oi l pan (Fi g. 28).
(12) Remove the transmi ssi on oi l fi l ter screws (Fi g.
29).
(13) Remove transmi ssi on oi l fi l ter (Fi g. 30).
(14) Remove the oi l fi l ter o-ri ng from the val ve
body (Fi g. 31).
Fig. 28 Remove Transmission Oil Pan
1 - TRANSMISSION OIL PAN
Fig. 29 Remove Oil Filter Screws
1 - OIL FILTER
2 - SCREWS
Fig. 30 Remove Transmission Filter
1 - TRANSMISSION FILTER
Fig. 31 Remove Oil Filter O-Ring
1 - VALVE BODY
2 - O-RING
TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 89
AUTOMATIC TRANSMISSION - 42RLE (Continued)
(15) Remove val ve body-to-case bol ts (Fi g. 32).
CAUTION: Do not handle the valve body by the
manual shaft. Damage could result.
(16) Remove val ve body from transmi ssi on (Fi g.
33).
(17) Remove underdri ve and overdri ve accumul a-
tors (Fi g. 34).
(18) Remove the l ow/reverse accumul ator snap
ri ng (Fi g. 35).
Fig. 32 Remove Valve Body Bolts
1 - BOLTS
Fig. 33 Remove Valve Body From Transmission
1 - VALVE BODY
Fig. 34 Underdrive and Overdrive Accumulators
1 - OVERDRIVE PISTON AND SPRING
2 - UNDERDRIVE PISTON AND SPRING
Fig. 35 Remove Low/Reverse Accumulator
1 - SNAP RING
2 - LOW/REVERSE ACCUMULATOR
21 - 90 AUTOMATIC TRANSMISSION - 42RLE TJ
AUTOMATIC TRANSMISSION - 42RLE (Continued)
(19) Remove the l ow/reverse accumul ator pl ug
(Fi g. 36).
(20) Remove l ow/reverse accumul ator pi ston usi ng
sui tabl e pl i ers (Fi g. 37). Remove pi ston and spri ngs
(Fi g. 38).
(21) Remove and di scard the oi l pump-to-case bol ts
(Fi g. 39). The oi l pump bol ts are not to be reused.
Fig. 36 Remove Low/Reverse Accumulator Plug
1 - ADJUSTABLE PLIERS
2 - PLUG
Fig. 37 Low/Reverse Accumulator Piston
1 - ACCUMULATOR PISTON
Fig. 38 Low/Reverse Accumulator
1 - PISTON
2 - RETURN SPRINGS
Fig. 39 Remove Oil Pump Attaching Bolts
1 - BOLTS
2 - OIL PUMP
TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 91
AUTOMATIC TRANSMISSION - 42RLE (Continued)
(22) Remove oi l pump usi ng C-3752 Pul l ers (Fi g.
40).
(23) Remove oi l pump whi l e pushi ng i n on i nput
shaft (Fi g. 41).
(24) Remove oi l pump gasket (Fi g. 42).
CAUTION: By-pass valve must be replaced if trans-
mission failure occurs.
(25) Remove the cool er by-pass val ve (Fi g. 43).
Fig. 40 Oil Pump Pullers
1 - OIL PUMP
2 - PULLERS
Fig. 41 Remove Oil Pump
1 - “PUSH IN” ON INPUT SHAFT WHILE REMOVING PUMP
Fig. 42 Remove Oil Pump Gasket
1 - BELLHOUSING
2 - OIL PUMP GASKET
Fig. 43 Remove By-Pass Valve
1 - BYPASS VALVE
21 - 92 AUTOMATIC TRANSMISSION - 42RLE TJ
AUTOMATIC TRANSMISSION - 42RLE (Continued)
(26) Remove the #1 caged needl e beari ng (Fi g. 44).
(27) Remove the i nput cl utch assembl y (Fi g. 45).
(28) Remove the #4 thrust pl ate (Fi g. 46).
(29) Remove the front sun gear assembl y and #4
thrust washer (i f sti l l i n pl ace) (Fi g. 47).
Fig. 44 Remove No. 1 Caged Needle Bearing
1 - #1 CAGED NEEDLE BEARING
2 - NOTE: TANGED SIDE OUT
Fig. 45 Remove Input Clutch Assembly
1 - INPUT CLUTCH ASSEMBLY
Fig. 46 Remove #4 Thrust Plate
1 - OVERDRIVE SHAFT ASSEMBLY
2 - #4 THRUST PLATE (SELECT)
3 - PETROLATUM FOR RETENTION
Fig. 47 Remove Front Sun Gear Assembly
1 - FRONT SUN GEAR ASSEMBLY
2 - #4 THRUST WASHER (FOUR TABS)
TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 93
AUTOMATIC TRANSMISSION - 42RLE (Continued)
(30) Remove the front carri er/rear annul us and #6
needl e beari ng (Fi g. 48).
(31) Remove the rear sun gear and #7 needl e bear-
i ng (Fi g. 49) and (Fi g. 50).
NOTE: The number seven needle bearing has three
antireversal tabs and is common with the number
five and number two position. The orientation
should allow the bearing to seat flat against the
rear sun gear (Fig. 50).
NOTE: Verify that Tool 5058A is centered properly
over the 2/4 clutch retainer before compressing. If
necessary, fasten the 5058A bar to the bellhousing
flange with any combination of locking pliers and
bolts to center the tool properly.
(32) I nstal l and l oad Tool 5058A to remove the 2/4
cl utch retai ner snap ri ng (Fi g. 51).
Fig. 48 Remove Front Carrier/Rear Annulus
1 - #6 NEEDLE BEARING
2 - FRONT CARRIER AND REAR ANNULUS ASSEMBLY (TWIST
AND PULL OR PUSH TO REMOVE OR INSTALL).
Fig. 49 Remove Rear Sun Gear
1 - #7 NEEDLE BEARING
2 - REAR SUN GEAR
Fig. 50 Number 7 Bearing
1 - #7 BEARING
2 - REAR SUN GEAR
Fig. 51 Remove 2/4 Clutch Retainer Snap Ring
1 - TOOL 5058
2 - SCREWDRIVER
3 - SNAP RING
4 - 2/4 CLUTCH RETAINER
21 - 94 AUTOMATIC TRANSMISSION - 42RLE TJ
AUTOMATIC TRANSMISSION - 42RLE (Continued)
NOTE: The 2/4 Clutch Piston has bonded seals
which are not individually serviceable. Seal replace-
ment requires replacement of the piston assembly.
(33) Remove the 2/4 cl utch retai ner (Fi g. 52) and
(Fi g. 53).
(34) Remove the 2/4 cl utch return spri ng (Fi g. 54).
(35) Remove the 2/4 cl utch pack (Fi g. 55).
Fig. 52 Remove 2/4 Clutch Retainer
1 - 2/4 CLUTCH RETAINER
Fig. 53 2/4 Clutch Retainer
1 - 2/4 CLUTCH RETAINER
2 - 2/4 CLUTCH RETURN SPRING
Fig. 54 Remove 2/4 Clutch Return Spring
1 - 2/4 CLUTCH RETURN SPRING
Fig. 55 Remove 2/4 Clutch Pack
1 - CLUTCH PLATE (4)
2 - CLUTCH DISC (4)
TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 95
AUTOMATIC TRANSMISSION - 42RLE (Continued)
(36) Remove the tapered snap ri ng (Fi g. 56).
(37) Remove the l ow/reverse reacti on pl ate (Fi g.
57).
(38) Remove one (1) l ow/reverse cl utch di sc to faci l -
i tate snap ri ng removal (Fi g. 58).
(39) Remove the l ow/reverse reacti on pl ate snap
ri ng (Fi g. 59).
Fig. 56 Remove Tapered Snap Ring
1 - LOW/REVERSE CLUTCH REACTION PLATE
2 - LONG TAB
3 - SCREWDRIVER
4 - LOW/REVERSE TAPERED SNAP RING (TAPERED SIDE UP)
5 - OIL PAN FACE
Fig. 57 Remove Low/Reverse Reaction Plate
1 - LOW/REVERSE REACTION PLATE (FLAT SIDE UP)
Fig. 58 Remove One Disc
1 - ONE DISC FROM LOW/REVERSE CLUTCH
Fig. 59 Remove Low/Reverse Reaction Plate Snap
Ring
1 - SCREWDRIVER
2 - LOW/REVERSE REACTION PLATE FLAT SNAP RING
3 - DO NOT SCRATCH CLUTCH PLATE
21 - 96 AUTOMATIC TRANSMISSION - 42RLE TJ
AUTOMATIC TRANSMISSION - 42RLE (Continued)
(40) Remove the l ow/reverse cl utch pack (Fi g. 60).
CAUTION: Failure to grind and open stakes of the
output shaft nut will result in thread damage to the
shaft during nut removal.
WARNING: WEAR SAFETY GOGGLES WHILE
GRINDING STAKE NUTS.
(41) Usi ng a di e gri nder or equi val ent, gri nd the
stakes i n the shoul der of the shaft nuts as shown i n
(Fi g. 61) (Fi g. 62). Do not gri nd al l the way through
the nut and i nto the shaft. There are two stakes on
each nut.
(42) Usi ng a smal l chi sel , careful l y open the stakes
on nut (Fi g. 63).
Fig. 60 Remove Low/Reverse Clutch Pack
1 - CLUTCH PLATES (5)
2 - CLUTCH DISCS (5)
Fig. 61 Grinding Stakes
1 - TRANSFER SHAFT
2 - GRIND HERE
3 - GRIND HERE
4 - NUT STAKE
Fig. 62 Stake Grinding Pattern
1 - TRANSFER SHAFT
2 - TRANSFER SHAFT NUT
Fig. 63 Opening Nut Stakes
1 - CHISEL
2 - NUT STAKE
TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 97
AUTOMATIC TRANSMISSION - 42RLE (Continued)
(43) Use speci al tool 6497 and 6498A to remove
the transfer shaft nut or the output shaft nut (Fi g.
64).
(44) Remove the output shaft from case usi ng a
shop press (Fi g. 65).
Use speci al tool 6596 wi th a shop press to remove
the front output shaft beari ng cup (Fi g. 66).
(45) Use speci al tool 6597 and handl e C-4171 and
C-4171-2 to press the rear output shaft beari ng cup
rearward (Fi g. 67).
Fig. 64 Remove Output Shaft Nut
1 - SPECIAL TOOL 6497
2 - SPECIAL TOOL 6498A
3 - BREAKER BAR
Fig. 65 Use Arbor Press to Remove Output Shaft
from Case
1 - OUTPUT SHAFT
2 - ARBOR PRESS
3 - TRANSMISSION CASE
Fig. 66 Remove Front Bearing Cup - Typical
1 - ARBOR PRESS
2 - SPECIAL TOOL 6596
Fig. 67 Remove Rear Bearing Cup
1 - SPECIAL TOOL 4171 AND 4171-2
2 - SPECIAL TOOL 6597
21 - 98 AUTOMATIC TRANSMISSION - 42RLE TJ
AUTOMATIC TRANSMISSION - 42RLE (Continued)
(46) Remove the rear carri er front beari ng cone
(Fi g. 68).
(47) I nstal l and l oad compressor (Fi g. 69) as shown
i n (Fi g. 70).
(48) Remove the l ow/reverse bel l evi l l e spri ng snap
ri ng (Fi g. 71).
Fig. 68 Remove Rear Carrier Front Bearing Cone
1 - SPECIAL TOOL 5048-1
2 - SPECIAL TOOL 6545
3 - REAR CARRIER
4 - SPECIAL TOOL 5048
Fig. 69 Low/Reverse Spring Compressor Tool
1 - TOOL 6057
2 - TOOL 5059
3 - TOOL 5058-3
Fig. 70 Compressor Tool in Use
1 - LOW/REVERSE CLUTCH RETURN SPRING
2 - SNAP RING (INSTALL AS SHOWN)
3 - TOOL 5058A-3
4 - TOOL 5059A
5 - SPECIAL TOOL 6057
Fig. 71 Remove Snap Ring
1 - SNAP RING OPENING MUST BE BETWEEN SPRING LEVERS
(AS SHOWN)
2 - SNAP RING PLIERS
3 - SPECIAL TOOL 5059A
TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 99
AUTOMATIC TRANSMISSION - 42RLE (Continued)
(49) Remove the l ow/reverse pi ston bel l evi l l e
spri ng (Fi g. 72).
(50) Remove the park sprag pi vot retai ni ng screw.
(51) Dri ve out the anchor shaft usi ng sui tabl e
punch (Fi g. 73).
(52) Remove the gui de bracket pi vot shaft (Fi g.
74). I nspect al l components (Fi g. 75) for wear and
repl ace i f necessary.
Fig. 72 Low/Reverse Piston Belleville Spring
1 - LOW/REVERSE PISTON RETURN SPRING
2 - PISTON
Fig. 73 Anchor Shaft Removal
1 - PIN PUNCH
2 - GUIDE BRACKET ASSEMBLY
Fig. 74 Remove Guide Bracket Pivot Shaft
1 - PIVOT PIN
2 - GUIDE BRACKET ASSEMBLY
Fig. 75 Guide Bracket Disassembled
1 - GUIDE BRACKET
2 - PAWL
3 - SPLIT SLEEVE
4 - SPACER
5 - STEPPED SPACER
6 - ANTIRATCHET SPRING
21 - 100 AUTOMATIC TRANSMISSION - 42RLE TJ
AUTOMATIC TRANSMISSION - 42RLE (Continued)
NOTE: The Low/Reverse Clutch Piston has bonded
seals which are not individually serviceable. Seal
replacement requires replacement of the piston
assembly.
(53) Remove the l ow/reverse cl utch pi ston (Fi g.
76).
(54) Remove the l ow/reverse pi ston retai ner
screws.
(55) Remove l ow/reverse pi ston retai ner (Fi g. 77).
(56) Remove the l ow/reverse pi ston retai ner gasket
(Fi g. 78).
ASSEMBLY
NOTE: If the transmission assembly is being recon-
ditioned (clutch/seal replacement) or replaced, it is
necessary to perform the Quick Learn Procedure
using the DRBIIIா Scan Tool (Refer to 8 - ELECTRI-
CAL/ELECTRONIC CONTROL MODULES/TRANS-
MISSION CONTROL MODULE - STANDARD
PROCEDURE).
(1) I nstal l the output beari ng cups usi ng Speci al
Tool - 5050A (Fi g. 79).
Fig. 76 Remove Low/Reverse Clutch Piston
1 - LOW/REVERSE CLUTCH PISTON
2 - BONDED SEAL
3 - BONDED SEAL
Fig. 77 Remove Piston Retainer
1 - LOW/REVERSE CLUTCH PISTON RETAINER
2 - GASKET
Fig. 78 Remove Piston Retainer Gasket
1 - GASKET HOLES MUST LINE UP
2 - LOW/REVERSE CLUTCH PISTON RETAINER GASKET
Fig. 79 Bearing Cup Installation Special Tool -
5050A
TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 101
AUTOMATIC TRANSMISSION - 42RLE (Continued)
(2) I nstal l l ow/reverse pi ston retai ner gasket (Fi g.
80).
(3) I nstal l l ow/reverse pi ston retai ner (Fi g. 81).
(4) I nstal l l ow/reverse pi ston retai ner-to-case
screws (Fi g. 82) and torque to 5 N·m (45 i n. l bs.).
NOTE: The Low/Reverse Clutch Piston has bonded
seals which are not individually serviceable. Seal
replacement requires replacement of the piston
assembly.
(5) I nstal l l ow/reverse cl utch pi ston (Fi g. 83).
Fig. 80 Install Piston Retainer Gasket
1 - GASKET HOLES MUST LINE UP
2 - LOW/REVERSE CLUTCH PISTON RETAINER GASKET
Fig. 81 Install Piston Retainer
1 - LOW/REVERSE CLUTCH PISTON RETAINER
2 - GASKET
Fig. 82 Install Retainer Attaching Screws
1 - LOW/REVERSE CLUTCH PISTON RETAINER
2 - SCREWDRIVER
3 - TORX-LOC SCREWS
Fig. 83 Install Low/Reverse Clutch Piston
1 - LOW/REVERSE CLUTCH PISTON
2 - BONDED SEAL
3 - BONDED SEAL
21 - 102 AUTOMATIC TRANSMISSION - 42RLE TJ
AUTOMATIC TRANSMISSION - 42RLE (Continued)
(6) Assembl e gui de bracket assembl y as shown i n
(Fi g. 84) (Fi g. 85).
(7) I nstal l gui de bracket pi vot shaft (Fi g. 86).
CAUTION: When installing, be sure guide bracket
and split sleeve touch the rear of the transmission
case.
(8) I nstal l park sprag pi vot retai ni ng screw and
torque to 4.5 N·m (40 i n. l bs.).
(9) I nstal l l ow/reverse pi ston bel l evi l l e spri ng i nto
posi ti on (Fi g. 87).
Fig. 84 Guide Bracket Assembly
1 - GUIDE BRACKET
2 - PAWL
3 - SPLIT SLEEVE
4 - SPACER
5 - STEPPED SPACER
6 - ANTIRATCHET SPRING
Fig. 85 Guide Bracket
1 - GUIDE BRACKET
2 - ANTIRATCHET SPRING (MUST BE ASSEMBLED AS SHOWN)
3 - PAWL
Fig. 86 Install Guide Bracket Pivot Shaft
1 - PIVOT PIN
2 - GUIDE BRACKET ASSEMBLY
Fig. 87 Install Low/Reverse Piston Return Spring
1 - LOW/REVERSE PISTON RETURN SPRING
2 - PISTON
TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 103
AUTOMATIC TRANSMISSION - 42RLE (Continued)
(10) I nstal l and l oad l ow/reverse spri ng compressor
tool as shown i n (Fi g. 88) (Fi g. 89) to faci l i tate snap
ri ng i nstal l ati on.
(11) I nstal l snap ri ng and remove compressor tool
(Fi g. 90).
(12) I nstal l rear carri er front beari ng cone (Fi g.
91).
(13) Check output beari ng prel oad. Output bear-
ing preload must be checked and/or adjusted if
any of the following items have been replaced:
• Output shaft (rear carri er assembl y)
• Output shaft beari ngs
• Transmi ssi on case
Fig. 88 Low/Reverse Spring Compressor Tool
1 - TOOL 6057
2 - TOOL 5059
3 - TOOL 5058-3
Fig. 89 Compressor Tool in Use
1 - LOW/REVERSE CLUTCH RETURN SPRING
2 - SNAP RING (INSTALL AS SHOWN)
3 - TOOL 5058A-3
4 - TOOL 5059A
5 - SPECIAL TOOL 6057
Fig. 90 Install Snap Ring
1 - SNAP RING OPENING MUST BE BETWEEN SPRING LEVERS
(AS SHOWN)
2 - SNAP RING PLIERS
3 - TOOL 6057
Fig. 91 Install Rear Carrier Front Bearing Cone
1 - ARBOR PRESS
2 - SPECIAL TOOL C-4171
3 - SPECIAL TOOL 6052
4 - REAR CARRIER
21 - 104 AUTOMATIC TRANSMISSION - 42RLE TJ
AUTOMATIC TRANSMISSION - 42RLE (Continued)
(a) PRELOAD CHECK/SHIM SELECTION:
I nstal l rear output shaft beari ng cone and speci al
tool 6618A (Fi g. 92).
(b) I nstal l speci al tool 6618A (Fi g. 93). Li ghtl y
ti ghten retai ni ng screws. Screws shoul d be bel ow
the pl ate surface, but do not snug screws.
(c) Turn case over on arbor press so that the
pl ate i s resti ng on the press base. CAUTION: The
output shaft will extend through the hole of
tool 6618A. Ensure your press table has clear-
ance for the output shaft.
(d) I nstal l shi m on output shaft (Fi g. 94). Appl y
smal l amount of petrol atum onto the shi m to hol d
i t i n pl ace. Use the ori gi nal shi m as a starti ng
poi nt. I f ori gi nal shi m i s not avai l abl e, use the
thi ckest shi m avai l abl e.
(e) I nstal l output shaft/rear carri er i nto rear bear-
i ng. The shaft must be pressed i nto posi ti on. Use spe-
ci al tool MD-998911 (Di sc) and C- 4171 and C4171-2
(Handl e) to press shaft i nto rear beari ng (Fi g. 95).
(f) Do not re-use old output shaft nut
because the removed stake weakens the nut
flange. Usi ng speci al tool s 6497 and 6498-A,
i nstal l new output shaft nut. Do not reuse ol d out-
put shaft nut. Ti ghten new output shaft nut to 271
N·m (200 ft. l bs.).
Fig. 92 Bearing Installation
1 - SPECIAL TOOL 6618-A
2 - REAR OUTPUT SHAFT BEARING
Fig. 93 Special Tool Installed
1 - SPECIAL TOOL 6618-A
Fig. 94 Shim Installation
1 - SHIM
2 - OUTPUT SHAFT
Fig. 95 Press Shaft Into Case
1 - SPECIAL TOOL C-4171 AND C-4171-2
2 - SPECIAL TOOL MD-998911
TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 105
AUTOMATIC TRANSMISSION - 42RLE (Continued)
(g) Check the turni ng torque of the output shaft
(Fi g. 96). The shaft shoul d have 1 to 8 i n. l bs. of
turni ng torque. I f the turni ng torque i s higher
than 8 i n. l bs., i nstal l a thi cker shi m. I f turni ng
torque i s less than 1 i n. l b., i nstal l a thi nner shi m.
Make sure there i s no end pl ay.
(h) The new nut must be staked after the correct
turni ng torque i s obtai ned (Fi g. 97) (Fi g. 98). Use
speci al tool 6639 to stake output shaft nut. CAU-
TION: Failure to stake nut could allow the
nut to back-off during use.
Fig. 96 Checking Turning Torque
1 - TORQUE WRENCH
2 - SPECIAL TOOL 6498-A
3 - OUTPUT SHAFT NUT
Fig. 97 Staking Output Shaft Nut - Typical
1 - ARBOR PRESS
2 - STAKING TOOL - 6639
3 - NEW NUT
Fig. 98 Properly Staked Nut
1 - BOTTOMED IN SLOT
2 - CORRECTLY STAKED NUT
21 - 106 AUTOMATIC TRANSMISSION - 42RLE TJ
AUTOMATIC TRANSMISSION - 42RLE (Continued)
(14) I nstal l l ow/reverse cl utch pack (Fi g. 99).
Leave uppermost di sc out to faci l i tate snap ri ng
i nstal l ati on.
(15) I nstal l l ow/reverse reacti on pl ate snap ri ng
(Fi g. 100).
(16) I nstal l one l ow/reverse cl utch di sc (Fi g. 101).
(17) I nstal l l ow/reverse reacti on pl ate wi th fl at
si de up (Fi g. 102).
Fig. 99 Install Low/Reverse Clutch Pack
1 - CLUTCH PLATES (5)
2 - CLUTCH DISCS (5)
Fig. 100 Install Low/Reverse Reaction Plate Snap
Ring
1 - SCREWDRIVER
2 - LOW/REVERSE REACTION PLATE FLAT SNAP RING
3 - DO NOT SCRATCH CLUTCH PLATE
Fig. 101 Install One Disc
1 - ONE DISC FROM LOW/REVERSE CLUTCH
Fig. 102 Install Low/Reverse Reaction Plate
1 - LOW/REVERSE REACTION PLATE (FLAT SIDE UP)
TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 107
AUTOMATIC TRANSMISSION - 42RLE (Continued)
(18) I nstal l a new tapered snap ri ng (tapered si de
out) (Fi g. 103). Make sure that the snap ri ng ends
are ori ented as shown (Fi g. 104)
(19) Measure l ow/reverse cl utch pack. Set up di al
i ndi cator as shown i n (Fi g. 105). Press down cl utch
pack wi th fi nger and zero di al i ndi cator. Record mea-
surement i n four (4) pl aces and take average readi ng.
Low/Reverse clutch pack clearance is 0.84 to
1.60 mm (0.033 to 0.063 inch).
(20) Sel ect the proper l ow/reverse reacti on pl ate to
achi eve speci fi cati ons.
(21) I nstal l 2/4 cl utch pack (Fi g. 106).
Fig. 103 Snap Ring Installed
1 - SCREWDRIVER
2 - TAPERED SNAP RING (INSTALL AS SHOWN)
Fig. 104 Tapered Snap Ring Instructions
Fig. 105 Check Low/Reverse Clutch Clearance
1 - DIAL INDICATOR
2 - DIAL INDICATOR TIP TOOL 6268
3 - HOOK TOOL
Fig. 106 Install 2/4 Clutch Pack
1 - CLUTCH PLATE (4)
2 - CLUTCH DISC (4)
21 - 108 AUTOMATIC TRANSMISSION - 42RLE TJ
AUTOMATIC TRANSMISSION - 42RLE (Continued)
NOTE: The 2/4 Clutch Piston has bonded seals
which are not individually serviceable. Seal replace-
ment requires replacement of the piston assembly.
(22) I nstal l 2/4 cl utch bel l evi l l e spri ng (Fi g. 107)
(Fi g. 108).
(23) I nstal l 2/4 cl utch retai ner (Fi g. 109).
NOTE: Verify that Tool 5058A is centered properly
over the 2/4 clutch retainer before compressing. If
necessary, fasten the 5058A bar to the bellhousing
flange with any combination of locking pliers and
bolts to center the tool properly.
(24) Set up Tool 5058 as shown i n (Fi g. 110). Com-
press 2/4 cl utch just enough to faci l i tate snap ri ng
i nstal l ati on.
Fig. 107 Install 2/4 Clutch Return Spring
1 - 2/4 CLUTCH RETURN SPRING
Fig. 108 Proper Orientation of 2/4 Clutch
1 - NOTE POSITION
2 - RETURN SPRING
3 - 2/4 CLUTCH RETAINER
Fig. 109 Install 2/4 Clutch Retainer
1 - 2/4 CLUTCH RETAINER
Fig. 110 Remove 2/4 Clutch Retainer Snap Ring
1 - TOOL 5058
2 - SCREWDRIVER
3 - SNAP RING
4 - 2/4 CLUTCH RETAINER
TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 109
AUTOMATIC TRANSMISSION - 42RLE (Continued)
(25) Measure 2/4 clutch clearance: Set up di al
i ndi cator as shown i n (Fi g. 111). Press down cl utch
pack wi th fi nger and zero di al i ndi cator. Record mea-
surement i n four (4) pl aces and take average readi ng.
The 2/4 clutch pack clearance is 0.76 to 2.64 mm
(0.030 to 0.104 inch). I f not wi thi n speci fi cati ons,
the cl utch i s not assembl ed properl y or i s excessi vel y
worn. There is no adjustment for the 2/4 clutch
clearance.
(26) I nstal l the #7 needl e beari ng to the rear sun
gear (Fi g. 112). The number 7 needle bearing has
three antireversal tabs and is common with the
number 5 and number 2 position. The orienta-
tion should allow the bearing to seat flat
against the rear sun gear. A small amount of
petrolatum can be used to hold the bearing to
the rear sun gear.
(27) I nstal l rear sun gear and #7 needl e beari ng
(Fi g. 113).
(28) I nstal l front carri er/rear annul us assembl y
and #6 needl e beari ng (Fi g. 114).
Fig. 112 Number 7 Bearing
1 - #7 BEARING
2 - REAR SUN GEAR
Fig. 111 Check 2/4 Clutch Clearance
1 - DIAL INDICATOR
2 - HOOK TOOL
3 - DIAL INDICATOR TIP TOOL 6268
Fig. 113 Install Rear Sun Gear
1 - #7 NEEDLE BEARING
2 - REAR SUN GEAR
Fig. 114 Install Front Carrier/Rear Annulus
1 - #6 NEEDLE BEARING
2 - FRONT CARRIER AND REAR ANNULUS ASSEMBLY (TWIST
AND PULL OR PUSH TO REMOVE OR INSTALL).
21 - 110 AUTOMATIC TRANSMISSION - 42RLE TJ
AUTOMATIC TRANSMISSION - 42RLE (Continued)
(29) I nstal l front sun gear assembl y and #4 thrust
washer (Fi g. 115).
(30) Determine proper #4 thrust plate thickness.
(a) Sel ect the thi nnest #4 thrust pl ate thi ckness.
(b) I nstal l #4 thrust pl ate (Fi g. 116) usi ng petro-
l atum to hol d i nto posi ti on.
(c) I nstal l i nput cl utch assembl y. Ensure the
i nput cl utch assembl y i s compl etel y seated by vi ew-
i ng posi ti on through i nput speed sensor hol e. If
the speed sensor tone wheel is not centered
in the opening, the input clutch assembly is
not seated properly.
(d) Remove the oi l pump o-ri ng (Fi g. 117) and
i nstal l oi l pump and gasket to transmi ssi on.
Ti ghten the oi l pump bol ts to 30 N·m (265 i n. l bs.).
Use screw-in dowels or phillips-head screw-
drivers to align pump to case. Be sure to rein-
stall O-ring on oil pump after selecting the
proper No. 4 thrust plate.
(e) Measure the i nput shaft end pl ay wi th the
transmi ssi on i n the verti cal posi ti on. Thi s wi l l
ensure that the measurement wi l l be accurate.
(f) Set up and measure endpl ay usi ng End Pl ay
Set 8266 and Di al I ndi cator Set C3339 as shown i n
(Fi g. 118).
Fig. 116 Install #4 Thrust Plate
1 - OVERDRIVE SHAFT ASSEMBLY
2 - #4 THRUST PLATE (SELECT)
3 - PETROLATUM FOR RETENTION
Fig. 117 Remove Oil Pump O-Ring
1 - OIL PUMP ASSEMBLY
2 - O-RING
Fig. 118 Measure Input Shaft End Play Using Tool
8266 - Typical
1 - TOOL 8266-8
2 - TOOL 8266-2
3 - TOOL C-3339
Fig. 115 Install Front Sun Gear Assembly
1 - FRONT SUN GEAR ASSEMBLY
2 - #4 THRUST WASHER (FOUR TABS)
TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 111
AUTOMATIC TRANSMISSION - 42RLE (Continued)
(g) Measure i nput shaft end pl ay. Input shaft
end play must be 0.127 to 0.635 mm (0.005 to
0.025 inch). For exampl e, i f end pl ay readi ng i s
0.055 i nch, sel ect No. 4 Thrust Pl ate whi ch i s 0.071
to 0.074 thi ck. Thi s shoul d provi de an i nput shaft
end pl ay readi ng of 0.020 i nch, whi ch i s wi thi n
speci fi cati ons.
(h) Remove oi l pump, gasket, and i nput cl utch
assembl y to gai n access to and i nstal l proper #4
thrust pl ate.
(31) I nstal l i nput cl utch assembl y wi th proper
thrust pl ate (Fi g. 119).
(32) I nstal l #1 caged needl e beari ng (Fi g. 120).
(33) Repl ace cool er by-pass val ve i f transmi ssi on
fai l ure has occurred (Fi g. 121).
CAUTION: By-pass valve MUST be replaced if trans-
mission failure occurs.
NOTE: To align oil pump, gasket, and case during
installation, use threaded dowels or phillips screw-
drivers.
(34) I nstal l oi l pump gasket (Fi g. 122).
Fig. 120 Install No. 1 Caged Needle Bearing
1 - #1 CAGED NEEDLE BEARING
2 - NOTE: TANGED SIDE OUT
Fig. 121 Install By-Pass Valve
1 - BYPASS VALVE
Fig. 122 Install Oil Pump Gasket
1 - BELLHOUSING
2 - OIL PUMP GASKET
Fig. 119 Install Input Clutch Assembly
1 - INPUT CLUTCH ASSEMBLY
21 - 112 AUTOMATIC TRANSMISSION - 42RLE TJ
AUTOMATIC TRANSMISSION - 42RLE (Continued)
(35) I nstal l oi l pump and torque the new oi l pump-
to-case bol ts to 30 N·m (265 i n. l bs.) (Fi g. 123). Do
not reuse ori gi nal oi l pump bol ts.
(36) I nstal l l ow/reverse accumul ator as shown i n
(Fi g. 124).
(37) I nstal l l ow/reverse accumul ator pl ug (Fi g.
125).
(38) I nstal l l ow/reverse accumul ator snap ri ng
(Fi g. 126).
Fig. 123 Install Oil Pump Attaching Bolts
1 - BOLTS
2 - OIL PUMP
Fig. 124 Low/Reverse Accumulator
1 - PISTON
2 - RETURN SPRINGS
Fig. 125 Install Low/Reverse Accumulator Plug
1 - ADJUSTABLE PLIERS
2 - PLUG
Fig. 126 Install Low/Reverse Accumulator Snap
Ring
1 - SNAP RING
2 - LOW/REVERSE ACCUMULATOR
TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 113
AUTOMATIC TRANSMISSION - 42RLE (Continued)
(39) I nstal l underdri ve and overdri ve accumul ators
and spri ngs (Fi g. 127).
CAUTION: Do not handle the valve body by the
manual shaft. Damage could result.
(40) I nstal l val ve body i nto pl ace as shown i n (Fi g.
128).
(41) I nstal l seven (7) val ve body-to-case bol ts (Fi g.
129) and torque to 12 N·m (105 i n. l bs.).
(42) I nstal l transmi ssi on oi l fi l ter (Fi g. 130).
Ti ghten the bol ts to 5 N·m (45 i n. l bs.)
Fig. 127 Underdrive and Overdrive Accumulators
1 - OVERDRIVE PISTON AND SPRING
2 - UNDERDRIVE PISTON AND SPRING
Fig. 128 Install Valve Body Onto Transmission
1 - VALVE BODY
Fig. 129 Install Valve Body Bolts (7)
1 - BOLTS
Fig. 130 Install Transmission Filter
1 - TRANSMISSION FILTER
21 - 114 AUTOMATIC TRANSMISSION - 42RLE TJ
AUTOMATIC TRANSMISSION - 42RLE (Continued)
NOTE: Before installing the oil pan bolt in the bolt
hole located between the torque converter clutch
on and U/D clutch pressure tap circuits (Fig. 131), it
will be necessary to replentish the sealing patch on
the bolt using Moparா Lock & Seal Adhesive.
(43) I nstal l transmi ssi on oi l pan (Fi g. 132) wi th a
bead of Mopar௡ ATF RTV. Torque oi l pan-to-case
bol ts to 20 N·m (14.5 ft. l bs.).
NOTE: Before installing either speed sensor bolt, it
will be necessary to replentish the sealing patch on
the bolt using Moparா Lock & Seal Adhesive.
(44) I nstal l both speed sensors i nto transmi ssi on
case (Fi g. 133). Torque the speed sensor bol ts to 9
N·m (80 i n. l bs.).
Fig. 131 Pan Fastener
1 - FRONT DRIVESHAFT
2 - PRESSURE PORTS
3 - TRANSMISSION CASE
4 - TRANSMISSION OIL PAN
5 - SECOND TRANSMISSION OIL PAN BOLT ON LEFT SIDE
6 - FIRST TRANSMISSION OIL PAN BOLT
Fig. 132 Install Transmission Oil Pan
1 - TRANSMISSION OIL PAN
Fig. 133 Input and Output Speed Sensors and
Transmission Range Sensor
1 - INPUT SPEED SENSOR
2 - OUTPUT SPEED SENSOR
3 - TRANSMISSION RANGE SENSOR
TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 115
AUTOMATIC TRANSMISSION - 42RLE (Continued)
(45) As a fi nal check of the transmi ssi on, measure
the i nput shaft end pl ay. Thi s wi l l i ndi cate when a #4
thrust pl ate change i s requi red. The #4 thrust pl ate
i s l ocated behi nd the overdri ve cl utch hub. Attach a
di al i ndi cator to transmi ssi on bel l housi ng wi th i ts
pl unger seated agai nst end of i nput shaft (Fi g. 134).
Move i nput shaft i n and out to obtai n end pl ay read-
i ng. Input shaft end play must be 0.127 to 0.635
mm (0.005 to 0.025 inch). I f not wi thi n speci fi ca-
ti ons, make the necessary thrust pl ate adjustment.
(46) I nspect the l ube tube grommet (Fi g. 135) for
damage. I f the grommet l i p i s damaged, i t wi l l need
to be repl aced.
(47) I nstal l the 4X4 stub shaft onto the transmi s-
si on output shaft.
(48) Pl ace a bead of Mopar௡ ATF RTV on the rear
surface of the transmi ssi on case for the adapter
housi ng.
(49) I nstal l the adapter (Fi g. 136) housi ng onto the
transmi ssi on case.
Fig. 134 Measure Input Shaft End Play Using Tool
8266 - Typical
1 - TOOL 8266-8
2 - TOOL 8266-2
3 - TOOL C-3339
Fig. 135 Lube Tube Grommet
1 - HOUSING
2 - LUBE TUBE
3 - GROMMET
4 - PRY SLOTS
Fig. 136 Install Adapter Housing
1 - TRANSMISSION CASE
2 - ADAPTER HOUSING
21 - 116 AUTOMATIC TRANSMISSION - 42RLE TJ
AUTOMATIC TRANSMISSION - 42RLE (Continued)
NOTE: Before installing the lowermost four adapter
housing bolts (Fig. 137), it will be necessary to
replentish the sealing patch on the bolts using
Moparா Lock & Seal Adhesive.
(50) I nstal l the bol ts (Fi g. 138) that hol d the
adapter housi ng onto the transmi ssi on case. Be sure
to i nstal l any stud bol ts to thei r ori gi nal l ocati ons.
Ti ghten the bol ts to 54 N·m (40 ft.l bs.).
INSTALLATION
(1) Check torque converter hub and hub dri ve
notches for sharp edges burrs, scratches, or ni cks.
Pol i sh the hub and notches wi th 320/400 gri t paper
and crocus cl oth i f necessary. The hub must be
smooth to avoi d damagi ng pump seal at i nstal l ati on.
(2) Lubri cate converter dri ve hub and oi l pump
seal l i p wi th transmi ssi on fl ui d.
(3) Al i gn converter and oi l pump.
(4) Careful l y i nsert converter i n oi l pump. Then
rotate converter back and forth unti l ful l y seated i n
pump gears.
(5) Check converter seati ng wi th steel scal e and
strai ghtedge (Fi g. 139). Surface of converter l ugs
shoul d be 1/2 i n. to rear of strai ghtedge when con-
verter i s ful l y seated.
(6) Temporari l y secure converter wi th C-cl amp.
(7) Li ghtl y grease crankshaft fl ange hol e.
(8) Posi ti on transmi ssi on on jack and secure i t
wi th safety chai ns.
(9) Check condi ti on of converter dri vepl ate.
Repl ace the pl ate i f cracked, di storted or damaged.
Also be sure transmission dowel pins are seated
in engine block and protrude far enough to
hold transmission in alignment.
(10) Rai se transmi ssi on and al i gn converter wi th
dri ve pl ate and converter housi ng wi th engi ne bl ock.
(11) Move transmi ssi on forward. Then rai se, l ower
or ti l t transmi ssi on to al i gn converter housi ng wi th
engi ne bl ock dowel s.
Fig. 137 Adapter Housing Fasteners
1 - STUD, ADAPTER/EXTENSION
2 - TRANSMISSION MOUNT FASTENERS (4)
3 - TRANSMISSION MOUNT
4 - TRANSMISSION CASE
5 - NUT, EXHAUST HANGER BRACKET (2)
6 - STUD, ADAPTER/EXTENSION
7 - TRANSMISSION OIL PAN
8 - BOLT, ADAPTER/EXTENSION (2)
Fig. 138 Install Adapter Housing Bolts
1 - TRANSMISSION CASE
2 - ADAPTER HOUSING
3 - BOLTS
Fig. 139 Checking Converter Seating - Typical
1 - SCALE
2 - STRAIGHTEDGE
TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 117
AUTOMATIC TRANSMISSION - 42RLE (Continued)
(12) 22Careful l y work transmi ssi on forward and
over engi ne bl ock dowel s unti l converter hub i s
seated i n crankshaft.
(13) I nstal l and ti ghten bol ts that attach transmi s-
si on converter housi ng to engi ne bl ock.
CAUTION: Be sure the converter housing is fully
seated on the engine block dowels before tighten-
ing any bolts.
(14) I nstal l torque converter attachi ng bol ts.
Ti ghten bol ts to 88 N·m (65 ft. l bs.).
(15) On 4.0L engi ne equi pped vehi cl es, i nstal l the
crankshaft posi ti on sensor (Fi g. 140).
(16) I nstal l transmi ssi on fi l l tube and seal . I nstal l
new fi l l tube seal i n transmi ssi on before i nstal l ati on.
(17) Connect transmi ssi on cool er l i nes to transmi s-
si on.
(18) I nstal l transfer case onto transmi ssi on. (Refer
to 21 - TRANSMI SSI ON/TRANSFER CASE -
I NSTALLATI ON)
(19) I nstal l ski d pl ate (Fi g. 141) and attach trans-
mi ssi on rear support to ski d pl ate. (Refer to 13 -
FRAME & BUMPERS/FRAME/TRANSFER CASE
SKI D PLATE - I NSTALLATI ON)
(20) Remove engi ne support fi xture.
(21) Remove transmi ssi on jack.
(22) Connect i nput and output speed sensor wi res
(Fi g. 142).
Fig. 140 Crankshaft Position Sensor
1 - CRANKSHAFT POSITION SENSOR
2 - MOUNTING BOLT
3 - ELECTRICAL CONNECTOR
4 - TRANSMISSION BELLHOUSING
Fig. 141 Transmission Mount - Automatic
Transmission
1 - TRANSMISSION SUPPORT BRACKET
2 - AUTOMATIC TRANSMISSION
3 - SKID PLATE
4 - FRAME
5 - TRANSMISSION MOUNT SUPPORT BRACKET
6 - CUSHION
Fig. 142 Input and Output Speed Sensors and
Transmission Range Sensor
1 - INPUT SPEED SENSOR
2 - OUTPUT SPEED SENSOR
3 - TRANSMISSION RANGE SENSOR
21 - 118 AUTOMATIC TRANSMISSION - 42RLE TJ
AUTOMATIC TRANSMISSION - 42RLE (Continued)
(23) Connect wi res to the transmi ssi on range sen-
sor (Fi g. 142) and the sol enoi d/pressure swi tch
assembl y (Fi g. 143).
(24) I nstal l converter housi ng access cover.
(25) I nstal l exhaust pi pes and support brackets, i f
removed.
(26) I nstal l starter motor (Refer to 8 - ELECTRI -
CAL/STARTI NG/STARTER MOTOR - I NSTALLA-
TI ON) and cool er l i ne bracket.
(27) I nstal l new pl asti c retai ner grommet on any
shi ft l i nkage rod or l ever that was di sconnected.
Grommets shoul d not be reused. Use pry tool to
remove rod from grommet and cut away ol d grom-
met. Use pl i ers to snap new grommet i nto l ever and
to snap rod i nto grommet at assembl y.
(28) Connect gearshi ft cabl e.
(29) Connect transfer case shi ft l i nkage.
(30) Adjust gearshi ft l i nkage, i f necessary.
(31) Al i gn and connect propel l er shaft(s). (Refer to
3 - DI FFERENTI AL & DRI VELI NE/PROPELLER
SHAFT/PROPELLER SHAFT - I NSTALLATI ON)
(32) Fi l l transfer case to bottom edge of fi l l pl ug
hol e.
(33) Lower vehi cl e and connect battery negati ve
cabl e.
(34) Fi l l transmi ssi on to correct l evel wi th Mopar௡
ATF +4.
Fig. 143 Solenoid/Pressure Switch Assembly
1 - SOLENOID/PRESSURE SWITCH ASSEMBLY CONNECTOR
TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 119
AUTOMATIC TRANSMISSION - 42RLE (Continued)
SCHEMATICS AND DIAGRAMS - 42RLE TRANSMISSION
P
a
r
k
/
N
e
u
t
r
a
l
(
S
p
e
e
d
U
n
d
e
r
8
m
p
h
)
21 - 120 AUTOMATIC TRANSMISSION - 42RLE TJ
AUTOMATIC TRANSMISSION - 42RLE (Continued)
N
e
u
t
r
a
l
(
S
p
e
e
d
O
v
e
r
8
m
p
h
)
TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 121
AUTOMATIC TRANSMISSION - 42RLE (Continued)
R
e
v
e
r
s
e
21 - 122 AUTOMATIC TRANSMISSION - 42RLE TJ
AUTOMATIC TRANSMISSION - 42RLE (Continued)
R
e
v
e
r
s
e
B
l
o
c
k
(
S
h
i
f
t
t
o
R
e
v
e
r
s
e
w
/
S
p
e
e
d
O
v
e
r
8
m
p
h
)
TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 123
AUTOMATIC TRANSMISSION - 42RLE (Continued)
F
i
r
s
t
G
e
a
r
21 - 124 AUTOMATIC TRANSMISSION - 42RLE TJ
AUTOMATIC TRANSMISSION - 42RLE (Continued)
S
e
c
o
n
d
G
e
a
r
TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 125
AUTOMATIC TRANSMISSION - 42RLE (Continued)
S
e
c
o
n
d
G
e
a
r
(
E
M
C
C
)
21 - 126 AUTOMATIC TRANSMISSION - 42RLE TJ
AUTOMATIC TRANSMISSION - 42RLE (Continued)
D
i
r
e
c
t
G
e
a
r
TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 127
AUTOMATIC TRANSMISSION - 42RLE (Continued)
D
i
r
e
c
t
G
e
a
r
(
E
M
C
C
)
21 - 128 AUTOMATIC TRANSMISSION - 42RLE TJ
AUTOMATIC TRANSMISSION - 42RLE (Continued)
D
i
r
e
c
t
G
e
a
r
(
C
C
O
n
)
TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 129
AUTOMATIC TRANSMISSION - 42RLE (Continued)
O
v
e
r
d
r
i
v
e
21 - 130 AUTOMATIC TRANSMISSION - 42RLE TJ
AUTOMATIC TRANSMISSION - 42RLE (Continued)
O
v
e
r
d
r
i
v
e
(
E
M
C
C
)
TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 131
AUTOMATIC TRANSMISSION - 42RLE (Continued)
O
v
e
r
d
r
i
v
e
(
C
C
O
n
)
21 - 132 AUTOMATIC TRANSMISSION - 42RLE TJ
AUTOMATIC TRANSMISSION - 42RLE (Continued)
SPECIFICATIONS
42RLE AUTOMATIC TRANSMISSION
GENERAL SPECIFICATIONS
Transmission Type
Four-Speed Automatic, Electronically Controlled, Fully
Adaptive, Electronically Modulated Torque Converter
Lubrication Method Pump (internal - external gear-type)
Cooling Method
Water Heat Exchanger and/or Air-to-Oil Heat
Exchanger
GEAR RATIOS
1st Gear 2.84:1
2nd Gear 1.57:1
3rd Gear (Direct) 1.00:1
4th Gear (Overdrive) 0.69:1
Reverse Gear 2.21:1
BEARING PRELOAD (DRAG TORQUE)
Description Metric Standard
Output Shaft 0.22-0.903 N·m 1-8 in. lbs.
CLUTCH PACK
Description Metric Standard
Low/Reverse Clutch (Select
Reaction Plate)
0.84-1.60 mm 0.033-0.063 in.
Two/Four Clutch (No Select) 0.76-2.64 mm 0.030-0.104 in.
Reverse Clutch (Select Snap Ring) 0.89-1.37 mm 0.035-0.054 in.
Overdrive Clutch (No Select) 1.07-3.25 mm 0.042-0.128 in.
Underdrive Clutch (Select Reaction
Plate)
0.94-1.50 mm 0.037-0.059 in.
INPUT SHAFT
Description Metric Standard
End Play 0.127-0.635 mm 0.005-0.025 in.
TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 133
AUTOMATIC TRANSMISSION - 42RLE (Continued)
OIL PUMP CLEARANCES
DESCRIPTION METRIC STANDARD
Outer Gear-to-Crescent 0.060-0.298 mm 0.0023-0.0117 in.
Inner Gear-to-Crescent 0.093-0.385 mm 0.0036-0.0151 in.
Outer Gear-to-Pocket 0.089-0.202 mm 0.0035-0.0079 in.
Outer Gear Side Clearance 0.020-0.046 mm 0.0008-0.0018 in.
Inner Gear Side Clearance 0.020-0.046 mm 0.0008-0.0018 in.
TORQUE SPECIFICATIONS
Description N·m Ft. Lbs. In. Lbs.
Bolt, Converter-to-Driveplate 88 65 -
Bolt, Fluid Filter-to-Valve Body 5 - 45
Bolt, L/R Clutch Retainer-to-Case 5 - 45
Bolt, Adapter/Extension Housing 54 40 -
Bolt, Manual Valve Lever-to-Manual Valve 5 - 45
Bolt, Oil Pan-to-Case 20 14.5 -
Bolt, Oil Pump-to-Case 30 - 265
Bolt, Park Sprag Retainer 4.5 - 40
Bolt, Reaction Shaft Support Halves 28 - 250
Bolt, Solenoid/Pressure Switch Assy-to-
Valve Body
5.5 - 50
Bolt, Valve Body-to-Case 12 - 105
Bolt, Valve Body-to-Transfer Plate 5 - 45
Fitting, Cooler Line 47.5 35 -
Nut, Output Shaft 271 200 -
Plug, Pressure Tap 5 - 45
Bolt, Input Speed-to-Case Sensor 9 - 80
Bolt, Output Speed-to-Case Sensor 9 - 80
21 - 134 AUTOMATIC TRANSMISSION - 42RLE TJ
AUTOMATIC TRANSMISSION - 42RLE (Continued)
SPECIAL TOOLS
42RLE AUTOMATIC TRANSMISSION
Pressure Gauge (High) C-3293SP
Dial Indicator C-3339
Slide Hammer C-3752
Seal Puller C-3981B
Universal Handle C-4171
Handle Extension C-4171-2
Adapter Set L-4559
Puller Set 5048
TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 135
AUTOMATIC TRANSMISSION - 42RLE (Continued)
Installer 5050A
Compressor 5058A
Compressor 5059-A
Installer 5067
Installer 6052
Disk 6057
Tip 6268
Remover/Installer 6301
Remover/Installer 6302
Remover 6310
21 - 136 AUTOMATIC TRANSMISSION - 42RLE TJ
AUTOMATIC TRANSMISSION - 42RLE (Continued)
Wrench 6497
Wrench 6498-A
Puller Jaws 6545
Remover 6596
Remover 6597
Plate Set 6599
Support Plate 6618A
Staking Tool 6639
End Play Set 8266
Pressure Fixture 8391
TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 137
AUTOMATIC TRANSMISSION - 42RLE (Continued)
ACCUMULATOR
DESCRIPTION
The 42RLE underdri ve, overdri ve, l ow/reverse, and
2/4 cl utch hydraul i c ci rcui ts each contai n an accumu-
l ator. An accumul ator typi cal l y consi sts of a pi ston,
return spri ng(s), and a cover or pl ug. The overdri ve
and underdri ve accumul ators are l ocated wi thi n the
transmi ssi on case, and are retai ned by the val ve
body (Fi g. 144).
The l ow reverse accumul ator (Fi g. 145) i s al so
l ocated wi thi n the transmi ssi on case, but the assem-
bl y i s retai ned by a cover and a snap-ri ng.
The 2/4 accumul ator i s l ocated i n the val ve body. I t
i s retai ned by a cover and retai ni ng screws (Fi g.
146).
OPERATION
The functi on of an accumul ator i s to cushi on the
appl i cati on of a fri cti onal cl utch el ement. When pres-
suri zed fl ui d i s appl i ed to a cl utch ci rcui t, the appl i -
cati on force i s dampened by fl ui d col l ecti ng i n the
respecti ve accumul ator chamber agai nst the pi ston
and spri ngs. The i ntended resul t i s a smooth, fi rm
cl utch appl i cati on.
ADAPTER HOUSING SEAL
REMOVAL
(1) Remove the transfer case (Refer to 21 -
TRANSMI SSI ON/TRANSFER CASE - REMOVAL).
(2) Usi ng a screw mounted i n a sl i de hammer,
remove the adapter housi ng seal .
INSTALLATION
(1) I nstal l a new adapter housi ng seal wi th Tool
Handl e C-4171 and I nstal l er C-3860-A.
(2) I nstal l the transfer case (Refer to 21 - TRANS-
MI SSI ON/TRANSFER CASE - I NSTALLATI ON).
Fig. 144 Underdrive and Overdrive Accumulators
1 - OVERDRIVE PISTON AND SPRING
2 - UNDERDRIVE PISTON AND SPRING
Fig. 145 Low/Reverse Accumulator
1 - PISTON
2 - RETURN SPRINGS
Fig. 146 2/4 Accumulator Assembly
1 - VALVE BODY
2 - RETAINER PLATE
3 - DETENT SPRING
4 - RETURN SPRINGS
5 - PISTON
21 - 138 AUTOMATIC TRANSMISSION - 42RLE TJ
AUTOMATIC TRANSMISSION - 42RLE (Continued)
BEARINGS
ADJ USTMENTS
BEARING ADJUSTMENT PROCEDURES
Take extreme care when removi ng and i nstal l i ng
beari ng cups and cones. Use only an arbor press
for installation, as a hammer may not properl y
al i gn the beari ng cup or cone. Burrs or ni cks on the
beari ng seat wi l l gi ve a fal se end pl ay readi ng, whi l e
gaugi ng for proper shi ms. I mproperl y seated beari ng
cup and cones are subject to l ow-mi l eage fai l ure.
Beari ng cups and cones shoul d be repl aced i f they
show si gns of pi tti ng or heat di stress.
I f di stress i s seen on ei ther the cup or beari ng rol l -
ers, both cup and cone must be repl aced.
NOTE: Bearing drag torque specifications must be
maintained to avoid premature bearing failures.
Used (ori gi nal ) beari ng may l ose up to 50 percent
of the ori gi nal drag torque after break-i n.
NOTE: All bearing adjustments must be made with
no other component interference or gear inter-
mesh.
Oi l al l beari ngs before checki ng turni ng torque.
BRAKE TRANSMISSION SHIFT
INTERLOCK MECHANISM
DESCRIPTION
The Brake Transmi ssi on Shi fter/I gni ti on I nterl ock
(BTSI ), i s a cabl e and sol enoi d operated system. I t
i nterconnects the automati c transmi ssi on fl oor
mounted shi fter to the steeri ng col umn i gni ti on
swi tch (Fi g. 147).
Fig. 147 Ignition Interlock Cable Routing
1 - SHIFT MECHANISM 5 - SOLENOID
2 - LOCK-TAB 6 - WIRE CONNECTOR
3 - IGNITION LOCK INTERLOCK 7 - TIE STRAP
4 - STEERING COLUMN 8 - PARK/BRAKE INTERLOCK CABLE
TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 139
OPERATION
The system l ocks the shi fter i nto the PARK posi -
ti on. The I nterl ock system i s engaged whenever the
i gni ti on swi tch i s i n the LOCK or ACCESSORY posi -
ti on. An addi ti onal el ectri cal l y acti vated feature wi l l
prevent shi fti ng out of the PARK posi ti on unl ess the
brake pedal i s depressed at l east one-hal f an i nch. A
magneti c hol di ng devi ce i n l i ne wi th the park/brake
i nterl ock cabl e i s energi zed when the i gni ti on i s i n
the RUN posi ti on. When the key i s i n the RUN posi -
ti on and the brake pedal i s depressed, the shi fter i s
unl ocked and wi l l move i nto any posi ti on. The i nter-
l ock system al so prevents the i gni ti on swi tch from
bei ng turned to the LOCK or ACCESSORY posi ti on
(Fi g. 148) unl ess the shi fter i s ful l y l ocked i nto the
PARK posi ti on.
REMOVAL
(1) Remove l ower steeri ng col umn cover. (Refer to
23 - BODY/I NSTRUMENT PANEL/STEERI NG COL-
UMN OPENI NG COVER - REMOVAL)
(2) Remove l ower steeri ng col umn shroud.
(3) Remove ti e strap near the sol enoi d retai ni ng
the brake transmi ssi on i nterl ock cabl e to the steeri ng
col umn.
(4) Di sengage wi re connector from sol enoi d.
(5) Wi th the i gni ti on removed or i n the unl ocked
posi ti on, di sengage l ock tab hol di ng cabl e end to
steeri ng col umn (Fi g. 149).
(6) Pul l cabl e end from steeri ng col umn.
(7) Remove the fl oor consol e and rel ated tri m.
(Refer to 23 - BODY/I NTERI OR/FLOOR CONSOLE -
REMOVAL)
(8) Di sconnect the cabl e from the bel l crank (Fi g.
150).
(9) Di sconnect and remove the cabl e from the shi ft
bracket.
INSTALLATION
(1) Route repl acement cabl e behi nd i nstrument
panel and under fl oor consol e area to shi ft mecha-
ni sm.
(2) I nsert cabl e end i nto openi ng i n steeri ng col -
umn hub under i gni ti on l ock. Push cabl e i nward
unti l l ock tab engages.
(3) I nsert the cabl e end i nto the shi fter bel l crank.
(4) Pl ace gear sel ector i n PARK.
(5) Push the spri ng-l oaded cabl e adjuster forward
and snap cabl e i nto bracket.
(6) Adjust the brake transmi ssi on shi fter i nterl ock
cabl e.
(7) Veri fy that the cabl e adjuster l ock cl amp i s
pushed downward to the l ocked posi ti on.
(8) Test the park-l ock cabl e operati on.
(9) I nstal l the fl oor consol e and rel ated tri m.
(10) I nstal l ti e strap to hol d cabl e to base of steer-
i ng col umn.
(11) I nstal l l ower steeri ng col umn shroud and i gni -
ti on l ock.
(12) I nstal l l ower steeri ng col umn cover.
ADJ USTMENTS
ADJUSTMENT - BRAKE TRANSMISSION SHIFT
INTERLOCK CABLE
(1) Shi ft transmi ssi on i nto PARK.
(2) Remove shi ft l ever bezel and consol e screws.
Rai se bezel and consol e for access to cabl e.
(3) Pul l cabl e l ock button up to rel ease cabl e.
(4) Turn i gni ti on swi tch to LOCK posi ti on.
(5) Use a spacer to create a one mi l l i meter gap
between the shi fter pawl and top of the shi ft gate.
Fig. 148 Ignition Key Cylinder Actuation
1 - SLIDER LOCKED
2 - CAM RETURN SPRING
3 - INTERLOCK CABLE
4 - CAM
5 - SLIDER
Fig. 149 Brake/Park Interlock Cable
1 - IGNITION LOCK
2 - LOCK TAB
3 - CABLE END
21 - 140 AUTOMATIC TRANSMISSION - 42RLE TJ
BRAKE TRANSMISSION SHIFT INTERLOCK MECHANISM (Continued)
(6) Pul l the cabl e forward and rel ease.Ensure the
cabl e end i s seated i n the bel l crank and press cabl e
l ock button down unti l i t snaps i n pl ace.
(7) Check adjustment as fol l ows:
(a) Check movement of rel ease shi ft handl e but-
ton (fl oor shi ft) or rel ease l ever (col umn shi ft). You
shoul d not be abl e to press button i nward or move
col umn l ever.
(b) Turn i gni ti on swi tch to RUN posi ti on.
(c) Shi fti ng out of park shoul d not be possi bl e.
(d) Appl y the brake and attempt to shi ft out of
PARK. Shi fti ng shoul d be possi bl e.
(e) Whi l e the transmi ssi on i s shi fted out of
PARK, rel ease the brake and attempt to shi ft
through al l gears. Rel ease the shi ft button at l east
once duri ng thi s procedure. The i gni ti on key shoul d
not go to the LOCK posi ti on.
(f) Return transmi ssi on to the PARK posi ti on
wi thout appl yi ng the brake.
(8) Move shi ft l ever back to PARK and check i gni -
ti on swi tch operati on. You shoul d be abl e to turn
swi tch to LOCK posi ti on and shi ft l ever rel ease but-
ton/l ever shoul d not move.
Fig. 150 Cable and Shifter
1 - SHIFT MECHANISM 5 - SOLENOID
2 - LOCK-TAB 6 - WIRE CONNECTOR
3 - IGNITION LOCK INTERLOCK 7 - TIE STRAP
4 - STEERING COLUMN 8 - PARK/BRAKE INTERLOCK CABLE
TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 141
BRAKE TRANSMISSION SHIFT INTERLOCK MECHANISM (Continued)
DRIVING CLUTCHES
DESCRIPTION
Three hydraul i cal l y appl i ed i nput cl utches are used
to dri ve pl anetary components. The underdri ve, over-
dri ve, and reverse cl utches are consi dered i nput
cl utches and are contai ned wi thi n the i nput cl utch
assembl y (Fi g. 151). The i nput cl utch assembl y al so
contai ns:
• I nput shaft
• I nput hub
• Cl utch retai ner
• Underdri ve pi ston
• Overdri ve/reverse pi ston
• Overdri ve hub
• Underdri ve hub
OPERATION
The three i nput cl utches are responsi bl e for dri vi ng
di fferent components of the pl anetary geartrai n.
NOTE: (Refer to 21 - TRANSMISSION/AUTOMATIC -
42RLE - DIAGNOSIS AND TESTING) for a collective
view of which clutch elements are applied at each
position of the selector lever.
UNDERDRIVE CLUTCH
The underdri ve cl utch i s hydraul i cal l y appl i ed i n
fi rst, second, and thi rd (di rect) gears by pressuri zed
fl ui d agai nst the underdri ve pi ston. When the under-
dri ve cl utch i s appl i ed, the underdri ve hub dri ves the
rear sun gear.
OVERDRIVE CLUTCH
The overdri ve cl utch i s hydraul i cal l y appl i ed i n
thi rd (di rect) and overdri ve gears by pressuri zed fl ui d
agai nst the overdri ve/reverse pi ston. When the over-
dri ve cl utch i s appl i ed, the overdri ve hub dri ves the
front pl anet carri er.
REVERSE CLUTCH
The reverse cl utch i s hydraul i cal l y appl i ed i n
reverse gear onl y by pressuri zed fl ui d agai nst the
overdri ve/reverse pi ston. When the reverse cl utch i s
appl i ed, the front sun gear assembl y i s dri ven.
FLUID AND FILTER
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - CAUSES OF
BURNT FLUID
Burnt, di scol ored fl ui d i s a resul t of overheati ng
whi ch has two pri mary causes.
(1) A resul t of restri cted fl ui d fl ow through the mai n
and/or auxi l i ary cool er. Thi s condi ti on i s usual l y the
resul t of a damaged mai n cool er, or severe restri cti ons i n
the cool ers and l i nes caused by debri s or ki nked l i nes.
(2) Heavy duty operati on wi th a vehi cl e not properl y
equi pped for thi s type of operati on. Trai l er towi ng or
si mi l ar hi gh l oad operati on wi l l overheat the transmi s-
si on fl ui d i f the vehi cl e i s i mproperl y equi pped. Such
vehi cl es shoul d have an auxi l i ary transmi ssi on fl ui d
cool er, a heavy duty cool i ng system, and the engi ne/axl e
rati o combi nati on needed to handl e heavy l oads.
DIAGNOSIS AND TESTING - EFFECTS OF
INCORRECT FLUID LEVEL
A l ow fl ui d l evel al l ows the pump to take i n ai r al ong
wi th the fl ui d. Ai r i n the fl ui d wi l l cause fl ui d pressures
to be l ow and devel op sl ower than normal . I f the trans-
mi ssi on i s overfi l l ed, the gears churn the fl ui d i nto
foam. Thi s aerates the fl ui d and causi ng the same con-
di ti ons occurri ng wi th a l ow l evel . I n ei ther case, ai r
bubbl es cause fl ui d overheati ng, oxi dati on and varni sh
bui l dup whi ch i nterferes wi th val ve and cl utch opera-
ti on. Foami ng al so causes fl ui d expansi on whi ch can
resul t i n fl ui d overfl ow from the transmi ssi on vent or
fi l l tube. Fl ui d overfl ow can easi l y be mi staken for a
l eak i f i nspecti on i s not careful .
Fig. 151 Input Clutch Assembly
1 - INPUT SHAFT
2 - UNDERDRIVE CLUTCH
3 - OVERDRIVE CLUTCH
4 - REVERSE CLUTCH
5 - OVERDRIVE SHAFT
6 - UNDERDRIVE SHAFT
21 - 142 AUTOMATIC TRANSMISSION - 42RLE TJ
DIAGNOSIS AND TESTING - FLUID
CONTAMINATION
Transmi ssi on fl ui d contami nati on i s general l y a
resul t of:
• addi ng i ncorrect fl ui d
• fai l ure to cl ean di psti ck and fi l l tube when
checki ng l evel
• engi ne cool ant enteri ng the fl ui d
• i nternal fai l ure that generates debri s
• overheat that generates sl udge (fl ui d break-
down)
• fai l ure to repl ace contami nated converter after
repai r
The use of non-recommended fl ui ds can resul t i n
transmi ssi on fai l ure. The usual resul ts are errati c
shi fts, sl i ppage, abnormal wear and eventual fai l ure
due to fl ui d breakdown and sl udge formati on. Avoi d
thi s condi ti on by usi ng recommended fl ui ds onl y.
The di psti ck cap and fi l l tube shoul d be wi ped
cl ean before checki ng fl ui d l evel . Di rt, grease and
other forei gn materi al on the cap and tube coul d fal l
i nto the tube i f not removed beforehand. Take the
ti me to wi pe the cap and tube cl ean before wi thdraw-
i ng the di psti ck.
Engi ne cool ant i n the transmi ssi on fl ui d i s gener-
al l y caused by a cool er mal functi on. The onl y remedy
i s to repl ace the radi ator as the cool er i n the radi ator
i s not a servi ceabl e part. I f cool ant has ci rcul ated
through the transmi ssi on, an overhaul i s necessary.
The torque converter shoul d be repl aced whenever
a fai l ure generates sl udge and debri s. Thi s i s neces-
sary because normal converter fl ushi ng procedures
wi l l not remove al l contami nants.
STANDARD PROCEDURE
STANDARD PROCEDURE - FLUID LEVEL
CHECK
FLUID LEVEL CHECK
The transmi ssi on sump has a di psti ck to check oi l
si mi l ar to most automati c transmi ssi ons. I t i s l ocated
on the l eft si de of the engi ne. Be sure to wi pe al l di rt
from di psti ck handl e before removi ng.
The torque converter fi l l s i n both the PARK and
NEUTRAL posi ti ons. Pl ace the sel ector l ever i n
PARK to be sure that the fl ui d l evel check i s accu-
rate. The engine should be running at idle
speed for at least one minute, with the vehicle
on level ground. At normal operati ng temperature
(approxi matel y 82 C. or 180 F.), the fl ui d l evel i s cor-
rect i f i t i s i n the HOT regi on (cross-hatched area) on
the oi l l evel i ndi cator. The fl ui d l evel shoul d be i n
COLD regi on at 70° F fl ui d temperature. Adjust fl ui d
l evel as necessary. Use onl y Mopar௡ ATF+4, Auto-
mati c Transmi ssi on Fl ui d.
FLUID LEVEL CHECK USING DRB
NOTE: Engine and Transmission should be at nor-
mal operating temperature before performing this
procedure.
(1) Start engi ne and appl y parki ng brake.
(2) Connect DRBI I I ௡ scan tool and sel ect transmi s-
si on.
(3) Sel ect sensors.
(4) Read the transmi ssi on temperature val ue.
(5) Compare the fl ui d temperature val ue wi th the
chart.
(6) Adjust transmi ssi on fl ui d l evel shown on the
di psti ck accordi ng to the chart (Fi g. 152). Use onl y
Mopar௡ ATF+4, Automati c Transmi ssi on Fl ui d.
(7) Check transmi ssi on for l eaks.
STANDARD PROCEDURE - FLUID/FILTER
SERVICE
NOTE: Only fluids of the type labeled Moparா
ATF+4, Automatic Transmission Fluid, should be
used in the transmission sump. A filter change
should be made at the time of the transmission oil
change. The magnet (on the inside of the oil pan)
should also be cleaned with a clean, dry cloth.
NOTE: If the transmission is disassembled for any
reason, the fluid and filter should be changed.
(1) Rai se vehi cl e on a hoi st. Pl ace a drai n con-
tai ner wi th a l arge openi ng, under transmi ssi on oi l
pan.
NOTE: One of the oil pan bolts has a sealing patch
applied from the factory. Seperate this bolt for
reuse.
(2) Loosen pan bol ts and tap the pan at one corner
to break i t l oose al l owi ng fl ui d to drai n, then remove
the oi l pan.
(3) I nstal l a new fi l ter and o-ri ng on bottom of the
val ve body and ti ghten retai ni ng screws to 5 N·m (40
i n. l bs.).
NOTE: Before installing the oil pan bolt in the bolt
hole located between the torque converter clutch
on and U/D clutch pressure tap circuits (Fig. 153), it
will be necessary to replentish the sealing patch on
the bolt using Moparா Lock & Seal Adhesive.
TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 143
FLUID AND FILTER (Continued)
(4) Cl ean the oi l pan and magnet. Rei nstal l pan
usi ng new Mopar௡ Si l i cone Adhesi ve seal ant. Ti ghten
oi l pan bol ts to 19 N·m (165 i n. l bs.).
(5) Pour four quarts of Mopar௡ ATF+4, Automati c
Transmi ssi on Fl ui d, through the di psti ck openi ng.
(6) Start engi ne and al l ow to i dl e for at l east one
mi nute. Then, wi th parki ng and servi ce brakes
appl i ed, move sel ector l ever momentari l y to each
posi ti on, endi ng i n the park or neutral posi ti on.
(7) Check the transmi ssi on fl ui d l evel and add an
appropri ate amount to bri ng the transmi ssi on fl ui d
l evel to 3mm (1/8 i n.) bel ow the l owest mark on the
di psti ck.
(8) Recheck the fl ui d l evel after the transmi ssi on
has reached normal operati ng temperature (180°F.).
(9) To prevent di rt from enteri ng transmi ssi on,
make certai n that di psti ck i s ful l y seated i nto the
di psti ck openi ng.
STANDARD PROCEDURE - TRANSMISSION
FILL
To avoi d overfi l l i ng transmi ssi on after a fl ui d
change or overhaul , perform the fol l owi ng procedure:
(1) Remove di psti ck and i nsert cl ean funnel i n
transmi ssi on fi l l tube.
(2) Add fol l owi ng i ni ti al quanti ty of Mopar௡ ATF
+4, Automati c Transmi ssi on Fl ui d, to transmi ssi on:
(a) I f onl y fl ui d and fi l ter were changed, add 6
pints (3 quarts) of ATF +4 to transmi ssi on.
(b) I f transmi ssi on was compl etel y overhaul ed,
or torque converter was repl aced or drai ned, add
10 pints (5 quarts) of ATF +4 to transmi ssi on.
(3) Appl y parki ng brakes.
(4) Start and run engi ne at normal curb i dl e
speed.
Fig. 152 42RLE Fluid Temperature Chart
Fig. 153 Pan Fastener
1 - FRONT DRIVESHAFT
2 - PRESSURE PORTS
3 - TRANSMISSION CASE
4 - TRANSMISSION OIL PAN
5 - SECOND TRANSMISSION OIL PAN BOLT ON LEFT SIDE
6 - FIRST TRANSMISSION OIL PAN BOLT
21 - 144 AUTOMATIC TRANSMISSION - 42RLE TJ
FLUID AND FILTER (Continued)
(5) Appl y servi ce brakes, shi ft transmi ssi on
through al l gear ranges then back to NEUTRAL, set
parki ng brake, and l eave engi ne runni ng at curb i dl e
speed.
(6) Remove funnel , i nsert di psti ck and check fl ui d
l evel . I f l evel i s l ow, add fluid to bring level to
MIN mark on dipstick. Check to see i f the oi l l evel
i s equal on both si des of the di psti ck. I f one si de i s
noti cabl y hi gher than the other, the di psti ck has
pi cked up some oi l from the di psti ck tube. Al l ow the
oi l to drai n down the di psti ck tube and re-check.
(7) Dri ve vehi cl e unti l transmi ssi on fl ui d i s at nor-
mal operati ng temperature.
(8) Wi th the engi ne runni ng at curb i dl e speed, the
gear sel ector i n NEUTRAL, and the parki ng brake
appl i ed, check the transmi ssi on fl ui d l evel .
CAUTION: Do not overfill transmission, fluid foam-
ing and shifting problems can result.
(9) Add fl ui d to bri ng l evel up to MAX arrow
mark.
When fl ui d l evel i s correct, shut engi ne off, rel ease
park brake, remove funnel , and i nstal l di psti ck i n fi l l
tube.
GEARSHIFT CABLE
REMOVAL
(1) Shi ft transmi ssi on i nto PARK.
(2) Remove shi ft l ever bezel and necessary consol e
parts for access to shi ft l ever assembl y. (Refer to 23 -
BODY/I NTERI OR/FLOOR CONSOLE - REMOVAL)
(3) Di sconnect cabl e at shi ft l ever (Fi g. 154) and
feed cabl e through dash panel openi ng to undersi de
of vehi cl e.
(4) Rai se vehi cl e.
(5) Di sengage cabl e eyel et at transmi ssi on shi ft
l ever and removel cabl e from the mounti ng bracket.
Then remove ol d cabl e from vehi cl e.
INSTALLATION
(1) Route cabl e through hol e i n dash panel . Ful l y
seat cabl e grommet i nto dash panel .
(2) Pl ace the auto transmi ssi on manual shi ft con-
trol l ever i n “PARK” detent (rearmost) posi ti on and
rotate prop shaft to ensure transmi ssi on i s i n PARK.
(3) Snap the cabl e i nto the transmi ssi on bracket so
the retai ni ng cl i p i s engaged and connect cabl e end
fi tti ng onto the manual control l ever bal l stud.
Fig. 154 Shifter Cable Routing
1 - SHIFT MECHANISM 7 - MANUAL LEVER
2 - LOCK-TAB 8 - CABLE BRACKET
3 - IGNITION LOCK INTERLOCK 9 - SHIFTER CABLE
4 - STEERING COLUMN 10 - BELLHOUSING
5 - SOLENOID 11 - TIE STRAP
6 - WIRE CONNECTOR 12 - PARK/BRAKE INTERLOCK CABLE
TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 145
FLUID AND FILTER (Continued)
(4) Pl ace the fl oor shi fter l ever i n PARK posi ti on.
(5) Connect shi ft cabl e to shi fter mechani sm by
snappi ng cabl e retai ni ng ears i nto shi fter bracket
and press cabl e end fi tti ng onto l ever bal l stud.
(6) Snap the cabl e i nto the transmi ssi on bracket so
the retai ni ng ears are engaged and connect cabl e end
fi tti ng onto the manual control l ever bal l stud.
(7) Adjust the shi ft mechani sm.
(8) I nstal l any fl oor consol e components removed
previ ousl y. (Refer to 23 - BODY/I NTERI OR/FLOOR
CONSOLE - I NSTALLATI ON)
HOLDING CLUTCHES
DESCRIPTION
Two hydraul i cal l y appl i ed mul ti -di sc cl utches are
used to hol d pl anetary geartrai n components stati on-
ary whi l e the i nput cl utches dri ve others. The 2/4
and Low/Reverse cl utches are consi dered hol di ng
cl utches and are contai ned at the rear of the trans-
mi ssi on case (Fi g. 155).
OPERATION
NOTE: (Refer to 21 - TRANSMISSION/AUTOMATIC -
42RLE - DIAGNOSIS AND TESTING) for a collective
view of which clutch elements are applied at each
position of the selector lever.
2/4 CLUTCH
The 2/4 cl utch i s hydraul i cal l y appl i ed i n second
and fourth gears by pressuri zed fl ui d agai nst the 2/4
cl utch pi ston. When the 2/4 cl utch i s appl i ed, the
front sun gear assembl y i s hel d or grounded to the
transmi ssi on case.
LOW/REVERSE CLUTCH
The Low/Reverse cl utch i s hydraul i cal l y appl i ed i n
park, reverse, neutral , and fi rst gears by pressuri zed
fl ui d agai nst the Low/Reverse cl utch pi ston. When
the Low/Reverse cl utch i s appl i ed, the front pl anet
carri er/rear annul us assembl y i s hel d or grounded to
the transmi ssi on case.
INPUT CLUTCH ASSEMBLY
DISASSEMBLY
(1) Mount i nput cl utch assembl y to I nput Cl utch
Pressure Fi xture (Tool 8391).
(2) Tap down reverse cl utch reacti on pl ate to
rel ease pressure from snap ri ng (Fi g. 156).
Fig. 155 2/4 and Low/Reverse Clutches
1 - FRONT PLANET CARRIER/REAR ANNULUS
2 - 2/4 CLUTCH
3 - L/R CLUTCH
4 - REAR PLANET CARRIER/FRONT ANNULUS
5 - REAR SUN GEAR
6 - FRONT SUN GEAR ASSEMBLY
Fig. 156 Tapping Reaction Plate
1 - #4 THRUST PLATE (SELECT)
2 - TAP DOWN REVERSE CLUTCH REACTION PLATE TO
REMOVE OR INSTALL SNAP RING
3 - INPUT CLUTCH RETAINER
4 - REVERSE CLUTCH REACTION PLATE
21 - 146 AUTOMATIC TRANSMISSION - 42RLE TJ
GEARSHIFT CABLE (Continued)
(3) Remove reverse cl utch snap ri ng (Fi g. 157).
(4) Pry up and remove reverse cl utch reacti on
pl ate (Fi g. 158) (Fi g. 159).
(5) Remove the reverse cl utch pack (two fi bers/one
steel ) (Fi g. 160).
NOTE: Tag reverse clutch pack for reassembly iden-
tification.
Fig. 157 Reverse Clutch Snap Ring
1 - REACTION PLATE
2 - SCREWDRIVER
3 - REVERSE CLUTCH SNAP RING (SELECT)
Fig. 158 Pry Reverse Clutch Reaction Plate
1 - REVERSE CLUTCH REACTION PLATE
2 - SCREWDRIVER
3 - SCREWDRIVER
Fig. 159 Reverse Clutch Reaction Plate
1 - REVERSE CLUTCH REACTION PLATE (INSTALL FLAT SIDE
DOWN)
Fig. 160 Reverse Clutch Pack
1 - REVERSE CLUTCH PLATE
2 - REVERSE CLUTCH DISC
TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 147
INPUT CLUTCH ASSEMBLY (Continued)
(6) Remove the OD/Reverse reacti on pl ate snap
ri ng (Fi g. 161).
(7) Remove OD/Reverse pressure pl ate (Fi g. 162).
(8) Remove OD/Reverse reacti on pl ate wave snap
ri ng (Fi g. 163).
(9) Remove OD shaft/hub and OD cl utch pack (Fi g.
164), (Fi g. 165).
NOTE: Tag overdrive clutch pack for reassembly
identification.
Fig. 161 OD/Reverse Pressure Plate Snap Ring
1 - OD/REVERSE PRESSURE PLATE
2 - SCREWDRIVER
3 - OD/REVERSE PRESSURE PLATE SNAP RING
Fig. 162 OD/Reverse Reaction Plate
1 - OD/REVERSE PRESSURE PLATE (STEP SIDE DOWN)
2 - (STEP SIDE DOWN)
Fig. 163 Waved Snap Ring
1 - OVERDRIVE SHAFT ASSEMBLY
2 - OD/REVERSE CLUTCH WAVED SNAP RING
3 - SCREWDRIVER
Fig. 164 Remove OD Clutch Pack
1 - OVERDRIVE SHAFT ASSEMBLY AND OD CLUTCH PACK
2 - #3 THRUST PLATE
3 - #3 THRUST WASHER
4 - UNDERDRIVE SHAFT ASSEMBLY
21 - 148 AUTOMATIC TRANSMISSION - 42RLE TJ
INPUT CLUTCH ASSEMBLY (Continued)
(10) Remove and i nspect #3 & #4 thrust washers
(Fi g. 166).
(11) Remove the underdri ve shaft assembl y (Fi g.
167).
(12) Remove the #2 needl e beari ng (Fi g. 168).
Fig. 165 Overdrive Clutch Pack
1 - OVERDRIVE CLUTCH PLATE
2 - OVERDRIVE SHAFT ASSEMBLY
3 - OVERDRIVE CLUTCH DISC
Fig. 166 #3 and #4 Thrust Washers
1 - #3 THRUST PLATE (3 TABS)
2 - OD SHAFT ASSEMBLY
3 - #4 THRUST PLATE (3 SLOTS)
Fig. 167 Underdrive Shaft Assembly
1 - #3 THRUST WASHER (5 TABS)
2 - UNDERDRIVE SHAFT ASSEMBLY
Fig. 168 No 2 Needle Bearing
1 - #2 NEEDLE BEARING (NOTE 3 TABS)
TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 149
INPUT CLUTCH ASSEMBLY (Continued)
(13) Remove the OD/UD reacti on pl ate tapered
snap ri ng (Fi g. 169).
NOTE: The OD/UD clutch reaction plate has a step
on both sides. The OD/UD clutches reaction plate
goes tapered step side up.
(14) Remove the OD/UD reacti on pl ate (Fi g. 170).
(15) Remove the fi rst UD cl utch di sc (Fi g. 171).
(16) Remove the UD cl utch fl at snap ri ng (Fi g.
172).
NOTE: Tag underdrive clutch pack for reassembly
identification.
Fig. 169 Tapered Snap Ring
1 - OVERDRIVE/UNDERDRIVE CLUTCHES REACTION PLATE
TAPERED SNAP RING
2 - SCREWDRIVER (DO NOT SCRATCH REACTION PLATE)
Fig. 170 OD/UD Reaction Plate
1 - OD/UD CLUTCH REACTION PLATE (STEP SIDE DOWN)
Fig. 171 Remove Last UD Clutch Disc
1 - ONE UNDERDRIVE CLUTCH DISC
Fig. 172 UD Clutch Flat Snap Ring
1 - UNDERDRIVE CLUTCH REACTION PLATE FLAT SNAP RING
2 - SCREWDRIVER
21 - 150 AUTOMATIC TRANSMISSION - 42RLE TJ
INPUT CLUTCH ASSEMBLY (Continued)
(17) Remove the UD cl utch pack (Fi g. 173).
CAUTION: Compress return spring just enough to
remove or install snap ring.
(18) Usi ng Tool 5059A and an arbor press, com-
press UD cl utch pi ston enough to remove snap ri ng
(Fi g. 174), (Fi g. 175).
(19) Remove spri ng retai ner (Fi g. 175).
(20) Remove UD cl utch pi ston (Fi g. 176).
Fig. 173 Underdrive Clutch Pack
1 - CLUTCH PLATE
2 - ONE UD CLUTCH DISC
3 - CLUTCH DISC
Fig. 174 UD Spring Retainer Snap Ring
1 - SNAP RING PLIERS
2 - ARBOR PRESS RAM
3 - SNAP RING
4 - SPECIAL TOOL 5059A
Fig. 175 UD Return Spring and Retainer
1 - UNDERDRIVE SPRING RETAINER
2 - SNAP RING
3 - SEAL
4 - PISTON RETURN SPRING
Fig. 176 Underdrive Clutch Piston
1 - PISTON
TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 151
INPUT CLUTCH ASSEMBLY (Continued)
(21) Remove i nput hub tapered snap ri ng (Fi g.
177).
(22) Tap on i nput hub wi th soft faced hammer and
separate i nput hub from OD/Reverse pi ston and
cl utch retai ner (Fi g. 178), (Fi g. 179).
(23) Separate cl utch retai ner from OD/Reverse pi s-
ton (Fi g. 180).
Fig. 177 Input Hub Tapered Snap Ring
1 - INPUT SHAFT
2 - INPUT HUB SNAP RING (TAPERED SIDE UP WITH TABS IN
CAVITY)
3 - SNAP RING PLIERS
Fig. 178 Tap on Input Hub
1 - INPUT SHAFT AND HUB ASSEMBLY
2 - PLASTIC HAMMER
Fig. 179 Input Hub Removed
1 - INPUT SHAFT AND HUB ASSEMBLY
2 - INPUT CLUTCH RETAINER
3 - O-RING
4 - SEAL
5 - OVERDRIVE/REVERSE PISTON
Fig. 180 Pull Retainer from Piston
1 - OVERDRIVE/REVERSE PISTON
2 - INPUT CLUTCH RETAINER
21 - 152 AUTOMATIC TRANSMISSION - 42RLE TJ
INPUT CLUTCH ASSEMBLY (Continued)
(24) Usi ng Tool 6057 and an arbor press, compress
return OD/Reverse pi ston return spri ng just enough
to remove snap ri ng (Fi g. 181), (Fi g. 182).
(25) Remove i nput shaft to i nput cl utch hub snap
ri ng (Fi g. 183).
(26) Usi ng a sui tabl y si zed socket and an arbor
press, remove i nput shaft from i nput shaft hub (Fi g.
184).
Fig. 181 Remove Snap Ring
1 - ARBOR PRESS RAM (COMPRESS RETURN SPRING JUST
ENOUGH TO REMOVE OR INSTALL SNAP RING)
2 - SCREWDRIVER
3 - SNAP RING
4 - SPECIAL TOOL 6057
5 - OD/REVERSE PISTON
6 - RETURN SPRING
Fig. 182 Return Spring and Snap Ring
1 - OD/REVERSE PISTON
2 - RETURN SPRING
3 - SNAP RING
4 - O-RING
Fig. 183 Remove Input Shaft Snap Ring
1 - INPUT SHAFT
2 - SHARP-POINTED TOOL
3 - SNAP RING
4 - O-RINGS
5 - SEALS
Fig. 184 Remove Input Shaft
1 - ARBOR PRESS RAM
2 - SOCKET
3 - SEAL
4 - O-RINGS
5 - INPUT SHAFT
6 - SEAL
7 - INPUT CLUTCH HUB
TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 153
INPUT CLUTCH ASSEMBLY (Continued)
ASSEMBLY
Use petrol atum on al l seal s to ease assembl y of
components.
(1) Usi ng an arbor press, i nstal l i nput shaft to
i nput shaft hub (Fi g. 185).
(2) I nstal l i nput shaft snap ri ng (Fi g. 186).
(3) Usi ng an arbor press and Tool 6057, I nstal l
OD/Reverse pi ston return spri ng and snap ri ng (Fi g.
187), (Fi g. 188).
Fig. 185 Install Input Shaft
1 - INPUT SHAFT
2 - ARBOR PRESS RAM
3 - INPUT CLUTCH HUB
Fig. 186 Install Input Shaft Snap Ring
1 - INPUT SHAFT
2 - SCREWDRIVER (DO NOT SCRATCH BEARING SURFACE)
3 - SNAP RING
4 - O-RINGS
5 - SEALS
Fig. 187 Return Spring and Snap Ring
1 - OD/REVERSE PISTON
2 - RETURN SPRING
3 - SNAP RING
4 - O-RING
Fig. 188 Install Snap Ring
1 - ARBOR PRESS RAM (COMPRESS RETURN SPRING JUST
ENOUGH TO REMOVE OR INSTALL SNAP RING)
2 - SCREWDRIVER
3 - SNAP RING
4 - SPECIAL TOOL 6057
5 - OD/REVERSE PISTON
6 - RETURN SPRING
21 - 154 AUTOMATIC TRANSMISSION - 42RLE TJ
INPUT CLUTCH ASSEMBLY (Continued)
(4) I nstal l the OD/Reverse pi ston assembl y to the
i nput cl utch retai ner as shown i n (Fi g. 189).
(5) I nstal l the i nput hub/shaft assembl y to the
OD/Reverse pi ston/cl utch retai ner assembl y (Fi g.
190).
(6) I nstal l i nput hub tapered snap ri ng (Fi g. 191).
Make sure snap ring is fully seated.
(7) I nstal l UD cl utch pi ston (Fi g. 192).
Fig. 189 Install OD/Reverse Piston
1 - PUSH DOWN TO INSTALL OVERDRIVE/REVERSE PISTON
2 - INPUT CLUTCHES RETAINER
Fig. 190 Install Input Shaft Hub Assembly
1 - PUSH DOWN TO INSTALL INPUT SHAFT HUB ASSEMBLY
(ROTATE TO ALIGN SPLINES)
2 - OD/REV. PISTON
Fig. 191 Install Input Hub Tapered Snap Ring
1 - INPUT SHAFT
2 - INPUT HUB SNAP RING (TAPERED SIDE UP WITH TABS IN
CAVITY)
3 - SNAP RING PLIERS
Fig. 192 Underdrive Clutch Piston
1 - PISTON
TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 155
INPUT CLUTCH ASSEMBLY (Continued)
(8) I nstal l UD pi ston return spri ng and Tool 5067
as shown i n (Fi g. 193).
(9) Usi ng Tool 5059A and an arbor press, i nstal l
the UD spri ng retai ner and snap ri ng. (Fi g. 194),
(Fi g. 195) Compress just enough to i nstal l snap ri ng.
CAUTION: Compress return spring just enough to
install snap ring.
(10) I nstal l the UD cl utch pack (four fi bers/four
steel s) (Fi g. 196). Leave the top di sc out unti l after
the snap ri ng i s i nstal l ed.
Fig. 193 Seal Compressor Special Tool 5067
1 - PISTON RETURN SPRING
2 - SPECIAL TOOL 5067
3 - INPUT CLUTCH RETAINER
Fig. 194 UD Return Spring and Retainer
1 - UNDERDRIVE SPRING RETAINER
2 - SNAP RING
3 - SEAL
4 - PISTON RETURN SPRING
Fig. 195 Install UD Spring Retainer and Snap Ring
1 - ARBOR PRESS RAM
2 - SNAP RING PLIERS
3 - SNAP RING
4 - OD/REVERSE PISTON
5 - TOOL 5067
6 - TOOL 5059A
Fig. 196 Underdrive Clutch Pack
1 - CLUTCH PLATE
2 - ONE UD CLUTCH DISC
3 - CLUTCH DISC
21 - 156 AUTOMATIC TRANSMISSION - 42RLE TJ
INPUT CLUTCH ASSEMBLY (Continued)
(11) I nstal l the UD cl utch fl at snap ri ng (Fi g. 197).
(12) I nstal l the l ast UD cl utch di sc (Fi g. 198).
(13) I nstal l the OD/UD cl utch reacti on pl ate and
snap ri ng (Fi g. 199), (Fi g. 200). The OD/UD cl utches
reacti on pl ate has a step on both si des. I nstal l the
OD/UD cl utches reacti on pl ate tapered step si de up.
NOTE: Snap ring ends must be located within one
finger of the input clutch hub. Be sure that snap
ring is fully seated, by pushing with screwdriver,
into snap ring groove all the way around.
Fig. 197 UD Clutch Flat Snap Ring
1 - UNDERDRIVE CLUTCH REACTION PLATE FLAT SNAP RING
2 - SCREWDRIVER
Fig. 198 Install Last UD Clutch Disc
1 - ONE UNDERDRIVE CLUTCH DISC
Fig. 199 OD/UD Reaction Plate
1 - OD/UD CLUTCH REACTION PLATE (STEP SIDE DOWN)
Fig. 200 Tapered Snap Ring
1 - OVERDRIVE/UNDERDRIVE CLUTCHES REACTION PLATE
TAPERED SNAP RING
2 - SCREWDRIVER (DO NOT SCRATCH REACTION PLATE)
TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 157
INPUT CLUTCH ASSEMBLY (Continued)
(14) Seat tapered snap ri ng to ensure proper
i nstal l ati on (Fi g. 201).
(15) I nstal l i nput cl utch assembl y to the I nput
Cl utch Pressure Fi xture - Tool 8391 (Fi g. 202).
(16) Set up di al i ndi cator on the UD cl utch pack as
shown i n (Fi g. 203).
(17) Usi ng moderate pressure, press down and
hol d (near i ndi cator) the UD cl utch pack wi th screw-
dri ver or sui tabl e tool and zero di al i ndi cator (Fi g.
204). When rel easi ng pressure on cl utch pack, i ndi ca-
tor readi ng shoul d advance 0.005–0.010.
Fig. 201 Seating Tapered Snap Ring
1 - OVERDRIVE/UNDERDRIVE CLUTCHES REACTION PLATE
TAPERED SNAP RING
2 - SCREWDRIVER
Fig. 202 Input Clutch Assembly on Pressure Fixture
Tool - 8391
1 - INPUT CLUTCH ASSEMBLY
2 - INPUT CLUTCH PRESSURE FIXTURE - 8391
Fig. 203 Set Up Dial Indicator to Measure UD Clutch
Clearance
1 - DIAL INDICATOR
2 - UNDERDRIVE CLUTCH
Fig. 204 Press Down on UD Clutch Pack and Zero
Dial Indicator
1 - DIAL INDICATOR
2 - UNDERDRIVE CLUTCH
21 - 158 AUTOMATIC TRANSMISSION - 42RLE TJ
INPUT CLUTCH ASSEMBLY (Continued)
CAUTION: Do not apply more than 30 psi (206 kPa)
to the underdrive clutch pack.
(18) Appl y 30 psi (206 kPa) to the underdri ve hose
on Tool 8391 and measure UD cl utch cl earance. Mea-
sure and record UD cl utch pack measurement i n four
(4) pl aces, 90° apart.
(19) Take average of four measurements and com-
pare wi th UD cl utch pack cl earance speci fi cati on.
Underdrive clutch pack clearance must be 0.94-
1.50 mm (0.037-0.059 in.).
(20) I f necessary, sel ect the proper reacti on pl ate
to achi eve speci fi cati ons:
(21) I nstal l the OD cl utch pack (four fi bers/three
steel s) (Fi g. 205).
(22) I nstal l OD reacti on pl ate waved snap ri ng
(Fi g. 206).
(23) I nstal l the OD/Reverse reacti on pl ate wi th
l arge step down (towards OD cl utch pack) (Fi g. 207).
(24) I nstal l OD reacti on pl ate fl at snap ri ng (Fi g.
208).
Fig. 205 Install OD Clutch Pack
1 - OVERDRIVE CLUTCH PACK
Fig. 206 Install Waved Snap Ring
1 - OVERDRIVE REACTION PLATE WAVED SNAP RING
2 - SCREWDRIVER
Fig. 207 OD/Reverse Reaction Plate
1 - OVERDRIVE/REVERSE PRESSURE PLATE
2 - (STEP SIDE DOWN)
Fig. 208 Install Flat Snap Ring
1 - ARBOR PRESS RAM
2 - TOOL 5059A
3 - FLAT SNAP RING
TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 159
INPUT CLUTCH ASSEMBLY (Continued)
(25) Measure OD cl utch pack cl earance. Set up
di al i ndi cator on top of the OD/Reverse reacti on pl ate
as shown i n (Fi g. 209).
(26) Zero di al i ndi cator and appl y 30 psi (206 kPa)
ai r pressure to the overdri ve cl utch hose on Tool
8391. Measure and record OD cl utch pack measure-
ment i n four (4) pl aces, 90° apart.
(27) Take average of four measurements and com-
pare wi th OD cl utch pack cl earance speci fi cati on.
The overdrive (OD) clutch pack clearance is
1.07-3.25 mm (0.042-0.128 in.).
I f not wi thi n speci fi cati ons, the cl utch i s not
assembl ed properl y. There i s no adjustment for the
OD cl utch cl earance.
(28) I nstal l reverse cl utch pack (two fi bers/one
steel ) (Fi g. 210).
(29) I nstal l reverse cl utch reacti on pl ate wi th the
fl at si de down towards reverse cl utch (Fi g. 211).
(30) Tap reacti on pl ate down to al l ow i nstal l ati on
of the reverse cl utch snap ri ng. I nstal l reverse cl utch
snap ri ng (Fi g. 212).
Fig. 209 Measure OD Clutch Pack Clearance
1 - DIAL INDICATOR
2 - OD/REVERSE PRESSURE PLATE
Fig. 210 Install Reverse Clutch Pack
1 - REVERSE CLUTCH PLATE
2 - REVERSE CLUTCH DISCS
Fig. 211 Install Reaction Plate
1 - REVERSE CLUTCH REACTION PLATE (FLAT SIDE DOWN)
Fig. 212 Install Reverse Clutch Snap Ring
1 - REVERSE CLUTCH SNAP RING (SELECT)
2 - SCREWDRIVER
3 - REVERSE CLUTCH REACTION PLATE
21 - 160 AUTOMATIC TRANSMISSION - 42RLE TJ
INPUT CLUTCH ASSEMBLY (Continued)
(31) Pry up reverse reacti on pl ate to seat agai nst
snap ri ng (Fi g. 213).
(32) Set up a di al i ndi cator on the reverse cl utch
pack as shown i n (Fi g. 214).
(33) Usi ng moderate pressure, press down and
hol d (near i ndi cator) reverse cl utch di sc wi th screw-
dri ver or sui tabl e tool and zero di al i ndi cator (Fi g.
215). When rel easi ng pressure, i ndi cator shoul d
advance 0.005-0.010. as cl utch pack rel axes.
(34) Appl y 30 psi (206 kPa) ai r pressure to the
reverse cl utch hose on Tool 8391. Measure and record
reverse cl utch pack measurement i n four (4) pl aces,
90° apart.
(35) Take average of four measurements and com-
pare wi th reverse cl utch pack cl earance speci fi cati on.
The reverse clutch pack clearance is 0.89-1.37
mm (0.035-0.054 in.). Sel ect the proper reverse
cl utch snap ri ng to achi eve speci fi cati ons:
(36) To compl ete the assembl y, reverse cl utch and
overdri ve cl utch must be removed.
Fig. 213 Pry Up Reaction Plate
1 - SCREWDRIVER
2 - SNAP RING
3 - SCREWDRIVER
4 - MUST RAISE REVERSE REACTION PLATE TO RAISE SNAP
RING
Fig. 214 Measure Reverse Clutch Pack Clearance
1 - DIAL INDICATOR
2 - REVERSE CLUTCH
Fig. 215 Press Down on Reverse Clutch and Zero
Indicator
1 - DIAL INDICATOR
2 - REVERSE CLUTCH
TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 161
INPUT CLUTCH ASSEMBLY (Continued)
(37) I nstal l the #2 needl e beari ng (Fi g. 216).
(38) I nstal l the underdri ve shaft assembl y (Fi g.
217).
(39) I nstal l the #3 thrust washer to the underdri ve
shaft assembl y. Be sure fi ve tabs are seated properl y
(Fi g. 218).
(40) I nstal l the #3 thrust pl ate to the bottom of the
overdri ve shaft assembl y. Retai n wi th petrol atum or
transmi ssi on assembl y gel (Fi g. 219).
Fig. 216 Install No. 2 Needle Bearing
1 - #2 NEEDLE BEARING (NOTE 3 SMALL TABS)
2 - TABS UP
Fig. 217 Install Underdrive Shaft Assembly
1 - UNDERDRIVE SHAFT ASSEMBLY
2 - #2 NEEDLE BEARING
Fig. 218 Install No. 3 Thrust Washer
1 - #3 THRUST WASHER (NOTE 5 TABS)
2 - UNDERDRIVE SHAFT ASSEMBLY
Fig. 219 Install No. 3 Thrust Plate
1 - OVERDRIVE SHAFT ASSEMBLY
2 - DABS OF PETROLATUM (FOR RETENTION)
3 - #3 THRUST PLATE (NOTE 3 TABS)
21 - 162 AUTOMATIC TRANSMISSION - 42RLE TJ
INPUT CLUTCH ASSEMBLY (Continued)
(41) I nstal l the overdri ve shaft assembl y (Fi g.
220).
(42) Rei nstal l overdri ve and reverse cl utch as
shown (Fi g. 221). Rechecking these clutch clear-
ances is not necessary.
INPUT SPEED SENSOR
DESCRIPTION
The I nput and Output Speed Sensors (Fi g. 222) are
two-wi re magneti c pi ckup devi ces that generate AC
si gnal s as rotati on occurs. They are mounted i n the
l eft si de of the transmi ssi on case and are consi dered
pri mary i nputs to the Transmi ssi on Control Modul e
(TCM).
OPERATION
The I nput Speed Sensor provi des i nformati on on
how fast the i nput shaft i s rotati ng. As the teeth of
the i nput cl utch hub pass by the sensor coi l , an AC
vol tage i s generated and sent to the TCM. The TCM
i nterprets thi s i nformati on as i nput shaft rpm.
The Output Speed Sensor generates an AC si gnal
i n a si mi l ar fashi on, though i ts coi l i s exci ted by rota-
ti on of the rear pl anetary carri er l ugs. The TCM
i nterprets thi s i nformati on as output shaft rpm.
The TCM compares the i nput and output speed
si gnal s to determi ne the fol l owi ng:
• Transmi ssi on gear rati o
• Speed rati o error detecti on
• CVI cal cul ati on
The TCM al so compares the i nput speed si gnal and
the engi ne speed si gnal to determi ne the fol l owi ng:
• Torque converter cl utch sl i ppage
• Torque converter el ement speed rati o
REMOVAL
(1) Rai se vehi cl e.
(2) Pl ace a sui tabl e fl ui d catch pan under the
transmi ssi on.
(3) Remove the wi ri ng connector from the i nput
speed sensor (Fi g. 223).
NOTE: The speed sensor bolt has a sealing patch
applied from the factory. Be sure to reuse the same
bolt.
(4) Remove the bol t hol di ng the i nput speed sensor
to the transmi ssi on case.
(5) Remove the i nput speed sensor from the trans-
mi ssi on case.
Fig. 220 Install Overdrive Shaft Assembly
1 - OVERDRIVE SHAFT ASSEMBLY
2 - #3 THRUST PLATE
3 - #3 THRUST WASHER
Fig. 221 Input Clutch Assembly
1 - INPUT CLUTCH ASSEMBLY
2 - OVERDRIVE SHAFT ASSEMBLY
Fig. 222 Input and Output Speed Sensors and
Transmission Range Sensor
1 - INPUT SPEED SENSOR
2 - OUTPUT SPEED SENSOR
3 - TRANSMISSION RANGE SENSOR
TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 163
INPUT CLUTCH ASSEMBLY (Continued)
INSTALLATION
(1) I nstal l the i nput speed sensor i nto the trans-
mi ssi on case.
NOTE: Before installing the speed sensor bolt, it
will be necessary to replentish the sealing patch on
the bolt using Moparா Lock & Seal Adhesive.
(2) I nstal l the bol t to hol d the i nput speed sensor
i nto the transmi ssi on case. Ti ghten the bol t to 9 N·m
(80 i n.l bs.).
(3) I nstal l the wi ri ng connector onto the i nput
speed sensor
(4) Veri fy the transmi ssi on fl ui d l evel . Add fl ui d as
necessary.
(5) Lower vehi cl e.
OIL PUMP
DESCRIPTION
The oi l pump i s l ocated i n the pump housi ng i nsi de
the bel l housi ng of the transmi ssi on case. The oi l
pump assembl y (Fi g. 224) consi sts of an i nner and
outer gear, a housi ng, and a cover that al so serves as
the reacti on shaft support.
OPERATION
As the torque converter rotates, the converter hub
rotates the i nner and outer gears. As the gears
rotate, the cl earance between the gear teeth
i ncreases i n the crescent area, and creates a sucti on
at the i nl et si de of the pump. Thi s sucti on draws
fl ui d through the pump i nl et from the oi l pan. As the
cl earance between the gear teeth i n the crescent area
decreases, i t forces pressuri zed fl ui d i nto the pump
outl et and to the val ve body.
DISASSEMBLY
(1) Remove the reacti on shaft support bol ts.
(2) Remove reacti on shaft support from pump
housi ng (Fi g. 225).
Fig. 223 Input Speed Sensor
1 - INPUT SPEED SENSOR
2 - OUTPUT SPEED SENSOR
3 - TRANSMISSION RANGE SENSOR
Fig. 224 Oil Pump Assembly
1 - PUMP HOUSING
2 - OUTER PUMP GEAR
3 - INNER PUMP GEAR
4 - REACTION SHAFT SUPPORT
5 - SEAL RINGS (4)
6 - REACTION SHAFT
7 - CRESCENT
Fig. 225 Reaction Shaft Support
1 - PUMP HOUSING
2 - REACTION SHAFT SUPPORT
3 - PUMP GEARS
21 - 164 AUTOMATIC TRANSMISSION - 42RLE TJ
INPUT SPEED SENSOR (Continued)
(3) Remove the pump gears (Fi g. 226) and check
for wear and damage on pump housi ng and gears.
(4) Re-i nstal l the gears and check cl earances.
(5) Measure the cl earance between the outer gear
and the pump pocket (Fi g. 227). Cl earance shoul d be
0.089-0.202 mm (0.0035-0.0079 i n.).
(6) Measure cl earance between outer gear and
crescent. Cl earance shoul d be 0.060-0.298 mm
(0.0023-0.0117 i n.).
(7) Measure cl earance between i nner gear and
crescent. Cl earance shoul d be 0.093-0.385 mm
(0.0036-0.0151 i n.).
(8) Posi ti on an appropri ate pi ece of Pl asti gage
across both pump gears.
(9) Al i gn the Pl asti gage to a fl at area on the reac-
ti on shaft support housi ng.
(10) I nstal l the reacti on shaft to the pump hous-
i ng. Ti ghten the bol ts to 27 N·m (20 ft. l bs.).
(11) Remove bol ts and careful l y separate the hous-
i ngs. Measure the Pl asti gage fol l owi ng the i nstruc-
ti ons suppl i ed.
(12) Cl earance between outer gear si de and the
reacti on shaft support shoul d be 0.020-0.046 mm
(0.0008-0.0018 i n.). Cl earance between i nner gear
si de and the reacti on shaft support shoul d be 0.020-
0.046 mm (0.0008-0.0018 i n.).
ASSEMBLY
(1) Assembl e oi l pump as shown i n (Fi g. 228)
(2) I nstal l and torque reacti on shaft support-to-oi l
pump housi ng bol ts to 28 N·m (20 ft. l bs.) torque.
Fig. 226 Oil Pump Assembly
1 - PUMP HOUSING
2 - OUTER PUMP GEAR
3 - INNER PUMP GEAR
4 - REACTION SHAFT SUPPORT
5 - SEAL RINGS (4)
6 - REACTION SHAFT
7 - CRESCENT
Fig. 227 Measure Outer Gear to Pocket
1 - OUTER GEAR
2 - POCKET
Fig. 228 Oil Pump Assembly
1 - PUMP HOUSING
2 - OUTER PUMP GEAR
3 - INNER PUMP GEAR
4 - REACTION SHAFT SUPPORT
5 - SEAL RINGS (4)
6 - REACTION SHAFT
7 - CRESCENT
TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 165
OIL PUMP (Continued)
OUTPUT SPEED SENSOR
DESCRIPTION
The I nput and Output Speed Sensors (Fi g. 229) are
two-wi re magneti c pi ckup devi ces that generate AC
si gnal s as rotati on occurs. They are mounted i n the
l eft si de of the transmi ssi on case and are consi dered
pri mary i nputs to the Transmi ssi on Control Modul e
(TCM).
OPERATION
The I nput Speed Sensor provi des i nformati on on
how fast the i nput shaft i s rotati ng. As the teeth of
the i nput cl utch hub pass by the sensor coi l , an AC
vol tage i s generated and sent to the TCM. The TCM
i nterprets thi s i nformati on as i nput shaft rpm.
The Output Speed Sensor generates an AC si gnal
i n a si mi l ar fashi on, though i ts coi l i s exci ted by rota-
ti on of the rear pl anetary carri er l ugs. The TCM
i nterprets thi s i nformati on as output shaft rpm.
The TCM compares the i nput and output speed
si gnal s to determi ne the fol l owi ng:
• Transmi ssi on gear rati o
• Speed rati o error detecti on
• CVI cal cul ati on
The TCM al so compares the i nput speed si gnal and
the engi ne speed si gnal to determi ne the fol l owi ng:
• Torque converter cl utch sl i ppage
• Torque converter el ement speed rati o
REMOVAL
(1) Rai se vehi cl e.
(2) Pl ace a sui tabl e fl ui d catch pan under the
transmi ssi on.
(3) Remove the wi ri ng connector from the output
speed sensor (Fi g. 230).
NOTE: The speed sensor bolt has a sealing patch
applied from the factory. Be sure to reuse the same
bolt.
(4) Remove the bol t hol di ng the output speed sen-
sor to the transmi ssi on case.
(5) Remove the output speed sensor from the
transmi ssi on case.
INSTALLATION
(1) I nstal l the output speed sensor i nto the trans-
mi ssi on case.
NOTE: Before installing the speed sensor bolt, it
will be necessary to replentish the sealing patch on
the bolt using Moparா Lock & Seal Adhesive.
(2) I nstal l the bol t to hol d the output speed sensor
i nto the transmi ssi on case. Ti ghten the bol t to 9 N·m
(80 i n.l bs.).
(3) I nstal l the wi ri ng connector onto the output
speed sensor
(4) Veri fy the transmi ssi on fl ui d l evel . Add fl ui d as
necessary.
(5) Lower vehi cl e.
Fig. 229 Input and Output Speed Sensors and
Transmission Range Sensor
1 - INPUT SPEED SENSOR
2 - OUTPUT SPEED SENSOR
3 - TRANSMISSION RANGE SENSOR
Fig. 230 Input and Output Speed Sensors and
Transmission Range Sensor
1 - INPUT SPEED SENSOR
2 - OUTPUT SPEED SENSOR
3 - TRANSMISSION RANGE SENSOR
21 - 166 AUTOMATIC TRANSMISSION - 42RLE TJ
OVERDRIVE SWITCH
DESCRIPTION
The overdri ve OFF (control ) swi tch i s l ocated i n
the center consol e (Fi g. 231). The swi tch i s a momen-
tary contact devi ce that si gnal s the PCM to toggl e
current status of the overdri ve functi on.
OPERATION
At key-on, overdri ve operati on i s al l owed. Pressi ng
the swi tch once causes the overdri ve OFF mode to be
entered and the overdri ve OFF swi tch l amp to be
i l l umi nated. Pressi ng the swi tch a second ti me
causes normal overdri ve operati on to be restored and
the overdri ve l amp to be turned off. The overdri ve
OFF mode defaul ts to ON after the i gni ti on swi tch i s
cycl ed OFF and ON. The normal posi ti on for the con-
trol swi tch i s the ON posi ti on. The swi tch must be i n
thi s posi ti on to energi ze the sol enoi d and al l ow a 3-4
upshi ft. The control swi tch i ndi cator l i ght i l l umi nates
onl y when the overdri ve swi tch i s turned to the OFF
posi ti on, or when i l l umi nated by the transmi ssi on
control modul e.
REMOVAL
(1) Remove the accessory swi tch bezel (Fi g.
232)(Refer to 23 - BODY/I NSTRUMENT PANEL/AC-
CESSORY SWI TCH BEZEL - REMOVAL).
(2) Remove the overdri ve off swi tch from the acces-
sory swi tch bezel .
INSTALLATION
(1) I nstal l the overdri ve off swi tch to the accessory
swi tch bezel .
(2) I nstal l the accesory swi tch bezel (Refer to 23 -
BODY/I NSTRUMENT PANEL/ACCESSORY
SWI TCH BEZEL - I NSTALLATI ON).
PLANETARY GEARTRAIN
DESCRIPTION
The pl anetary geartrai n i s l ocated between the
i nput cl utch assembl y and the rear of the transmi s-
si on case. The pl anetary geartrai n consi sts of two
sun gears, two pl anetary carri ers, two annul us (ri ng)
gears, and one output shaft (Fi g. 233).
Fig. 231 Overdrive Off Switch
1 - ACCESSORY SWITCH BEZEL
2 - OVERDRIVE OFF SWITCH
Fig. 232 Overdrive Off Switch
1 - ACCESSORY SWITCH BEZEL
2 - OVERDRIVE OFF SWITCH
Fig. 233 Planetary Geartrain
1 - FRONT SUN GEAR ASSEMBLY
2 - #6 THRUST BEARING
3 - #7 THRUST BEARING
4 - REAR CARRIER FRONT ANNULUS ASSEMBLY
5 - REAR SUN GEAR
6 - FRONT CARRIER REAR ANNULUS ASSEMBLY
TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 167
OPERATION
The pl anetary geartrai n uti l i zes two pl anetary gear
sets that connect the transmi ssi on i nput shaft to the
output shaft. I nput and hol di ng cl utches dri ve or l ock
di fferent pl anetary members to change output rati o
or di recti on.
SEAL - OIL PUMP
REMOVAL
(1) Remove the transmi ssi on from the vehi cl e
(Refer to 21 - TRANSMI SSI ON/AUTOMATI C -
42RLE - REMOVAL).
(2) Remove the torque converter from the trans-
mi ssi on bel l housi ng.
(3) Use speci al tool C-3981B to remove oi l pump
seal .
INSTALLATION
(1) Cl ean and i nspect oi l pump seal seat. Then
i nstal l seal usi ng speci al tool C-4193-A.
(2) Cl ean and i nspect torque converter hub. I f
ni cks, scratches or hub wear are found, torque con-
verter repl acement wi l l be requi red.
CAUTION: If the torque converter is being replaced,
apply a light coating of grease to the crankshaft
pilot hole. Also inspect the engine drive plate for
cracks. If any cracks are found replace the drive
plate. Do not attempt to repair a cracked drive plate.
Always use new torque converter to drive plate
bolts.
(3) Appl y a l i ght fi l m of transmi ssi on oi l to the
torque converter hub and oi l seal l i ps. Then i nstal l
torque converter i nto transmi ssi on. Be sure that the
hub l ugs mesh wi th the front pump l ugs when
i nstal l i ng.
(4) Rei nstal l the transmi ssi on i nto the vehi cl e.
SHIFT MECHANISM
DESCRIPTION
The shi ft mechani sm i s cabl e operated and pro-
vi des si x shi ft posi ti ons. The shi ft i ndi cator i s l ocated
on the consol e next to the gear shi ft. The shi ft posi -
ti ons are:
• Park (P)
• Reverse (R)
• Neutral (N)
• Dri ve (D)
• Manual Second (2)
• Manual Low (1)
OPERATION
Manual l ow (1) range provi des fi rst gear onl y. Over
run braki ng i s al so provi ded i n thi s range. Manual
second (2) range provi des fi rst and second gear onl y.
Dri ve range provi des fi rst, second, and thi rd gear
ranges.
DIAGNOSIS AND TESTING - SHIFT
MECHANISM
(1) The fl oor shi fter l ever and gate posi ti ons
shoul d be i n al i gnment wi th al l transmi ssi on PARK,
NEUTRAL, and gear detent posi ti ons.
(2) Engi ne starts must be possi bl e wi th fl oor shi ft
l ever i n PARK or NEUTRAL gate posi ti ons onl y.
Engi ne starts must not be possi bl e i n any other gear
posi ti on.
(3) Wi th fl oor shi ft l ever handl e push-button not
depressed and l ever i n:
(a) PARK posi ti on - Appl y forward force on cen-
ter of handl e and remove pressure. Engi ne starts
must be possi bl e.
(b) PARK posi ti on - Appl y rearward force on cen-
ter of handl e and remove pressure. Engi ne starts
must be possi bl e.
(c) NEUTRAL posi ti on - Normal posi ti on. Engi ne
starts must be possi bl e.
(d) NEUTRAL posi ti on - Engi ne runni ng and
brakes appl i ed, appl y forward force on center of
shi ft handl e. Transmi ssi on shal l not be abl e to shi ft
from NEUTRAL to REVERSE.
ADJUSTMENTS - SHIFT MECHANISM
Check adjustment by starti ng the engi ne i n PARK
and NEUTRAL. Adjustment i s CORRECT i f the
engi ne starts onl y i n these posi ti ons. Adjustment i s
I NCORRECT i f the engi ne starts i n one but not both
posi ti ons. I f the engi ne starts i n any posi ti on other
than PARK or NEUTRAL, or i f the engi ne wi l l not
start at al l , the TRS may be faul ty.
Gearshift Adjustment Procedure
(1) Shi ft transmi ssi on i nto PARK.
(2) Remove fl oor consol e as necessary for access to
the shi ft cabl e adjustment. (Refer to 23 - BODY/I N-
TERI OR/FLOOR CONSOLE - REMOVAL)
(3) Loosen the shi ft cabl e adjustment nut.
(4) Rai se vehi cl e.
(5) Unsnap cabl e eyel et from transmi ssi on shi ft
l ever.
(6) Veri fy transmi ssi on shi ft l ever i s i n PARK
detent by movi ng l ever ful l y rearward. Last rearward
detent i s PARK posi ti on.
(7) Veri fy posi ti ve engagement of transmi ssi on
park l ock by attempti ng to rotate propel l er shaft.
Shaft wi l l not rotate when park l ock i s engaged.
(8) Snap cabl e eyel et onto transmi ssi on shi ft l ever.
21 - 168 AUTOMATIC TRANSMISSION - 42RLE TJ
PLANETARY GEARTRAIN (Continued)
(9) Lower vehi cl e
(10) Ti ghten the shi ft cabl e adjustment screw to 12
N·m (105 i n.l bs.).
(11) Veri fy correct operati on.
(12) I nstal l any fl oor consol e components removed
for access. (Refer to 23 - BODY/I NTERI OR/FLOOR
CONSOLE - I NSTALLATI ON)
SOLENOID
DESCRIPTION
The typi cal el ectri cal sol enoi d used i n automoti ve
appl i cati ons i s a l i near actuator. I t i s a devi ce that
produces moti on i n a strai ght l i ne. Thi s strai ght l i ne
moti on can be ei ther forward or backward i n di rec-
ti on, and short or l ong di stance.
A sol enoi d i s an el ectromechani cal devi ce that uses
a magneti c force to perform work. I t consi sts of a coi l
of wi re, wrapped around a magneti c core made from
steel or i ron, and a spri ng l oaded, movabl e pl unger,
whi ch performs the work, or strai ght l i ne moti on.
The sol enoi ds used i n transmi ssi on appl i cati ons
are attached to val ves whi ch can be cl assi fi ed as nor-
mally open (Fig. 234) or normally closed (Fig.
235). The normally open sol enoi d val ve i s defi ned
as a val ve whi ch al l ows hydraul i c fl ow when no cur-
rent or vol tage i s appl i ed to the sol enoi d. The nor-
mally closed sol enoi d val ve i s defi ned as a val ve
whi ch does not al l ow hydraul i c fl ow when no current
or vol tage i s appl i ed to the sol enoi d. These val ves
perform hydraul i c control functi ons for the transmi s-
si on and must therefore be durabl e and tol erant of
di rt parti cl es. For these reasons, the val ves have
hardened steel poppets and bal l val ves. The sol enoi ds
operate the val ves di rectl y, whi ch means that the
sol enoi ds must have very hi gh outputs to cl ose the
val ves agai nst the si zabl e fl ow areas and l i ne pres-
sures found i n current transmi ssi ons. Fast response
ti me i s al so necessary to ensure accurate control of
the transmi ssi on.
The strength of the magneti c fi el d i s the pri mary
force that determi nes the speed of operati on i n a par-
ti cul ar sol enoi d desi gn. A stronger magneti c fi el d wi l l
cause the pl unger to move at a greater speed than a
weaker one. There are basi cal l y two ways to i ncrease
the force of the magneti c fi el d:
1. I ncrease the amount of current appl i ed to the
coi l or
2. I ncrease the number of turns of wi re i n the coi l .
The most common practi ce i s to i ncrease the num-
ber of turns by usi ng thi n wi re that can compl etel y
fi l l the avai l abl e space wi thi n the sol enoi d housi ng.
The strength of the spri ng and the l ength of the
pl unger al so contri bute to the response speed possi -
bl e by a parti cul ar sol enoi d desi gn.
A sol enoi d can al so be descri bed by the method by
whi ch i t i s control l ed. Some of the possi bi l i ti es
i ncl ude vari abl e force, pul se-wi dth modul ated, con-
stant ON, or duty cycl e. The vari abl e force and pul se-
wi dth modul ated versi ons uti l i ze si mi l ar methods to
control the current fl ow through the sol enoi d to posi -
Fig. 234 2/4 - Low Reverse and Underdrive
Solenoids
1 - MANUAL VALVE
2 - LINE PRESSURE
3 - 2/4 - LOW REVERSE SOLENOID ENERGIZED
4 - UNDERDRIVE SOLENOID DE-ENERGIZED
5 - UNDERDRIVE CLUTCH
Fig. 235 Low Reverse/Converter Clutch and
Overdrive Solenoids
1 - OVERDRIVE CLUTCH
2 - NO VENT
3 - OVERDRIVE SOLENOID ENERGIZED
4 - MANUAL VALVE
5 - LOW REVERSE/CONVERTER CLUTCH SOLENOID DE-
ENERGIZED
6 - SOLENOID SWITCH VALVE
7 - TAPER
8 - VENT TO SUMP
9 - ORIFICE
10 - CHECK BALL
TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 169
SHIFT MECHANISM (Continued)
ti on the sol enoi d pl unger at a desi red posi ti on some-
where between ful l ON and ful l OFF. The constant
ON and duty cycl ed versi ons control the vol tage
across the sol enoi d to al l ow ei ther ful l fl ow or no fl ow
through the sol enoi d’s val ve.
OPERATION
When an el ectri cal current i s appl i ed to the sol e-
noi d coi l , a magneti c fi el d i s created whi ch produces
an attracti on to the pl unger, causi ng the pl unger to
move and work agai nst the spri ng pressure and the
l oad appl i ed by the fl ui d the val ve i s control l i ng. The
pl unger i s normal l y di rectl y attached to the val ve
whi ch i t i s to operate. When the current i s removed
from the coi l , the attracti on i s removed and the
pl unger wi l l return to i ts ori gi nal posi ti on due to
spri ng pressure.
The pl unger i s made of a conducti ve materi al and
accompl i shes thi s movement by provi di ng a path for
the magneti c fi el d to fl ow. By keepi ng the ai r gap
between the pl unger and the coi l to the mi ni mum
necessary to al l ow free movement of the pl unger, the
magneti c fi el d i s maxi mi zed.
SOLENOID/PRESSURE
SWITCH ASSY
DESCRIPTION
The Sol enoi d/Pressure Swi tch Assembl y (Fi g. 236)
i s i nsi de the transmi ssi on and mounted to the val ve
body assembl y. The assembl y consi sts of four sol e-
noi ds that control hydraul i c pressure to the L/R, 2/4,
OD, and UD fri cti on el ements (transmi ssi on
cl utches), and the torque converter cl utch. The
reverse cl utch i s control l ed by l i ne pressure from the
manual val ve i n the val ve body. The sol enoi ds are
contai ned wi thi n the Sol enoi d/Pressure Swi tch
Assembl y, and can onl y be servi ced by repl aci ng the
assembl y.
The sol enoi d assembl y al so contai ns pressure
swi tches that moni tor and send hydraul i c ci rcui t
i nformati on to the PCM. Li kewi se, the pressure
swi tches can onl y be servi ce by repl aci ng the assem-
bl y.
OPERATION
SOLENOIDS
The sol enoi ds recei ve el ectri cal power from the
Transmi ssi on Control Rel ay through a si ngl e wi re.
The PCM energi zes or operates the sol enoi ds i ndi vi d-
ual l y by groundi ng the return wi re of the sol enoi d
needed. When a sol enoi d i s energi zed, the sol enoi d
val ve shi fts, and a fl ui d passage i s opened or cl osed
(vented or appl i ed), dependi ng on i ts defaul t operat-
i ng state. The resul t i s an appl y or rel ease of a fri c-
ti onal el ement.
The 2/4 and UD sol enoi ds are normal l y appl i ed,
whi ch al l ows fl ui d to pass through i n thei r rel axed or
“off” state. By desi gn, thi s al l ows transmi ssi on
l i mp-i n (P,R,N,2) i n the event of an el ectri cal fai l ure.
The conti nui ty of the sol enoi ds and ci rcui ts are
peri odi cal l y tested. Each sol enoi d i s turned on or off
dependi ng on i ts current state. An i nducti ve spi ke
shoul d be detected by the pcm duri ng thi s test. I f no
spi ke i s detected, the ci rcui t i s tested agai n to veri fy
the fai l ure. I n addi ti on to the peri odi c testi ng, the
sol enoi d ci rcui ts are tested i f a speed rati o or pres-
sure swi tch error occurs.
Fig. 236 Valve Body Assembly
1 - SOLENOID/PRESSURE SWITCH ASSEMBLY
2 - TRS
3 - TRANSFER PLATE
4 - SEPARATOR PLATE
5 - VALVE BODY
21 - 170 AUTOMATIC TRANSMISSION - 42RLE TJ
SOLENOID (Continued)
PRESSURE SWITCHES
The PCM rel i es on three pressure swi tches to mon-
i tor fl ui d pressure i n the L/R, 2/4, and OD hydraul i c
ci rcui ts. The pri mary purpose of these swi tches i s to
hel p the PCM detect when cl utch ci rcui t hydraul i c
fai l ures occur. The range for the pressure swi tch cl os-
i ng and openi ng poi nts i s 11-23 psi . Typi cal l y the
swi tch openi ng poi nt wi l l be approxi matel y one psi
l ower than the cl osi ng poi nt. For exampl e, a swi tch
may cl ose at 18 psi and open at 17 psi . The swi tches
are conti nuousl y moni tored by the PCM for the cor-
rect states (open or cl osed) i n each gear as shown i n
the fol l owi ng chart:
PRESSURE SWITCH STATES
GEAR L/R 2/4 OD
R OP OP OP
P/N CL OP OP
1st CL OP OP
2nd OP CL OP
D OP OP CL
OD OP CL CL
OP = OPEN
CL = CLOSED
A Di agnosti c Troubl e Code (DTC) wi l l set i f the
PCM senses any swi tch open or cl osed at the wrong
ti me i n a gi ven gear.
The PCM al so tests the 2/4 and OD pressure
swi tches when they are normal l y off (OD and 2/4 are
tested i n 1st gear, OD i n 2nd gear, and 2/4 i n 3rd
gear). The test si mpl y veri fi es that they are opera-
ti onal , by l ooki ng for a cl osed state when the corre-
spondi ng el ement i s appl i ed. I mmedi atel y after a
shi ft i nto 1st, 2nd, or 3rd gear wi th the engi ne speed
above 1000 rpm, the PCM momentari l y turns on el e-
ment pressure to the 2/4 and/or OD cl utch ci rcui ts to
i denti fy that the appropri ate swi tch has cl osed. I f i t
doesn’t cl ose, i t i s tested agai n. I f the swi tch fai l s to
cl ose the second ti me, the appropri ate Di agnosti c
Troubl e Code (DTC) wi l l set.
REMOVAL
NOTE: If the Solenoid/Pressure Switch Assembly is
being replaced, the Quick Learn Procedure must be
performed. (Refer to 8 - ELECTRICAL/ELECTRONIC
CONTROL MODULES/TRANSMISSION CONTROL
MODULE - STANDARD PROCEDURE)
(1) Rai se vehi cl e on hoi st.
(2) Remove val ve body assembl y from transmi s-
si on. (Refer to 21 - TRANSMI SSI ON/AUTOMATI C -
42RLE/VALVE BODY - REMOVAL)
(3) Remove Sol enoi d/Pressure Swi tch Assembl y
retai ni ng screws from sol enoi d (Fi g. 237).
(4) Remove Sol enoi d/Pressure Swi tch Assembl y
and screen from val ve body (Fi g. 238).
INSTALLATION
NOTE: If the Solenoid/Pressure Switch assembly is
being replaced, the Quick Learn Procedure must be
performed. (Refer to 8 - ELECTRICAL/ELECTRONIC
CONTROL MODULES/TRANSMISSION CONTROL
MODULE - STANDARD PROCEDURE)
Fig. 237 Solenoid Retaining Screws
1 - SOLENOID/PRESSURE SWITCH ASSEMBLY
2 - RETAINING SCREWS
Fig. 238 Solenoid/Pressure Switch Assembly and
Screen
1 - SOLENOID/PRESSURE SWITCH ASSEMBLY
2 - VALVE BODY
3 - SCREEN
TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 171
SOLENOID/PRESSURE SWITCH ASSY (Continued)
(1) I nstal l Sol enoi d/Pressure Swi tch Assembl y and
screen to the separator and transfer pl ates.
(2) I nstal l and ti ghten retai ni ng screws to 5.5 N·m
(50 i n. l bs.) torque.
(3) I nstal l val ve body. (Refer to 21 - TRANSMI S-
SI ON/AUTOMATI C - 42RLE/VALVE BODY -
I NSTALLATI ON)
TORQUE CONVERTER
DESCRIPTION
The torque converter (Fi g. 239) i s a hydraul i c
devi ce that coupl es the engi ne crankshaft to the
transmi ssi on. The torque converter consi sts of an
outer shel l wi th an i nternal turbi ne, a stator, an
overrunni ng cl utch, an i mpel l er and an el ectroni cal l y
appl i ed converter cl utch. The converter cl utch pro-
vi des reduced engi ne speed and greater fuel economy
when engaged. Cl utch engagement al so provi des
reduced transmi ssi on fl ui d temperatures. The torque
converter hub dri ves the transmi ssi on oi l (fl ui d)
pump.
The torque converter i s a seal ed, wel ded uni t that
i s not repai rabl e and i s servi ced as an assembl y.
CAUTION: The torque converter must be replaced if
a transmission failure resulted in large amounts of
metal or fiber contamination in the fluid.
Fig. 239 Torque Converter Assembly
1 - TURBINE
2 - IMPELLER
3 - HUB
4 - STATOR
5 - FRONT COVER
6 - CONVERTER CLUTCH DISC
7 - DRIVE PLATE
21 - 172 AUTOMATIC TRANSMISSION - 42RLE TJ
SOLENOID/PRESSURE SWITCH ASSY (Continued)
IMPELLER
The i mpel l er (Fi g. 240) i s an i ntegral part of the
converter housi ng. The i mpel l er consi sts of curved
bl ades pl aced radi al l y al ong the i nsi de of the housi ng
on the transmi ssi on si de of the converter. As the con-
verter housi ng i s rotated by the engi ne, so i s the
i mpel l er, because they are one and the same and are
the dri vi ng members of the system.
Fig. 240 Impeller
1 - ENGINE FLEXPLATE 4 - ENGINE ROTATION
2 - OIL FLOW FROM IMPELLER SECTION INTO TURBINE SECTION 5 - ENGINE ROTATION
3 - IMPELLER VANES AND COVER ARE INTEGRAL
TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 173
TORQUE CONVERTER (Continued)
TURBINE
The turbi ne (Fi g. 241) i s the output, or dri ven,
member of the converter. The turbi ne i s mounted
wi thi n the housi ng opposi te the i mpel l er, but i s not
attached to the housi ng. The i nput shaft i s i nserted
through the center of the i mpel l er and spl i ned i nto
the turbi ne. The desi gn of the turbi ne i s si mi l ar to
the i mpel l er, except the bl ades of the turbi ne are
curved i n the opposi te di recti on.
Fig. 241 Turbine
1 - TURBINE VANE 4 - PORTION OF TORQUE CONVERTER COVER
2 - ENGINE ROTATION 5 - ENGINE ROTATION
3 - INPUT SHAFT 6 - OIL FLOW WITHIN TURBINE SECTION
21 - 174 AUTOMATIC TRANSMISSION - 42RLE TJ
TORQUE CONVERTER (Continued)
STATOR
The stator assembl y (Fi g. 242) i s mounted on a sta-
ti onary shaft whi ch i s an i ntegral part of the oi l
pump. The stator i s l ocated between the i mpel l er and
turbi ne wi thi n the torque converter case (Fi g. 243).
The stator contai ns an over-runni ng cl utch, whi ch
al l ows the stator to rotate onl y i n a cl ockwi se di rec-
ti on. When the stator i s l ocked agai nst the over-run-
ni ng cl utch, the torque mul ti pl i cati on feature of the
torque converter i s operati onal .
TORQUE CONVERTER CLUTCH (TCC)
The TCC (Fi g. 244) was i nstal l ed to i mprove the
effi ci ency of the torque converter that i s l ost to the
sl i ppage of the fl ui d coupl i ng. Al though the fl ui d cou-
pl i ng provi des smooth, shock-free power transfer, i t i s
natural for al l fl ui d coupl i ngs to sl i p. I f the i mpel l er
and turbi ne were mechani cal l y l ocked together, a
zero sl i ppage condi ti on coul d be obtai ned. A hydraul i c
pi ston was added to the turbi ne, and a fri cti on mate-
ri al was added to the i nsi de of the front cover to pro-
vi de thi s mechani cal l ock-up.
Fig. 242 Stator Components
1 - CAM (OUTER RACE)
2 - ROLLER
3 - SPRING
4 - INNER RACE
Fig. 243 Stator Location
1 - STATOR
2 - IMPELLER
3 - FLUID FLOW
4 - TURBINE
Fig. 244 Torque Converter Clutch (TCC)
1 - IMPELLER FRONT COVER
2 - THRUST WASHER ASSEMBLY
3 - IMPELLER
4 - STATOR
5 - TURBINE
6 - PISTON
7 - FRICTION DISC
TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 175
TORQUE CONVERTER (Continued)
OPERATION
The converter i mpel l er (Fi g. 245) (dri vi ng member),
whi ch i s i ntegral to the converter housi ng and bol ted
to the engi ne dri ve pl ate, rotates at engi ne speed.
The converter turbi ne (dri ven member), whi ch reacts
from fl ui d pressure generated by the i mpel l er, rotates
and turns the transmi ssi on i nput shaft.
TURBINE
As the fl ui d that was put i nto moti on by the i mpel -
l er bl ades stri kes the bl ades of the turbi ne, some of
the energy and rotati onal force i s transferred i nto the
turbi ne and the i nput shaft. Thi s causes both of them
(turbi ne and i nput shaft) to rotate i n a cl ockwi se
di recti on fol l owi ng the i mpel l er. As the fl ui d i s l eav-
i ng the trai l i ng edges of the turbi ne’s bl ades i t con-
ti nues i n a “hi nderi ng” di recti on back toward the
i mpel l er. I f the fl ui d i s not redi rected before i t stri kes
the i mpel l er, i t wi l l stri ke the i mpel l er i n such a
di recti on that i t woul d tend to sl ow i t down.
Fig. 245 Torque Converter Fluid Operation
1 - APPLY PRESSURE 3 - RELEASE PRESSURE
2 - THE PISTON MOVES SLIGHTLY FORWARD 4 - THE PISTON MOVES SLIGHTLY REARWARD
21 - 176 AUTOMATIC TRANSMISSION - 42RLE TJ
TORQUE CONVERTER (Continued)
STATOR
Torque mul ti pl i cati on i s achi eved by l ocki ng the
stator’s over-runni ng cl utch to i ts shaft (Fi g. 246).
Under stal l condi ti ons (the turbi ne i s stati onary), the
oi l l eavi ng the turbi ne bl ades stri kes the face of the
stator bl ades and tri es to rotate them i n a counter-
cl ockwi se di recti on. When thi s happens the overrun-
ni ng cl utch of the stator l ocks and hol ds the stator
from rotati ng. Wi th the stator l ocked, the oi l stri kes
the stator bl ades and i s redi rected i nto a “hel pi ng”
di recti on before i t enters the i mpel l er. Thi s ci rcul a-
ti on of oi l from i mpel l er to turbi ne, turbi ne to stator,
and stator to i mpel l er, can produce a maxi mum
torque mul ti pl i cati on of about 2.4:1. As the turbi ne
begi ns to match the speed of the i mpel l er, the fl ui d
that was hi tti ng the stator i n such as way as to
cause i t to l ock-up i s no l onger doi ng so. I n thi s con-
di ti on of operati on, the stator begi ns to free wheel
and the converter acts as a fl ui d coupl i ng.
TORQUE CONVERTER CLUTCH (TCC)
The torque converter cl utch i s hydraul i cal l y
appl i ed and i s rel eased when fl ui d i s vented from the
hydraul i c ci rcui t by the torque converter control
(TCC) sol enoi d on the val ve body. The torque con-
verter cl utch i s control l ed by the Powertrai n Control
Modul e (PCM). The torque converter cl utch engages
i n fourth gear, and i n thi rd gear under vari ous con-
di ti ons, such as when the O/D swi tch i s OFF, when
the vehi cl e i s crui si ng on a l evel surface after the
vehi cl e has warmed up. The torque converter cl utch
wi l l di sengage momentari l y when an i ncrease i n
engi ne l oad i s sensed by the PCM, such as when the
vehi cl e begi ns to go uphi l l or the throttl e pressure i s
i ncreased.
REMOVAL
(1) Remove transmi ssi on and torque converter
from vehi cl e.
(2) Pl ace a sui tabl e drai n pan under the converter
housi ng end of the transmi ssi on.
CAUTION: Verify that transmission is secure on the
lifting device or work surface, the center of gravity
of the transmission will shift when the torque con-
verter is removed creating an unstable condition.
The torque converter is a heavy unit. Use caution
when separating the torque converter from the
transmission.
(3) Pul l the torque converter forward unti l the cen-
ter hub cl ears the oi l pump seal .
(4) Separate the torque converter from the trans-
mi ssi on.
INSTALLATION
Check converter hub and dri ve notches for sharp
edges, burrs, scratches, or ni cks. Pol i sh the hub and
notches wi th 320/400 gri t paper or crocus cl oth i f nec-
essary. The hub must be smooth to avoi d damagi ng
the pump seal at i nstal l ati on.
(1) Lubri cate oi l pump seal l i p wi th transmi ssi on
fl ui d.
(2) Pl ace torque converter i n posi ti on on transmi s-
si on.
CAUTION: Do not damage oil pump seal or bushing
while inserting torque converter into the front of the
transmission.
(3) Al i gn torque converter to oi l pump seal open-
i ng.
(4) I nsert torque converter hub i nto oi l pump.
(5) Whi l e pushi ng torque converter i nward, rotate
converter unti l converter i s ful l y seated i n the oi l
pump gears.
Fig. 246 Stator Operation
1 - DIRECTION STATOR WILL FREE WHEEL DUE TO OIL
PUSHING ON BACKSIDE OF VANES
2 - FRONT OF ENGINE
3 - INCREASED ANGLE AS OIL STRIKES VANES
4 - DIRECTION STATOR IS LOCKED UP DUE TO OIL PUSHING
AGAINST STATOR VANES
TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 177
TORQUE CONVERTER (Continued)
(6) Check converter seati ng wi th a scal e and
strai ghtedge (Fi g. 247). Surface of converter l ugs
shoul d be 1/2 i n. to rear of strai ghtedge when con-
verter i s ful l y seated.
(7) I f necessary, temporari l y secure converter wi th
C-cl amp attached to the converter housi ng.
(8) I nstal l the transmi ssi on i n the vehi cl e.
(9) Fi l l the transmi ssi on wi th the recommended
fl ui d.
TRANSMISSION CONTROL
RELAY
DESCRIPTION
The rel ay i s suppl i ed fused B+ vol tage, energi zed
by the TCM, and i s used to suppl y power to the sol e-
noi d pack when the transmi ssi on i s i n normal oper-
ati ng mode.
OPERATION
When the rel ay i s “off”, no power i s suppl i ed to the
sol enoi d pack and the transmi ssi on i s i n “l i mp-i n”
mode. After a control l er reset, the TCM energi zes the
rel ay. Pri or to thi s, the TCM veri fi es that the con-
tacts are open by checki ng for no vol tage at the
swi tched battery termi nal s. After thi s i s veri fi ed, the
vol tage at the sol enoi d pack pressure swi tches i s
checked. After the rel ay i s energi zed, the TCM mon-
i tors the termi nal s to veri fy that the vol tage i s
greater than 3 vol ts.
TRANSMISSION RANGE
SENSOR
DESCRIPTION
The Transmi ssi on Range Sensor (TRS) i s mounted
to the top of the val ve body i nsi de the transmi ssi on
and can onl y be servi ced by removi ng the val ve body
assembl y. The el ectri cal connector extends through
the transmi ssi on case (Fi g. 248).
The Transmi ssi on Range Sensor (TRS) has four
swi tch contacts that moni tor shi ft l ever posi ti on and
send the i nformati on to the PCM.
OPERATION
The Transmi ssi on Range Sensor (TRS) communi -
cates shi ft l ever posi ti on (SLP) to the PCM as a com-
bi nati on of open and cl osed swi tches. Each shi ft l ever
posi ti on has an assi gned combi nati on of swi tch states
(open/cl osed) that the PCM recei ves from four sense
ci rcui ts. The PCM i nterprets thi s i nformati on and
determi nes the appropri ate transmi ssi on gear posi -
ti on and shi ft schedul e.
Si nce there are four swi tches, there are 16 possi bl e
combi nati ons of open and cl osed swi tches (codes).
Seven of these codes are rel ated to gear posi ti on and
three are recogni zed as “between gear” codes. Thi s
resul ts i n si x codes whi ch shoul d never occur. These
Fig. 247 Checking Torque Converter Seating -
Typical
1 - SCALE
2 - STRAIGHTEDGE
Fig. 248 Valve Body Assembly
1 - SOLENOID/PRESSURE SWITCH ASSEMBLY
2 - TRS
3 - TRANSFER PLATE
4 - SEPARATOR PLATE
5 - VALVE BODY
21 - 178 AUTOMATIC TRANSMISSION - 42RLE TJ
TORQUE CONVERTER (Continued)
are cal l ed “i nval i d” codes. An i nval i d code wi l l resul t
i n a DTC, and the PCM wi l l then determi ne the shi ft
l ever posi ti on based on pressure swi tch data. Thi s
al l ows reasonabl y normal transmi ssi on operati on
wi th a TRS fai l ure.
TRS SWITCH STATES
SLP T42 T41 T3 T1
P CL CL CL OP
R CL OP OP OP
N CL CL OP CL
D OP OP OP CL
2 OP OP CL OP
1 CL OP CL CL
REMOVAL
(1) Di sconnect the TRS connector.
(2) Remove val ve body assembl y from vehi cl e.
(3) Remove the manual shaft seal (Fi g. 249).
(4) Remove manual shaft/TRS retai ni ng screw
(Fi g. 250).
(5) Sl i de TRS off of manual val ve shaft.
INSTALLATION
(1) I nstal l the TRS to the manual shaft. Make sure
TRS l ocati ng pi n rests i n manual val ve bore sl ot.
(2) I nstal l the TRS/manual shaft retai ni ng screw
and torque to 5 N·m (45 i n. l bs.) torque.
(3) I nstal l the manual shaft seal .
(4) I nstal l val ve body to the transmi ssi on.
TRANSMISSION
TEMPERATURE SENSOR
DESCRIPTION
The transmi ssi on temperature sensor (Fi g. 251) i s
l ocated i n the transmi ssi on range sensor and commu-
ni cates transmi ssi on sump temperature to the PCM.
Fig. 249 Manual Shaft Seal - Typical
1 - SEAL
2 - MANUAL SHAFT
Fig. 250 Manual Shaft Retaining Screw
1 - SCREW
2 - TRS
Fig. 251 Transmission Temperature Sensor
1 - TRANSMISSION RANGE SENSOR
2 - TEMPERATURE SENSOR
TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 179
TRANSMISSION RANGE SENSOR (Continued)
OPERATION
The TRS has an i ntegrated thermi stor that the
PCM uses to moni tor the transmi ssi on’s sump tem-
perature. Si nce fl ui d temperature can affect trans-
mi ssi on shi ft qual i ty and convertor l ock up, the PCM
requi res thi s i nformati on to determi ne whi ch shi ft
schedul e to operate i n. The PCM al so moni tors thi s
temperature data so i t can energi ze the vehi cl e cool -
i ng fan(s) when a transmi ssi on “overheat” condi ti on
exi sts. I f the thermi stor ci rcui t fai l s, the PCM wi l l
revert to cal cul ated oi l temperature usage.
CALCULATED TEMPERATURE
A fai l ure i n the temperature sensor or ci rcui t wi l l
resul t i n cal cul ated temperature bei ng substi tuted for
actual temperature. Cal cul ated temperature i s a pre-
di cted fl ui d temperature whi ch i s cal cul ated from a
combi nati on of i nputs:
• Battery (ambi ent) temperature
• Engi ne cool ant temperature
• I n-gear run ti me si nce start-up
VALVE BODY
DESCRIPTION
The val ve body assembl y (Fi g. 252) consi sts of a
cast al umi num val ve body, a separator pl ate, and
transfer pl ate. The val ve body contai ns val ves and
check bal l s that control fl ui d del i very to the torque
converter cl utch, sol enoi d/pressure swi tch assembl y,
and fri cti onal cl utches.
Al so mounted to the val ve body assembl y are the
sol enoi d/pressure swi tch assembl y and the transmi s-
si on range sensor (Fi g. 252).
The val ves contai ned wi thi n the val ve body i ncl ude
the fol l owi ng (Fi g. 253):
• Regul ator val ve
• Sol enoi d swi tch val ve
• Manual val ve
• Converter cl utch swi tch val ve
• Converter cl utch control val ve
• Torque converter regul ator val ve
• Low/Reverse swi tch val ve
I n addi ti on, the val ve body al so contai ns the ther-
mal val ve, #2, 3, 4 & 5 check bal l s and the 2/4 accu-
mul ator assembl y.
OPERATION
NOTE: (Refer to 21 - TRANSMISSION/AUTOMATIC -
42RLE - SCHEMATICS AND DIAGRAMS) for a visual
aid in determining valve location, operation and
design.
THERMAL VALVE
The thermal val ve i s a bi -metal l i c shudder val ve
that hel ps control the venti ng rate of oi l pressure i n
the underdri ve cl utch passage duri ng rel ease of the
cl utch (Fi g. 254). When the oi l temperature i s
approxi matel y 20 degrees Fahrenhei t or l ess, the
val ve i s ful l y open to assi st i n venti ng oi l past the U1
ori fi ce. At temperatures above 20 degrees, the val ve
starts to cl ose and becomes ful l y cl osed at approxi -
matel y 140 degrees. The thermal val ve i s l ocated i n
the transfer pl ate of the val ve body.
REGULATOR VALVE
The regul ator val ve (Fi g. 255) control s hydraul i c
pressure i n the transmi ssi on. I t recei ves unregul ated
pressure from the pump, whi ch works agai nst spri ng
tensi on to mai ntai n oi l at speci fi c pressures. A sys-
tem of sl eeves and ports al l ows the regul ator val ve to
work at one of three predetermi ned pressure l evel s.
Regul ated oi l pressure i s al so referred to as “l i ne
pressure.”
Fig. 252 Valve Body Assembly
1 - SOLENOID/PRESSURE SWITCH ASSEMBLY
2 - TRS
3 - TRANSFER PLATE
4 - SEPARATOR PLATE
5 - VALVE BODY
21 - 180 AUTOMATIC TRANSMISSION - 42RLE TJ
TRANSMISSION TEMPERATURE SENSOR (Continued)
Fig. 253 Valve Body - Exploded
1 - VALVE BODY
2 - T/C REGULATOR VALVE
3 - L/R SWITCH VALVE
4 - CONVERTER CLUTCH CONTROL VALVE
5 - MANUAL VALVE
6 - CONVERTER CLUTCH SWITCH VALVE
7 - SOLENOID SWITCH VALVE
8 - REGULATOR VALVE
Fig. 254 Thermal Valve
1 - THERMAL VALVE
2 - U1 ORIFICE
3 - NUMBER 2 CHECK BALL
Fig. 255 Regulator Valve
1 - FROM OVERDRIVE CLUTCH CIRCUIT
2 - FROM MANUAL VALVE
3 - HYDRAULIC PRESSURE
4 - FILTER
5 - PUMP INLET
6 - PUMP OUTLET
7 - OIL PRESSURE REGULATED AT THIS POINT
8 - SPRING TENSION
9 - REGULATOR VALVE
10 - TORQUE CONVERTER CONTROL VALVE
TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 181
VALVE BODY (Continued)
SOLENOID SWITCH VALVE
The sol enoi d swi tch val ve (Fi g. 256) control s l i ne
pressure from the LR/CC sol enoi d. I n one posi ti on, i t
al l ows the l ow/reverse cl utch to be pressuri zed. I n
the other, i t di rects l i ne pressure to the converter
control and converter cl utch val ves.
MANUAL VALVE
The manual val ve (Fi g. 257) i s operated by the
mechani cal shi ft l i nkage. I ts pri mary responsi bi l i ty i s
to send l i ne pressure to the appropri ate hydraul i c ci r-
cui ts and sol enoi ds. The val ve has three operati ng
ranges or posi ti ons.
Fig. 256 Solenoid Switch Valve De-Energized
1 - 2/4 CLUTCH
2 - MANUAL VALVE
3 - UD CLUTCH
4 - LR/CC SOLENOID DE-ENERGIZED
5 - MANUAL VALVE
6 - LINE PRESSURE
7 - CONVERTER CLUTCH SWITCH AND CONTROL VALVES
8 - LR CLUTCH
Fig. 257 Manual Valve
1 - UD CLUTCH
2 - LR/CC CLUTCH
3 - REVERSE CLUTCH
4 - MANUAL VALVE
5 - REGULATOR VALVE
6 - REGULATOR VALVE
7 - CONVERTER CLUTCH CONTROL VALVE
8 - 2/4 CLUTCH
9 - 2/4 - L/R SOLENOID
10 - L/R CLUTCH
21 - 182 AUTOMATIC TRANSMISSION - 42RLE TJ
VALVE BODY (Continued)
CONVERTER CLUTCH SWITCH VALVE
The mai n responsi bi l i ty of the converter cl utch
swi tch val ve (Fi g. 258) i s to control hydraul i c pres-
sure appl i ed to the front (off) si de of the converter
cl utch pi ston. Li ne pressure from the regul ator val ve
i s fed to the torque converter regul ator val ve. The
pressure i s then di rected to the converter cl utch
swi tch val ve and to the front si de of the converter
cl utch pi ston. Thi s pressure pushes the pi ston back
and di sengages the converter cl utch.
CONVERTER CLUTCH CONTROL VALVE
The converter cl utch control val ve (Fi g. 259) con-
trol s the back (on) si de of the torque converter cl utch.
When the control l er energi zes or modul ates the
LR/CC sol enoi d to appl y the converter cl utch pi ston,
both the converter cl utch control val ve and the con-
verter control val ve move, al l owi ng pressure to be
appl i ed to the back si de of the cl utch.
T/C REGULATOR VALVE
The torque converter regul ator val ve sl i ghtl y regu-
l ates the fl ow of fl ui d to the torque converter.
LOW/REVERSE SWITCH VALVE
The l ow/reverse cl utch i s appl i ed from di fferent
sources, dependi ng on whether l ow (1st) gear or
reverse i s sel ected. The l ow/reverse swi tch val ve
al ternates posi ti ons dependi ng on from whi ch di rec-
ti on fl ui d pressure i s appl i ed. By desi gn, when the
val ve i s shi fted by fl ui d pressure from one channel ,
the opposi ng channel i s bl ocked. The swi tch val ve
al i enates the possi bi l i ty of a sti cki ng bal l check, thus
provi di ng consi stent appl i cati on of the l ow/reverse
cl utch under these operati ng condi ti ons.
REMOVAL
NOTE: If valve body is being reconditioned or
replaced, it is necessary to perform the Quick Learn
Procedure.(Refer to 8 - ELECTRICAL/ELECTRONIC
CONTROL MODULES/TRANSMISSION CONTROL
MODULE - STANDARD PROCEDURE)
(1) Di sconnect the TRS and sol enoi d wi ri ng con-
nectors.
(2) Di sconnect the shi ft cabl e from the shi ft l ever
(at the transmi ssi on).
(3) Move the manual shi ft l ever cl ockwi se as far as
i t wi l l go. Thi s shoul d be one posi ti on past the L posi -
ti on. Then remove the manual shi ft l ever.
NOTE: One of the oil pan bolts has a sealing patch
applied from the factory. Seperate this bolts for
reuse.
Fig. 258 Converter Clutch Switch Valve
1 - CONVERTER CLUTCH
2 - TORQUE CONVERTER
3 - LR CLUTCH
4 - DRIBBLERS
5 - REGULATOR VALVE
6 - SOLENOID SWITCH VALVE
7 - CONVERTER CLUTCH CONTROL VALVE
8 - REGULATOR VALVE
9 - CONVERTER CLUTCH CONTROL VALVE
10 - CONVERTER CLUTCH SWITCH VALVE
11 - BYPASS VALVE
12 - LUBE
13 - COOLER
Fig. 259 Converter Clutch Control Valve
1 - CONVERTER CLUTCH
2 - TORQUE CONVERTER
3 - LR/CC SOLENOID
4 - FROM MANUAL VALVE
5 - CONVERTER CLUTCH CONTROL VALVE
6 - TORQUE CONVERTER REGULATOR VALVE
7 - CONVERTER CLUTCH SWITCH VALVE
8 - BYPASS VALVE
9 - COOLER
TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 183
VALVE BODY (Continued)
(4) Remove transmi ssi on pan bol ts (Fi g. 260).
(5) Remove transmi ssi on oi l pan (Fi g. 261).
(6) Remove oi l fi l ter from val ve body (Fi g. 262). I t
i s hel d i n pl ace by two screws.
(7) Remove val ve body bol ts-to-case (Fi g. 263).
Fig. 260 Remove Transmission Oil Pan Bolts
1 - TRANSMISSION OIL PAN
2 - BOLTS
Fig. 261 Remove Transmission Oil Pan
1 - TRANSMISSION OIL PAN
Fig. 262 Remove Transmission Filter
1 - TRANSMISSION FILTER
Fig. 263 Remove Valve Body Bolts
1 - BOLTS
21 - 184 AUTOMATIC TRANSMISSION - 42RLE TJ
VALVE BODY (Continued)
(8) Careful l y remove val ve body assembl y from
transmi ssi on (Fi g. 264).
CAUTION: The overdrive and underdrive accumula-
tors and springs may fall out when removing the
valve body.
DISASSEMBLY
NOTE: If the valve body is being reconditioned or
replaced, it is necessary to perform the Quick Learn
Procedure using the DRBIIIா Scan Tool (Refer to 8 -
ELECTRICAL/ELECTRONIC CONTROL MODULES/
TRANSMISSION CONTROL MODULE - STANDARD
PROCEDURE)
(1) Remove manual shaft seal .
(2) Remove manual shaft screw (Fi g. 265).
(3) Remove Transmi ssi on Range Sensor (TRS) and
manual shaft (Fi g. 266).
Fig. 264 Remove Valve Body From Transmission
1 - VALVE BODY
Fig. 265 Manual Shaft Retaining Screw
1 - SCREW
2 - TRS
Fig. 266 Manual Shaft/Rooster Comb and
Transmission Range Sensor
1 - TRANSMISSION RANGE SENSOR
2 - MANUAL SHAFT
3 - ROOSTER COMB
TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 185
VALVE BODY (Continued)
(4) Remove Sol enoi d/Pressure Swi tch Assembl y
from val ve body (Fi g. 267).
(5) Remove val ve body sti ffener pl ate (Fi g. 268).
(6) I nvert val ve body assembl y and remove trans-
fer pl ate-to-val ve body screws (Fi g. 269).
(7) Remove transfer/separator pl ate from val ve
body (Fi g. 270)
Fig. 267 Solenoid Retaining Screws
1 - SOLENOID/PRESSURE SWITCH ASSEMBLY
2 - RETAINING SCREWS
Fig. 268 Remove Stiffener Plate
1 - STIFFENER PLATE
Fig. 269 Remove Transfer Plate-to-Valve Body
Screws
1 - SCREW (24)
2 - TRANSFER PLATE
Fig. 270 Remove Transfer Plate to Valve Body
1 - TRANSFER PLATE
2 - VALVE BODY
21 - 186 AUTOMATIC TRANSMISSION - 42RLE TJ
VALVE BODY (Continued)
(8) Remove separator pl ate-to-transfer pl ate
screws (Fi g. 271).
(9) Remove separator pl ate from transfer pl ate
(Fi g. 272).
(10) Remove the oi l screen from the transfer pl ate
(Fi g. 273).
(11) Remove thermal val ve (Fi g. 274) from transfer
pl ate.
Fig. 271 Remove Separator Plate-to-Transfer Plate
Screws
1 - SEPARATOR PLATE
2 - SCREW (2)
3 - TRANSFER PLATE
Fig. 272 Remove Separator Plate to Transfer Plate
1 - SEPARATOR PLATE
2 - TRANSFER PLATE
Fig. 273 Remove Oil Screen to Transfer Plate
1 - OIL SCREEN
Fig. 274 Remove Thermal Valve to Transfer Plate
1 - THERMAL VALVE
TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 187
VALVE BODY (Continued)
(12) Remove val ve body check bal l s. Note thei r
l ocati on for assembl y ease (Fi g. 275).
(13) Remove 2/4 accumul ator assembl y as shown
i n (Fi g. 276).
(14) Remove dual retai ner pl ate from val ve body.
Use speci al tool 6301 to remove pl ate (Fi g. 277).
Fig. 275 Ball Check Location
1 - (#4) BALL CHECK LOCATION
2 - (#2) BALL CHECK LOCATION
3 - (#5) BALL CHECK LOCATION
4 - (#3) BALL CHECK LOCATION
Fig. 276 2/4 Accumulator Assembly
1 - VALVE BODY
2 - RETAINER PLATE
3 - DETENT SPRING
4 - RETURN SPRINGS
5 - PISTON
Fig. 277 Remove Dual Retainer Plate using Tool
6301
1 - TOOL 6301
2 - RETAINER
21 - 188 AUTOMATIC TRANSMISSION - 42RLE TJ
VALVE BODY (Continued)
(15) Remove regul ator val ve spri ng retai ner (Fi g. 278).
(16) Remove remai ni ng retai ners as shown i n (Fi g.
279).
(17) Remove val ves and spri ngs as shown i n (Fi g.
280).
Fig. 278 Remove Regulator Valve Spring Retainer
using Tool 6302
1 - TOOL 6302
2 - RETAINER
Fig. 279 Valve Retainer Location
1 - RETAINER
2 - RETAINER
Fig. 280 Valve Body Assembly
1 - VALVE BODY
2 - T/C REGULATOR VALVE
3 - L/R SWITCH VALVE
4 - CONVERTER CLUTCH CONTROL VALVE
5 - MANUAL VALVE
6 - CONVERTER CLUTCH SWITCH VALVE
7 - SOLENOID SWITCH VALVE
8 - REGULATOR VALVE
TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 189
VALVE BODY (Continued)
(18) Cl eanl i ness through enti re di sassembl y and
assembl y of the val ve body cannot be overempha-
si zed. When di sassembl i ng, each part shoul d be
washed i n a sui tabl e sol vent, then dri ed by com-
pressed ai r. Do not wipe parts with shop towels.
Al l mati ng surfaces i n the val ve body are accuratel y
machi ned; therefore, careful handl i ng of al l parts
must be exerci sed to avoi d ni cks or burrs.
ASSEMBLY
NOTE: If the valve body assembly is being recondi-
tioned or replaced, it is necessary to perform the
Quick Learn Procedure using the DRBIIIா Scan
Tool. (Refer to 8 - ELECTRICAL/ELECTRONIC CON-
TROL MODULES/TRANSMISSION CONTROL MOD-
ULE - STANDARD PROCEDURE)
(1) I nstal l val ves and spri ngs as shown i n (Fi g.
281).
(2) I nstal l regul ator val ve spri ng retai ner (Fi g.
282).
Fig. 281 Valve Body Assembly
1 - VALVE BODY
2 - T/C REGULATOR VALVE
3 - L/R SWITCH VALVE
4 - CONVERTER CLUTCH CONTROL VALVE
5 - MANUAL VALVE
6 - CONVERTER CLUTCH SWITCH VALVE
7 - SOLENOID SWITCH VALVE
8 - REGULATOR VALVE
Fig. 282 Install Regulator Valve Spring Retainer
using Tool 6302
1 - TOOL 6302
2 - RETAINER
21 - 190 AUTOMATIC TRANSMISSION - 42RLE TJ
VALVE BODY (Continued)
(3) I nstal l dual retai ner pl ate usi ng Tool 6301 (Fi g.
283).
(4) Veri fy that al l retai ners are i nstal l ed as shown
i n (Fi g. 284). Retai ners shoul d be fl ush or bel ow
val ve body surface.
(5) I nstal l 2/4 Accumul ator components as shown
i n (Fi g. 285). Torque 2/4 Accumul ator retai ner pl ate
to 5 N·m (45 i n. l bs.).
Fig. 283 Install Dual Retainer Plate using Tool 6301
1 - TOOL 6301
2 - RETAINER
Fig. 284 Valve Retainer Location
1 - RETAINER
2 - RETAINER
Fig. 285 2/4 Accumulator Assembly
1 - VALVE BODY
2 - RETAINER PLATE
3 - DETENT SPRING
4 - RETURN SPRINGS
5 - PISTON
TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 191
VALVE BODY (Continued)
(6) I nstal l check bal l s i nto posi ti on as shown i n
(Fi g. 286). I f necessary, secure them wi th petrol atum
or transmi ssi on assembl y gel for assembl y ease.
(7) I nstal l thermal val ve to the transfer pl ate (Fi g.
287).
(8) I nstal l the oi l screen to the transfer pl ate (Fi g.
288).
Fig. 286 Ball Check Location
1 - (#4) BALL CHECK LOCATION
2 - (#2) BALL CHECK LOCATION
3 - (#5) BALL CHECK LOCATION
4 - (#3) BALL CHECK LOCATION
Fig. 288 Install Oil Screen to Transfer Plate
1 - OIL SCREEN
Fig. 287 Install Thermal Valve to Transfer Plate
1 - THERMAL VALVE
21 - 192 AUTOMATIC TRANSMISSION - 42RLE TJ
VALVE BODY (Continued)
(9) I nstal l separator pl ate to transfer pl ate (Fi g.
289).
(10) I nstal l the two separator pl ate-to-transfer
pl ate screws (Fi g. 290).
(11) I nstal l the transfer pl ate to the val ve body
(Fi g. 291).
(12) I nstal l the transfer pl ate-to-val ve body screws
(Fi g. 292) and torque to 5 N·m (45 i n. l bs.).
Fig. 289 Install Separator Plate to Transfer Plate
1 - SEPARATOR PLATE
2 - TRANSFER PLATE
Fig. 290 Install Separator Plate-to-Transfer Plate
Screws
1 - SEPARATOR PLATE
2 - SCREW (2)
3 - TRANSFER PLATE
Fig. 291 Install Transfer Plate to Valve Body
1 - TRANSFER PLATE
2 - VALVE BODY
Fig. 292 Install Transfer Plate-to-Valve Body Screws
1 - SCREW (24)
2 - TRANSFER PLATE
TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 193
VALVE BODY (Continued)
2(13) I nstal l the sti ffener pl ate (Fi g. 293).
(14) I nstal l the sol enoi d/pressure swi tch assembl y
and to the transfer pl ate (Fi g. 294) and torque to 5.5
N·m (50 i n. l bs.).
(15) I nstal l the manual shaft/rooster comb and
transmi ssi on range sensor to the val ve body (Fi g.
295).
(16) I nstal l the TRS/manual shaft retai ni ng screw
(Fi g. 296) and torque to 5 N·m (45 i n. l bs.).
(17) I nstal l manual shaft seal .
Fig. 293 Install Stiffener Plate
1 - STIFFENER PLATE
Fig. 294 Solenoid Retaining Screws
1 - SOLENOID/PRESSURE SWITCH ASSEMBLY
2 - RETAINING SCREWS
Fig. 295 Manual Shaft/Rooster Comb and
Transmission Range Sensor
1 - TRANSMISSION RANGE SENSOR
2 - MANUAL SHAFT
3 - ROOSTER COMB
Fig. 296 Manual Shaft Retaining Screw
1 - SCREW
2 - TRS
21 - 194 AUTOMATIC TRANSMISSION - 42RLE TJ
VALVE BODY (Continued)
INSTALLATION
(1) I nstal l val ve body i nto posi ti on and start bol ts.
Torque val ve body to transmi ssi on case bol ts (Fi g.
297) to 12 N·m (105 i n. l bs.) torque.
(2) I nstal l transmi ssi on oi l fi l ter (Fi g. 298).
NOTE: Before installing the oil pan bolt in the bolt
hole located between the torque converter clutch
on and U/D clutch pressure tap circuits (Fig. 299), it
will be necessary to replentish the sealing patch on
the bolt using Moparா Lock & Seal Adhesive.
(3) Make sure oi l pan and case rai l are cl ean and
dry. I nstal l an 1/8” bead of RTV to the transmi ssi on
oi l pan and i nstal l to case. Ti ghten bol ts (Fi g. 300) to
20 N·m (14.5 ft. l bs.).
(4) Lower vehi cl e and connect the TRS connector.
(5) Connect sol enoi d/pressure swi tch assembl y con-
nector.
(6) Lower vehi cl e.
(7) Fi l l transmi ssi on wi th ATF+4, Automati c
Transmi ssi on Fl ui d. Veri fy proper fl ui d l evel . (Refer
to 21 - TRANSMI SSI ON/AUTOMATI C - 42RLE/
FLUI D - STANDARD PROCEDURE)
NOTE: If the valve body has been reconditioned or
replaced, it is necessary to perform the Quick Learn
Procedure. (Refer to 8 - ELECTRICAL/ELECTRONIC
CONTROL MODULES/TRANSMISSION CONTROL
MODULE - STANDARD PROCEDURE)
Fig. 297 Install Valve Body Bolts
1 - BOLTS
Fig. 298 Install Transmission Filter
1 - TRANSMISSION FILTER
Fig. 299 Pan Fastener Location
1 - FRONT DRIVESHAFT
2 - PRESSURE PORTS
3 - TRANSMISSION CASE
4 - TRANSMISSION OIL PAN
5 - SECOND TRANSMISSION OIL PAN BOLT ON LEFT SIDE
6 - FIRST TRANSMISSION OIL PAN BOLT
Fig. 300 Install Transmission Oil Pan Bolts
1 - TRANSMISSION OIL PAN
2 - BOLTS
TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 195
VALVE BODY (Continued)
TRANSFER CASE - NV231
TABLE OF CONTENTS
page page
TRANSFER CASE - NV231
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 196
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 197
DIAGNOSIS AND TESTING - TRANSFER
CASE - NV231 . . . . . . . . . . . . . . . . . . . . . . . 197
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 198
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 206
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 220
SPECIFICATIONS
TRANSFER CASE - NV231 . . . . . . . . . . . . . 221
SPECIAL TOOLS
NV231 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
FLUID
STANDARD PROCEDURE - FLUID DRAIN AND
FILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
FRONT OUTPUT SHAFT SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 224
REAR OUTPUT SHAFT SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 225
SHIFT LEVER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 227
ADJUSTMENTS - SHIFT LINKAGE . . . . . . . . . 228
SPEEDOMETER DRIVE ADAPTER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 228
VEHICLE SPEED SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 229
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 229
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 230
TRANSFER CASE - NV231
DESCRIPTION
The NV231 i s a part-ti me transfer case wi th a l ow
range reducti on gear system. The NV231 has three
operati ng ranges pl us a NEUTRAL posi ti on. A l ow
range system provi des a reducti on rati o for i ncreased
l ow speed torque capabi l i ty.
The geartrai n i s mounted i n two al umi num case
hal ves attached wi th bol ts. The mai nshaft front and
rear beari ngs are mounted i n al umi num retai ner
housi ngs bol ted to the case hal ves.
OPERATING RANGES
Transfer case operati ng ranges are:
• 2WD (2-wheel dri ve)
• 4x4 (4-wheel dri ve)
• 4 Lo (4-wheel dri ve l ow range
The 2WD range i s for use on any road surface at
any ti me.
The 4x4 and 4 Lo ranges are for off road use onl y.
They are not for use on hard surface roads. The onl y
excepti on bei ng when the road surface i s wet or sl i p-
pery or covered by i ce and snow.
The l ow range reducti on gear system i s operati ve
i n 4 Lo range onl y. Thi s range i s for extra pul l i ng
power i n off road si tuati ons. Low range reducti on
rati o i s 2.72:1.
SHIFT MECHANISM
Operati ng ranges are sel ected wi th a fl oor mounted
shi ft l ever. The shi ft l ever i s connected to the trans-
fer case range l ever by an adjustabl e l i nkage rod. A
strai ght l i ne shi ft pattern i s used. Range posi ti ons
are marked on the shi fter bezel cover pl ate.
IDENTIFICATION
A ci rcul ar I D tag i s attached to the rear case of
each transfer case (Fi g. 1). The I D tag provi des the
transfer case model number, assembl y number, seri al
number, and l ow range rati o.
The transfer case seri al number al so represents
the date of bui l d.
Fig. 1 Fill/Drain Plug And I.D. Tag Locations - Typical
1 - I.D. TAG
2 - FILL PLUG
3 - DRAIN PLUG
21 - 196 TRANSFER CASE - NV231 TJ
OPERATION
The i nput gear i s spl i ned to the transmi ssi on out-
put shaft. The i nput gear dri ves the mai nshaft
through the pl anetary assembl y and range hub. The
front output shaft i s operated by a dri ve chai n that
connects the shaft to a dri ve sprocket on the mai n-
shaft. The dri ve sprocket i s engaged/di sengaged by
the mode fork, whi ch operates the mode sl eeve and
hub. The sl eeve and hub are not equi pped wi th a
synchroni zer mechani sm for shi fti ng.
DIAGNOSIS AND TESTING - TRANSFER CASE - NV231
DIAGNOSIS CHART
Condition Possible Cause Correction
Transfer case difficult to shift or will
not shift into desired range.
1) Vehicle speed to great to permit
shifting.
1) Slow vehicle and shift into desired
range.
2) If vehicle was operated for an
extended period in 4H mode on dry
surface, driveline torque load may
cause difficulty.
2) Stop vehicle and shift transfer
case to Neutral position. Transfer
case can then be shifted to the
desired mode.
3) Transfer case shift linkage
binding.
3) Repair or replace linkage as
necessary.
4) Insufficient or incorrect lubricant. 4) Drain and refill transfer case with
the correct type and quantity of
lubricant.
5) Internal transfer case
components binding, worn, or
damaged.
5) Repair or replace components as
necessary.
Transfer case noisy in all drive
modes.
1) Insufficient or incorrect lubricant. 1) Drain and refill transfer case with
the correct type and quantity of
lubricant.
Transfer case noisy while in, or
jumps out of, 4L mode.
1) Transfer case not completely
engaged in 4L position.
1) Slow vehicle, shift transfer case
to the Neutral position, and then
shift into the 4L mode.
2) Transfer case shift linkage out of
adjustment.
2) Adjust linkage as necessary.
3) Transfer case shift linkage loose
or binding.
3) Repair, replace, or tighten linkage
components as necessary.
4) Range fork damaged, inserts
worn, or fork is binding on the shift
rail.
4) Repair or replace components as
necessary.
5) Low range gear worn or
damaged.
5) Repair or replace components as
necessary.
Lubricant leaking from transfer case
seals or vent.
1) Transfer case overfilled. 1) Drain lubricant to the correct
level.
2) Transfer case vent closed or
restricted.
2) Clean or replace vent as
necessary.
3) Transfer case seals damaged or
installed incorrectly.
3) Replace suspect seal.
Abnormal tire wear. 1) Extended operation in 4H mode
on dry surfaces,
1) Operate vehicle in 2H mode on
dry surfaces.
TJ TRANSFER CASE - NV231 21 - 197
TRANSFER CASE - NV231 (Continued)
REMOVAL
(1) Shi ft transfer case i nto NEUTRAL.
(2) Rai se vehi cl e.
(3) Drai n transfer case l ubri cant.
(4) Mark front and rear propel l er shaft yokes for
al i gnment reference.
(5) Support transmi ssi on wi th jack stand.
(6) Remove rear crossmember, or ski d pl ate.
(7) Di sconnect front/rear propel l er shafts at trans-
fer case.
(8) Di sconnect vehi cl e speed sensor wi res.
(9) Di sconnect transfer case l i nkage rod from
range l ever.
(10) Di sconnect transfer case vent hose (Fi g. 2)
and i ndi cator swi tch harness, i f necessary.
(11) Support transfer case wi th transmi ssi on jack.
(12) Secure transfer case to jack wi th chai ns.
(13) Remove nuts attachi ng transfer case to trans-
mi ssi on.
(14) Pul l transfer case and jack rearward to di sen-
gage transfer case.
(15) Remove transfer case from under vehi cl e.
DISASSEMBLY
Posi ti on transfer case on shal l ow drai n pan.
Remove drai n pl ug and drai n l ubri cant remai ni ng i n
case.
REAR RETAINER AND OIL PUMP
(1) Remove the speedometer adapter.
(2) Spread band cl amp whi ch hol ds output shaft
boot to the output shaft sl i nger, or output shaft
damper, wi th a sui tabl e awl , or equi val ent.
NOTE: Vehicles built with a 4.0L engine and a man-
ual transmission use a damper weight on the trans-
fer case output shaft. Be sure to identify the
transfer case before proceeding.
(3) Remove output shaft boot from sl i nger, or out-
put shaft damper, and output shaft.
(4) I f the vehi cl e i s not equi pped wi th an output
shaft damper, remove the output shaft rear sl i nger
usi ng Pul l er MD-998056-A (Fi g. 3).
(5) I f the vehi cl e i s equi pped wi th an output shaft
damper, use Screws 8421 and the pul l er yoke and
forci ng screw from a bol t-gri p pul l er set, such as
those used to remove steeri ng wheel s and harmoni c
bal ancers, to remove the transfer case output shaft
damper.
(6) Use a sui tabl e pry tool , or a sl i de hammer
mounted screw, to remove the seal from the rear
retai ner (Fi g. 4).
Fig. 4 Rear Retainer Seal
1 - REAR RETAINER
2 - OUTPUT SHAFT SEAL
Fig. 2 Transfer Case Mounting
1 - VENT TUBE
2 - TRANSFER CASE
3 - TRANSMISSION
Fig. 3 Rear Slinger Removal
1 - TRANSFER CASE
2 - SPECIAL TOOL MD-998056-A
3 - SLINGER
21 - 198 TRANSFER CASE - NV231 TJ
TRANSFER CASE - NV231 (Continued)
(7) Remove the rear output beari ng I .D. retai ni ng
ri ng (Fi g. 5).
(8) Remove the bol ts hol di ng the rear retai ner to
the rear case hal f.
(9) Tap rear retai ner wi th rawhi de or rubber mal -
l et to l oosen seal er bead.
(10) Remove rear retai ner from rear case hal f (Fi g.
6).
(11) Remove snap-ri ng hol di ng oi l pump i n posi ti on
on output shaft.
(12) Di sengage oi l pi ckup tube from oi l pump and
remove oi l pump assembl y. Remove oi l pump by ti l t-
i ng the edge of the oi l pump from under the edge of
the rear case hal f and sl i di ng the pump (Fi g. 7).
(13) Remove pi ck-up tube o-ri ng from oi l pump
(Fi g. 8), i f necessary. Do not di sassembl e the oi l
pump, i t i s not servi ceabl e.
Fig. 5 Output Shaft Rear Bearing Retaining Ring
1 - SNAP-RING PLIERS
2 - REAR BEARING I.D. RETAINING RING
Fig. 6 Rear Retainer Removal
1 - MAINSHAFT
2 - REAR RETAINER
Fig. 7 Oil Pump Removal
1 - OIL PUMP
Fig. 8 Pick-up Tube O-ring Location
1 - OIL PUMP
2 - O-RING
TJ TRANSFER CASE - NV231 21 - 199
TRANSFER CASE - NV231 (Continued)
YOKE AND RANGE LEVER
(1) Remove transfer case i ndi cator swi tch.
(2) Remove front yoke nut as fol l ows:
(a) Move range l ever to 4L posi ti on.
(b) Then remove nut wi th socket and i mpact
wrench (Fi g. 9).
(3) Remove yoke. I f yoke i s di ffi cul t to remove by
hand, remove i t wi th beari ng spl i tter, or wi th stan-
dard two jaw pul l er (Fi g. 10). Be sure pul l er tool i s
posi ti oned on yoke and not on sl i nger as sl i nger wi l l
be damaged.
(4) Remove seal washer from front output shaft.
Di scard washer as i t shoul d not be reused.
(5) Remove nut and washer that attach range
l ever to sector shaft. Then move sector to neutral
posi ti on and remove range l ever from shaft (Fi g. 11).
FRONT OUTPUT SHAFT AND DRIVE CHAIN
(1) Support transfer case so rear case i s faci ng
upward.
(2) Remove bol ts hol di ng front case to rear case.
The case al i gnment bol ts requi re fl at washers (Fi g.
12).
Fig. 12 Rear Case Alignment Bolt Locations
1 - DOWEL BOLT AND WASHER (2)
2 - CASE BOLT (5)
3 - SPLINE HEAD BOLT (1)
Fig. 9 Yoke Nut Removal
1 - IMPACT WRENCH
2 - SOCKET
3 - YOKE
Fig. 10 Yoke Removal
1 - PULLER TOOL
2 - YOKE
Fig. 11 Range Lever Removal
1 - RANGE LEVER
2 - SECTOR SHAFT
21 - 200 TRANSFER CASE - NV231 TJ
TRANSFER CASE - NV231 (Continued)
(3) Loosen rear case wi th fl at bl ade screwdri ver to
break seal er bead. I nsert pry tool bl ade onl y i nto
notches provi ded at each end of case (Fi g. 13).
(4) Remove rear case from front case.
(5) Remove oi l pi ckup tube from rear case (Fi g.
14).
(6) Remove mode fork spri ng (Fi g. 15).
(7) Pul l front output shaft upward and out of front
output shaft beari ng (Fi g. 16).
(8) Remove front output shaft and chai n.
Fig. 13 Loosening Rear Case - Typical
1 - REAR CASE
2 - PRY TOOL (IN CASE SLOT)
3 - FRONT CASE
Fig. 14 Oil Pickup Tube Removal
1 - CONNECTING HOSE
2 - PICKUP SCREEN
3 - PICKUP TUBE
Fig. 15 Mode Fork Spring Removal
1 - MODE SPRING
Fig. 16 Remove Front Output Shaft And Chain
1 - DRIVE CHAIN
2 - FRONT OUTPUT SHAFT
3 - SHAFT FRONT BEARING
TJ TRANSFER CASE - NV231 21 - 201
TRANSFER CASE - NV231 (Continued)
SHIFT FORKS AND MAINSHAFT
(1) Remove detent pl ug, O-ri ng, detent spri ng and
detent pl unger (Fi g. 17).
(2) Remove mai nshaft from mode sl eeve and i nput
gear pi l ot beari ng.
(3) Remove mode fork and sl eeve as an assembl y
(Fi g. 18). Note posi ti on of sl eeve for assembl y refer-
ence. The short si de of the sl eeve faces upward.
(4) Remove range fork and hub as an assembl y
(Fi g. 19). Note fork posi ti on for i nstal l ati on reference.
(5) Remove shi ft sector from front case (Fi g. 20).
(6) Remove shi ft sector bushi ng and O-ri ng (Fi g.
21).
Fig. 17 Detent Plug, Spring And Plunger Removal
1 - POPPET
2 - SPRING
3 - SCREW
4 - POPPET BORE (IN CASE)
Fig. 18 Mode Fork And Sleeve Removal
1 - MODE SLEEVE
2 - MODE FORK AND RAIL
Fig. 19 Range Fork And Sleeve Removal
1 - RANGE HUB
2 - RANGE FORK
Fig. 20 Shift Sector Removal
1 - SHIFT SECTOR
Fig. 21 Sector Bushing And O-Ring Removal
1 - SEAL RETAINER
2 - SECTOR SHAFT BORE
3 - O-RING SEAL
21 - 202 TRANSFER CASE - NV231 TJ
TRANSFER CASE - NV231 (Continued)
MAINSHAFT
(1) Remove mode hub retai ni ng ri ng wi th heavy
duty snap-ri ng pl i ers (Fi g. 22).
(2) Sl i de mode hub off mai nshaft (Fi g. 23).
(3) Sl i de dri ve sprocket off mai nshaft (Fi g. 24).
INPUT GEAR AND LOW RANGE GEAR
(1) Remove front beari ng retai ner attachi ng bol ts
(Fi g. 25).
Fig. 25 Front Bearing Retainer Bolts
1 - FRONT CASE
2 - FRONT BEARING RETAINER
3 - RETAINER BOLTS
Fig. 22 Mode Hub Retaining Ring Removal
1 - MODE HUB
2 - SNAP-RING PLIERS (HEAVY DUTY)
3 - MODE HUB RETAINING RING
Fig. 23 Mode Hub Removal
1 - MAINSHAFT
2 - MODE HUB
Fig. 24 Drive Sprocket Removal
1 - DRIVE SPROCKET
2 - MAINSHAFT
TJ TRANSFER CASE - NV231 21 - 203
TRANSFER CASE - NV231 (Continued)
(2) Remove front beari ng retai ner. Pry retai ner
l oose wi th pry tool posi ti oned i n sl ots at each end of
retai ner (Fi g. 26).
(3) Remove front beari ng retai ner seal . Tap seal
out wi th dri ft and hammer.
(4) Remove i nput gear retai ni ng ri ng wi th heavy
duty snap-ri ng pl i ers (Fi g. 27)
(5) Pl ace front case i n hori zontal posi ti on. Then
remove i nput gear and l ow range gear as an assem-
bl y (Fi g. 28). Tap gear out of beari ng wi th pl asti c
mal l et i f necessary.
INPUT AND LOW RANGE GEAR
(1) Remove snap-ri ng that retai ns i nput gear i n
l ow range gear (Fi g. 29).
Fig. 29 Input Gear Snap-Ring Removal
1 - CARRIER LOCK RETAINING RING
2 - INPUT GEAR
3 - PLANETARY CARRIER
4 - SCREWDRIVER
Fig. 26 Front Bearing Retainer Removal
1 - FRONT BEARING RETAINER
2 - RETAINER SLOT
Fig. 27 Removing Input Gear Retaining Ring
1 - INPUT GEAR BEARING RETAINING RING
2 - INPUT GEAR BEARING
3 - SNAP-RING PLIERS
Fig. 28 Input Gear And Planetary Carrier Removal
1 - PLANETARY ASSEMBLY
2 - INPUT GEAR
21 - 204 TRANSFER CASE - NV231 TJ
TRANSFER CASE - NV231 (Continued)
(2) Remove retai ner (Fi g. 30).
(3) Remove front tabbed thrust washer (Fi g. 31).
(4) Remove i nput gear (Fi g. 32).
(5) Remove rear tabbed thrust washer from l ow
range gear (Fi g. 33).
CLEANING
Cl ean the transfer case parts wi th a standard
parts cl eani ng sol vent. Remove al l traces of seal er
from the cases and retai ners wi th a scraper and
3M™ al l purpose cl eaner. Use compressed ai r to
remove sol vent resi due from oi l feed passages i n the
case hal ves, retai ners, gears, and shafts.
Fig. 30 Input Gear Retainer Removal
1 - INPUT GEAR
2 - LOW RANGE GEAR
3 - RETAINER
Fig. 31 Front Tabbed Thrust Washer Removal
1 - FRONT TABBED THRUST WASHER
Fig. 32 Input Gear Removal
1 - INPUT GEAR
2 - LOW RANGE GEAR
Fig. 33 Rear Tabbed Thrust Washer Removal
1 - LOW RANGE GEAR
2 - REAR TABBED THRUST WASHER
TJ TRANSFER CASE - NV231 21 - 205
TRANSFER CASE - NV231 (Continued)
INSPECTION
MAINSHAFT/SPROCKET/HUB
I nspect the spl i nes on the hub and shaft and the
teeth on the sprocket (Fi g. 34). Mi nor ni cks and
scratches can be smoothed wi th an oi l stone. However,
repl ace any part that i s damaged.
Check the contact surfaces i n the sprocket bore
and on the mai nshaft. Mi nor ni cks and scratches can
be smoothed wi th 320-400 gri t emery cl oth but do not
try to sal vage the shaft i f ni cks or wear i s severe.
INPUT GEAR AND PLANETARY CARRIER
Check the teeth on the gear (Fi g. 35). Mi nor ni cks
can be dressed off wi th an oi l stone but repl ace the
gear i f any teeth are broken, cracked, or chi pped. The
beari ng surface on the gear can be smoothed wi th
300-400 gri t emery cl oth i f necessary.
Exami ne the carri er body and pi ni on gears for
wear or damage. The carri er wi l l have to be repl aced
as an assembl y i f the body, pi ni on pi ns, or pi ni on
gears are damaged.
Fig. 34 Mainshaft, Mode Hub, And Drive Sprocket
1 - MODE HUB 3 - MAINSHAFT
2 - DRIVE SPROCKET 4 - MODE HUB RETAINING RING
Fig. 35 Input Gear And Carrier Components
1 - PLANETARY CARRIER 4 - CARRIER LOCK RING
2 - REAR THRUST WASHER 5 - CARRIER LOCK RETAINING RING
3 - FRONT THRUST WASHER 6 - INPUT GEAR
21 - 206 TRANSFER CASE - NV231 TJ
TRANSFER CASE - NV231 (Continued)
Check the l ock ri ng and both thrust washers for
wear or cracks. Repl ace them i f necessary. Al so
repl ace the l ock retai ni ng ri ng i f bent, di storted, or
broken.
SHIFT FORKS/HUBS/SLEEVES
Check condi ti on of the shi ft forks and mode fork
shi ft rai l (Fi g. 36). Mi nor ni cks on the shi ft rai l can
be smoothed wi th 320-400 gri t emery cl oth.
I nspect the shi ft fork wear pads (Fi g. 37). The
mode fork pads are servi ceabl e and can be repl aced i f
necessary. The range fork pads are not servi ceabl e.
The fork must be repl aced as an assembl y i f the pads
are worn or damaged.
Check both of the sl eeves for wear or damage,
especi al l y on the i nteri or teeth. Repl ace the sl eeves i f
wear or damage i s evi dent.
REAR RETAINER/BEARING/ SEAL/SLINGER/BOOT
I nspect the retai ner components (Fi g. 38). Repl ace
the beari ng i f rough or noi sy. Check the retai ner for
cracks or wear i n the beari ng bore. Cl ean the
retai ner seal i ng surfaces wi th a scraper and 3M™ al l
purpose cl eaner. Thi s wi l l ensure proper adhesi on of
the seal er duri ng reassembl y.
An output shaft sl i nger i s used on some vehi cl es,
whi l e an output shaft damper i s used on other vehi -
cl es. The output shaft sl i nger and seal shoul d be
repl aced outri ght; do not reuse ei ther part.
Repl ace any part i f di storted, bent, or broken. Al so
repl ace the boot i f cut or torn. Repl ace the boot band
cl amps, do not reuse them.
REAR OUTPUT SHAFT/YOKE/DRIVE CHAIN
Check condi ti on of the seal contact surfaces of the
yoke sl i nger (Fi g. 39). Thi s surface must be cl ean and
smooth to ensure proper seal l i fe. Repl ace the yoke
nut and seal washer as nei ther part shoul d be
reused.
I nspect the shaft threads, sprocket teeth, and bear-
i ng surfaces. Mi nor ni cks on the teeth can be
smoothed wi th an oi l stone. Use 320-400 gri t emery to
smooth mi nor scratches on the shaft beari ng sur-
faces. Rough threads on the shaft can be chased i f
necessary. Repl ace the shaft i f the threads are dam-
aged, beari ng surfaces are scored, or i f any sprocket
teeth are cracked or broken.
Exami ne the dri ve chai n and shaft beari ngs.
Repl ace the chai n and both sprockets i f the chai n i s
stretched, di storted, or i f any of the l i nks bi nd.
Repl ace the beari ngs i f rough, or noi sy.
LOW RANGE ANNULUS GEAR
I nspect annul us gear condi ti on careful l y. The gear
i s onl y servi ced as part of the front case. I f the gear
i s damaged, i t wi l l be necessary to repl ace the gear
and front case as an assembl y. Do not attempt to
remove the gear (Fi g. 40)
Fig. 36 Shift Forks
1 - RANGE FORK
2 - MODE FORK AND RAIL
3 - MODE SPRING
Fig. 37 Shift Fork And Wear Pad Locations
1 - RANGE FORK
2 - MODE FORK
3 - WEAR PADS (SERVICEABLE)
4 - WEAR PADS (NON-SERVICEABLE)
TJ TRANSFER CASE - NV231 21 - 207
TRANSFER CASE - NV231 (Continued)
Fig. 38 Rear Retainer Without Output Shaft Damper
1 - REAR RETAINER 5 - BAND CLAMPS
2 - REAR BEARING I.D. MAINSHAFT RETAINING RING 6 - REAR SLINGER
3 - REAR SEAL 7 - REAR BEARING O.D. RETAINING RING
4 - BOOT 8 - REAR BEARING
Fig. 39 Seal Contact Surface Of Yoke Slinger
1 - FRONT SLINGER (PART OF YOKE)
2 - SEAL CONTACT SURFACE MUST BE CLEAN AND SMOOTH
Fig. 40 Low Range Annulus Gear
1 - FRONT CASE
2 - LOW RANGE ANNULUS GEAR
21 - 208 TRANSFER CASE - NV231 TJ
TRANSFER CASE - NV231 (Continued)
FRONT/REAR CASES AND FRONT RETAINER
I nspect the cases and retai ner for wear and dam-
age. Cl ean the seal i ng surfaces wi th a scraper and
3M™ al l purpose cl eaner. Thi s wi l l ensure proper
seal er adhesi on at assembl y. Repl ace the i nput
retai ner seal ; do not reuse i t.
Check case condi ti on. I f l eaks were a probl em, l ook
for gouges and severe scori ng of case seal i ng sur-
faces. Al so make sure the front case mounti ng studs
are i n good condi ti on.
Check the front case mounti ng studs and vent
tube. The tube can be secured wi th Locti te™ 271 or
680 i f l oose. The stud threads can be cl eaned up wi th
a di e i f necessary. Al so check condi ti on of the fi l l /
drai n pl ug threads i n the rear case. The threads can
be repai red wi th a thread chaser or tap i f necessary.
Or the threads can be repai red wi th Hel i coi l ™ stai n-
l ess steel i nserts i f requi red.
OIL PUMP/OIL PICKUP
Exami ne the oi l pump pi ckup parts. Repl ace the
pump i f any part appears to be worn or damaged. Do
not di sassembl e the pump as i ndi vi dual parts are not
avai l abl e. The pump i s onl y avai l abl e as a compl ete
assembl y. The pi ckup screen, hose, and tube are the
onl y servi ceabl e parts and are avai l abl e separatel y.
ASSEMBLY
Lubri cate transfer case components wi th Mopar௡
ATF +4, Automati c Transmi ssi on Fl ui d, or petrol eum
jel l y (where i ndi cated) duri ng assembl y.
BEARINGS AND SEALS
CAUTION: The bearing bores in various transfer
case components contain oil feed holes. Make sure
replacement bearings do not block the holes.
(1) Remove the front output shaft seal from case
wi th pry tool (Fi g. 41).
(2) Remove the front output shaft beari ng retai n-
i ng ri ng wi th screwdri ver (Fi g. 42).
Fig. 41 Front Output Seal Removal - Typical
1 - OUTPUT SHAFT SEAL
2 - PRYBAR
Fig. 42 Front Output Shaft Bearing Retaining Ring
Removal
1 - SCREWDRIVERS
2 - SNAP-RING
3 - FRONT OUTPUT SHAFT BEARING
4 - FRONT CASE
TJ TRANSFER CASE - NV231 21 - 209
TRANSFER CASE - NV231 (Continued)
(3) Remove beari ng wi th Tool Handl e C-4171 and
Tool 5065 (Fi g. 43).
(4) I nstal l front output shaft front beari ng i n case
wi th Tool Handl e C-4171 and I nstal l er 5064 (Fi g. 44).
(5) I nstal l output shaft front beari ng retai ni ng
ri ng (Fi g. 45). Start ri ng i nto pl ace by hand. Then
use smal l screwdri ver to work ri ng i nto case groove.
Be sure ri ng i s ful l y seated before proceedi ng.
(6) I nstal l new front output seal i n front case wi th
I nstal l er Tool 8143-A as fol l ows:
(a) Pl ace new seal on tool . Garter spring on
seal goes toward interior of case.
(b) Start seal i n bore wi th l i ght taps from ham-
mer (Fi g. 46). Once seal i s started, conti nue tap-
pi ng seal i nto bore unti l i nstal l er tool bottoms
agai nst case.
Fig. 43 Front Output Shaft Bearing Removal
1 - FRONT CASE
2 - SPECIAL TOOL C-4171
3 - SPECIAL TOOL 5065
Fig. 44 Front Output Shaft Bearing Installation
1 - SPECIAL TOOL C-4171
2 - SPECIAL TOOL 5064
Fig. 45 Installing Output Shaft Front Bearing
Retaining Ring
1 - WORK RETAINING RING INTO BORE GROOVE WITH SMALL
SCREWDRIVER
Fig. 46 Front Output Seal Installation - Typical
1 - INSTALLER 8143-A
2 - TRANSFER CASE
21 - 210 TRANSFER CASE - NV231 TJ
TRANSFER CASE - NV231 (Continued)
(7) Remove the output shaft rear beari ng wi th the
screw and jaws from Remover L-4454 and Cup 8148
(Fi g. 47).
(8) I nstal l new beari ng wi th Tool Handl e C-4171
and I nstal l er 5066 (Fi g. 48). The beari ng bore i s
chamfered at the top. I nstal l the beari ng so i t i s
fl ush wi th the l ower edge of thi s chamfer (Fi g. 49).
Fig. 47 Output Shaft Rear Bearing Removal
1 - REAR CASE
2 - SPECIAL TOOL L-4454-1 AND L-4454-3
3 - SPECIAL TOOL 8148
Fig. 48 Output Shaft Rear Bearing Installation
1 - HANDLE C-4171
2 - OUTPUT SHAFT INNER BEARING
3 - INSTALLER 5066
Fig. 49 Output Shaft Rear Bearing Installation Depth
1 - BEARING (SEATED) AT LOWER EDGE OF CHAMFER
2 - CHAMFER
TJ TRANSFER CASE - NV231 21 - 211
TRANSFER CASE - NV231 (Continued)
(9) Usi ng Remover C-4210 and Handl e C-4171,
dri ve i nput shaft beari ng from i nsi de the annul us
gear openi ng i n the case (Fi g. 50).
(10) I nstal l l ocati ng ri ng on new beari ng.
(11) Posi ti on case so forward end i s faci ng upward.
(12) Usi ng Remover C-4210 and Handl e C-4171,
dri ve i nput shaft beari ng i nto case. The beari ng
l ocati ng ri ng must be ful l y seated agai nst case sur-
face (Fi g. 51).
(13) Remove i nput gear pi l ot beari ng by i nserti ng
a sui tabl y si zed dri ft i nto the spl i ned end of the i nput
gear and dri vi ng the beari ng out wi th the dri ft and a
hammer (Fi g. 52).
(14) I nstal l new pi l ot beari ng wi th I nstal l er 5065
and Handl e C-4171 (Fi g. 53).
Fig. 50 Input Shaft Bearing Removal
1 - SPECIAL TOOL C-4171
2 - SPECIAL TOOL C-4210
Fig. 51 Seating Input Shaft Bearing
1 - SNAP-RING
2 - INPUT SHAFT BEARING
Fig. 52 Remove Input Gear Pilot Bearing
1 - DRIFT
2 - INPUT GEAR
Fig. 53 Install Input Gear Pilot Bearing
1 - SPECIAL TOOL C-4171
2 - SPECIAL TOOL 5065
3 - INPUT GEAR
21 - 212 TRANSFER CASE - NV231 TJ
TRANSFER CASE - NV231 (Continued)
(15) Remove front beari ng retai ner seal wi th sui t-
abl e pry tool .
(16) I nstal l new front beari ng retai ner seal wi th
I nstal l er 7884 (Fi g. 54).
(17) Remove seal from oi l pump housi ng wi th a
sui tabl e pry tool
(18) I nstal l new seal i n oi l pump housi ng wi th
I nstal l er 7888 (Fi g. 55).
(19) Remove rear retai ner beari ng wi th I nstal l er
8128 and Handl e C-4171.
(20) I nstal l rear beari ng i n retai ner wi th Handl e
C-4171 and I nstal l er 5064 (Fi g. 56).
INPUT AND LOW RANGE GEAR
(1) I nstal l fi rst thrust washer i n l ow range gear
(Fi g. 57). Be sure washer tabs are properl y al i gned i n
gear notches.
(2) I nstal l i nput gear i n l ow range gear. Be sure
i nput gear i s ful l y seated.
Fig. 57 Input/Low Range Gear Components
1 - SNAP-RING
2 - RETAINER PLATE
3 - INPUT GEAR
4 - LOW RANGE GEAR
5 - THRUST WASHERS
Fig. 54 Install Front Bearing Retainer Seal
1 - FRONT BEARING RETAINER
2 - SPECIAL TOOL 7884
Fig. 55 Oil Pump Seal Installation
1 - HOUSING SEAL
2 - SPECIAL TOOL 7888
3 - OIL PUMP FEED HOUSING
Fig. 56 Installing Rear Bearing In Retainer
1 - SPECIAL TOOL C-4171
2 - SPECIAL TOOL 5064
3 - REAR RETAINER
TJ TRANSFER CASE - NV231 21 - 213
TRANSFER CASE - NV231 (Continued)
(3) I nstal l remai ni ng thrust washer i n l ow range
gear and on top of i nput gear. Be sure washer tabs
are properl y al i gned i n gear notches.
(4) I nstal l retai ner on i nput gear and i nstal l snap-
ri ng.
INPUT GEAR AND LOW RANGE GEAR
(1) Al i gn and i nstal l l ow range/i nput gear assem-
bl y i n front case (Fi g. 58). Be sure l ow range gear
pi ni ons are engaged i n annul us gear and that i nput
gear shaft i s ful l y seated i n front beari ng.
(2) I nstal l snap-ri ng to hol d i nput/l ow range gear
i nto front beari ng (Fi g. 59).
(3) Cl ean gasket seal er resi due from retai ner and
i nspect retai ner for cracks or other damage.
(4) Appl y a 3 mm (1/8 i n.) bead of Mopar௡ gasket
maker or si l i cone adhesi ve to seal i ng surface of
retai ner.
(5) Al i gn cavi ty i n seal retai ner wi th fl ui d return
hol e i n front of case.
CAUTION: Do not block fluid return cavity on seal-
ing surface of retainer when applying Moparா gas-
ket maker or silicone adhesive sealer. Seal failure
and fluid leak can result.
(6) I nstal l bol ts to hol d retai ner to transfer case
(Fi g. 60). Ti ghten to 21 N·m (16 ft. l bs.) of torque.
MAINSHAFT
(1) Lubri cate mai nshaft spl i nes wi th recommended
transmi ssi on fl ui d.
(2) Sl i de dri ve sprocket onto mai nshaft.
(3) Sl i de mode hub onto mai nshaft.
(4) I nstal l mode hub retai ni ng ri ng. Veri fy that the
retai ni ng ri ng i s ful l y seated i n mai nshaft groove.
Fig. 58 Input/Low Range Gear Installation
1 - ANNULUS GEAR
2 - INPUT/LOW RANGE GEAR
Fig. 59 Install Snap-Ring
1 - INPUT GEAR
2 - SNAP-RING
Fig. 60 Install Front Bearing Retainer
1 - FRONT BEARING RETAINER
21 - 214 TRANSFER CASE - NV231 TJ
TRANSFER CASE - NV231 (Continued)
SHIFT FORKS AND MAINSHAFT
(1) I nstal l new sector shaft O-ri ng and bushi ng
(Fi g. 61).
(2) I nstal l shi ft sector i n case (Fi g. 62). Lubri cate
sector shaft wi th transmi ssi on fl ui d before i nstal l a-
ti on.
(3) I nstal l range l ever, washer, and nut on sector
shaft (Fi g. 63). Ti ghten range l ever nut to 27-34 N·m
(20-25 ft. l bs.) torque.
(4) Assembl e and i nstal l range fork and hub (Fi g.
64). Be sure hub i s properl y seated i n l ow range gear
and engaged to the i nput gear.
(5) Al i gn and i nsert range fork pi n i n shi ft sector
sl ot.
Fig. 61 Sector O-Ring And Bushing Installation
1 - SECTOR BUSHING
2 - O-RING
Fig. 62 Shift Sector Installation
1 - SHIFT SECTOR
Fig. 63 Range Lever Installation
1 - RANGE LEVER
2 - LEVER NUT
Fig. 64 Install Range Fork And Sleeve Assembly
1 - RANGE HUB
2 - RANGE FORK
TJ TRANSFER CASE - NV231 21 - 215
TRANSFER CASE - NV231 (Continued)
(6) I nstal l assembl ed mai nshaft (Fi g. 65). Be sure
shaft i s seated i n pi l ot beari ng and i nput gear.
(7) I nstal l new pads on mode fork i f necessary.
(8) I nsert mode sl eeve i n mode fork mode fork. Be
sure l ong si de of sl eeve i s toward l ong end of shi ft
rai l (Fi g. 66).
(9) I nstal l assembl ed mode fork and sl eeve (Fi g.
67). Be sure fork rai l goes through range fork and
i nto case bore. Al so be sure sl eeve i s al i gned and
seated on mai nshaft hub.
(10) Rotate sector to NEUTRAL posi ti on.
(11) I nstal l new O-ri ng on detent pl ug (Fi g. 68).
(12) Lubri cate detent pl unger wi th transmi ssi on
fl ui d or l i ght coat of petrol eum jel l y.
(13) I nstal l detent pl unger, spri ng and pl ug (Fi g.
68).
(14) Veri fy that pl unger i s properl y engaged i n sec-
tor.
Fig. 65 Mainshaft Assembly Installation
1 - DRIVE SPROCKET
2 - MODE HUB
3 - MAINSHAFT
Fig. 66 Assembling Mode Fork And Sleeve
1 - MODE SLEEVE
2 - MODE FORK AND RAIL
Fig. 67 Mode Fork And Sleeve Installation
1 - MODE SLEEVE
2 - MODE FORK AND RAIL
Fig. 68 Shift Detent Components
1 - POPPET
2 - SPRING
3 - SCREW
4 - POPPET BORE (IN CASE)
21 - 216 TRANSFER CASE - NV231 TJ
TRANSFER CASE - NV231 (Continued)
FRONT OUTPUT SHAFT AND DRIVE CHAIN
(1) Lubri cate front output shaft-sprocket assembl y,
dri ve chai n, and dri ve sprocket wi th transmi ssi on
fl ui d.
(2) Assembl e dri ve chai n and front output shaft
(Fi g. 69).
(3) Start chai n on mai nshaft dri ve sprocket.
(4) Gui de front shaft i nto beari ng and dri ve
sprocket onto mai nshaft dri ve gear (Fi g. 69).
(5) I nstal l mode spri ng on upper end of mode fork
shi ft rai l (Fi g. 70).
OIL PUMP AND REAR CASE
(1) I nstal l magnet i n front case pocket (Fi g. 71).
(2) Assembl e oi l pi ckup screen, connecti ng hose,
and tube.
(3) I nstal l new pi ckup tube O-ri ng i n oi l pump
(Fi g. 72).
Fig. 69 Installing Drive Chain And Front Output Shaft
1 - FRONT OUTPUT SHAFT
2 - DRIVE CHAIN
3 - MAINSHAFT
4 - DRIVE SPROCKET
Fig. 70 Install Mode Fork Spring
1 - MODE SPRING
Fig. 71 Installing Case Magnet
1 - MAGNET
Fig. 72 Pickup Tube O-Ring Position
1 - OIL PUMP
2 - O-RING
TJ TRANSFER CASE - NV231 21 - 217
TRANSFER CASE - NV231 (Continued)
(4) I nsert oi l pi ckup tube i n oi l pump i nl et.
(5) Posi ti on assembl ed oi l pump and pi ckup tube
i n rear case. Be sure pi ckup screen i s securel y seated
i n case sl ot. Al so be sure oi l pump l ocati ng tabs are
outsi de rear case (Fi g. 73).
(6) Appl y 3 mm (1/8 i n.) wi de bead of Mopar௡ gas-
ket maker or si l i cone adhesi ve seal er to mounti ng
fl ange of front case. Work seal er bead around bol t
hol es.
(7) Li ft rear case and oi l pump and careful l y posi -
ti on assembl y on front case. Be sure case dowel s are
al i gned and that mode fork rai l extends through rear
case before seati ng rear case on front case.
(8) I nstal l case attachi ng bol ts. Al i gnment bol ts at
each end of case are onl y ones requi ri ng washers
(Fi g. 74).
(9) Ti ghten case bol ts to 27-34 N·m (20-25 ft. l bs.)
torque.
YOKE AND RANGE LEVER
(1) I nstal l i ndi cator swi tch i n front case. Ti ghten
swi tch to 20-34 N·m (15-25 ft. l bs.) torque.
(2) I nstal l range l ever, washer and l ocknut on sec-
tor shaft (Fi g. 75). Ti ghten l ocknut to 27-34 N·m
(20-25 ft. l bs.) torque.
(3) I nstal l new seal washer on front output shaft
(Fi g. 77).
(4) Lubri cate yoke hub wi th transmi ssi on fl ui d and
i nstal l yoke on front shaft.
(5) I nstal l new seal washer on front shaft.
(6) I nstal l yoke and new yoke nut on front output
shaft (Fi g. 76).
(7) Ti ghten yoke nut to 122-176 N·m (90-130 ft.
l bs.) torque. Use Tool C-3281, or si mi l ar tool to hol d
yoke whi l e ti ghteni ng yoke nut.
Fig. 73 Oil Pump And Pickup Tube Installation
1 - OIL PUMP
2 - PICKUP TUBE
3 - PICKUP SCREEN AND CONNECTOR
Fig. 74 Alignment Bolt Location
1 - ALIGNMENT BOLT AND WASHER (AT EACH END OF CASE)
Fig. 75 Range Lever Installation
1 - RANGE LEVER
2 - WASHER
3 - LOCKNUT
Fig. 76 Output Shaft Yoke Installation
1 - OUTPUT SHAFT YOKE
2 - YOKE NUT
21 - 218 TRANSFER CASE - NV231 TJ
TRANSFER CASE - NV231 (Continued)
REAR RETAINER
(1) Appl y bead of Mopar௡ Seal er P/N 82300234, or
Locti te™ Ul tra Gray, to mati ng surface of rear
retai ner. Seal er bead shoul d be a maxi mum of 3/16
i nch.
(2) I nstal l rear retai ner on rear case. Ti ghten
retai ner bol ts to 20-27 N·m (15-20 ft. l bs.) torque.
(3) I nstal l rear beari ng I .D. retai ni ng ri ng and
spacer on output shaft.
(4) Appl y l i beral quanti ty of petrol eum jel l y to new
rear seal and to output shaft. Petrol eum jel l y i s
needed to protect seal l i ps duri ng i nstal l ati on.
(5) Sl i de seal onto Seal Protector 6992 (Fi g. 78).
Sl i de seal protector and seal onto output shaft.
(6) Sl i de I nstal l er C-4076-B onto seal protector
wi th the recessed si de of the tool toward the seal .
Dri ve seal i nto rear beari ng retai ner wi th I nstal l er
C-4076-B and Handl e MD-998323 (Fi g. 79).
NOTE: Vehicles built with a 4.0L engine and a man-
ual transmission use a damper weight on the trans-
fer case output shaft. Be sure to identify the
transfer case before proceeding.
(7) I nstal l a new output shaft rear sl i nger wi th
I nstal l er 8408, i f the vehi cl e i s not equi pped wi th an
output shaft damper.
(8) I f the vehi cl e i s equi pped wi th an output shaft
damper, i nstal l the output shaft damper as fol l ows:
(a) Posi ti on the damper wei ght on the output
shaft. Start the damper onto the output shaft
chamfer, bei ng careful to keep the wei ght square to
the output shaft. (Fi g. 80)
Fig. 80 Position Damper on Output Shaft
1 - Transfer Case
2 - Output Shaft
3 - Damper Weight
4 - Chamfer
Fig. 77 Seal Washer Installation
1 - YOKE SEAL WASHER
Fig. 78 Output Shaft Seal and Protector
1 - OUTPUT SHAFT SEAL
2 - SPECIAL TOOL 6992
3 - TRANSFER CASE
Fig. 79 Rear Seal Installation
1 - SPECIAL TOOL C-4076-B
2 - SPECIAL TOOL MD-998323
3 - TRANSFER CASE
TJ TRANSFER CASE - NV231 21 - 219
TRANSFER CASE - NV231 (Continued)
(b) Posi ti on the dri ver porti on of I nstal l er 8422
(Fi g. 81) onto the damper, maki ng sure the l egs of
the damper are posi ti oned through the sl ots of the
damper.
(c) Thread the pul l er screw of I nstal l er 8422 i nto
the output shaft by hand onl y. Make sure the
screw i s ful l y threaded i nto the output shaft.
(d) Usi ng a wrench to hol d the pul l i ng screw sta-
ti onary (Fi g. 82), turn the pul l i ng screw nut unti l
the dri ver l egs contact the rear face of the transfer
case rear retai ner. When the l egs contact the
retai ner, the damper i s properl y posi ti oned on the
output shaft.
(9) I nstal l boot on output shaft sl i nger, or output
shaft damper, and cri mp retai ni ng cl amp wi th tool
C-4975-A (Fi g. 83).
INSTALLATION
(1) Mount transfer case on a transmi ssi on jack.
(2) Secure transfer case to jack wi th chai ns.
(3) Posi ti on transfer case under vehi cl e.
(4) Al i gn transfer case and transmi ssi on shafts
and i nstal l transfer case on transmi ssi on.
(5) I nstal l and ti ghten transfer case attachi ng nuts
to 35 N·m (26 ft. l bs.) torque (Fi g. 2).
(6) Connect vehi cl e speed sensor wi res, and vent
hose.
(7) Connect i ndi cator swi tch harness to transfer
case swi tch, i f necessary. Secure wi re harness to cl i ps
on transfer case.
(8) Al i gn and connect propel l er shafts. Refer to
Di fferenti al and Dri vel i ne for proper procedures and
speci fi cati ons.
(9) Fi l l transfer case wi th correct fl ui d. Check
transmi ssi on fl ui d l evel . Correct as necessary.
(10) I nstal l rear crossmember, or ski d pl ate.
Ti ghten crossmember bol ts to 41 N·m (30 ft. l bs.)
torque.
(11) Remove transmi ssi on jack and support stand.
(12) Connect shi ft rod to transfer case range l ever.
(13) Adjust transfer case shi ft l i nkage.
(14) Lower vehi cl e and veri fy transfer case shi ft
operati on.
Fig. 81 Driver Installer 8422
1 - Pulling Screw
2 - Pulling Screw Nut
3 - Bearing
4 - Driver Legs
5 -Installer Driver
Fig. 82 Install Damper
1 - Damper
2 - Installer Driver
3 - Pulling Screw Nut
4 - Pulling Screw
Fig. 83 Slinger Boot Installation - Typical
1 - SPECIAL TOOL C-4975–A
2 - SLINGER
3 - BOOT
4 - CLAMP
21 - 220 TRANSFER CASE - NV231 TJ
TRANSFER CASE - NV231 (Continued)
SPECIFICATIONS
TRANSFER CASE - NV231
TORQUE
DESCRIPTION N·m Ft. Lbs. In. Lbs.
Plug, Detent 16-24 12-18 -
Plug, Drain/Fill 20-34 15-25 -
Bolt, Front Brg. Retainer 21 16 -
Bolt, Case Half 27-34 20-25 -
Nut, Front Yoke 122-176 90-130 -
Nut, Range Lever 27-34 20-25 -
Bolt, Rear Retainer 35-46 26-34 -
Nuts, Mounting 35-47 26-35 -
Switch, Indicator 20-34 15-25 -
SPECIAL TOOLS
NV231
Installer - C-4076-B
Puller, Slinger - MD-998056-A
Installer - MD-998323
Protector, Seal - 8824
Installer, Boot Clamp - C-4975-A
Installer, Seal - 8143-A
TJ TRANSFER CASE - NV231 21 - 221
TRANSFER CASE - NV231 (Continued)
Handle, Universal - C-4171
Installer, Seal - C-4210
Installer, Bearing - 5052
Installer, Bearing - 5065
Installer, Bushing - 5066
Installer, Bearing - 8128
Remover - L-4454
Cup - 8148
Installer, Seal - 7884
Installer, Pump Housing Seal - 7888
21 - 222 TRANSFER CASE - NV231 TJ
TRANSFER CASE - NV231 (Continued)
FLUID
STANDARD PROCEDURE - FLUID DRAIN AND
FILL
The fi l l and drai n pl ugs are both i n the rear case
(Fi g. 84). Correct fi l l l evel i s to the bottom edge of
the fi l l pl ug hol e. Be sure the vehi cl e i s l evel to
ensure an accurate fl ui d l evel check.
FRONT OUTPUT SHAFT SEAL
REMOVAL
(1) Rai se vehi cl e.
(2) Remove front propel l er shaft. (Refer to 3 - DI F-
FERENTI AL & DRI VELI NE/PROPELLER SHAFT/
PROPELLER SHAFT - REMOVAL)
(3) Remove front output shaft yoke.
(4) Remove seal from front case wi th pry tool (Fi g.
85).
Installer, Transfer Case Damper Driver - 8422
Installer, Output Shaft Slinger - 8408
Fig. 84 Fill/Drain Plug And I.D. Tag Locations
1 - I.D. TAG
2 - FILL PLUG
3 - DRAIN PLUG
Fig. 85 Remove Front Output Shaft Seal - Typical
1 - OUTPUT SHAFT SEAL
2 - PRYBAR
TJ TRANSFER CASE - NV231 21 - 223
TRANSFER CASE - NV231 (Continued)
INSTALLATION
(1) I nstal l new front output seal i n front case wi th
I nstal l er Tool 8143-A as fol l ows:
(a) Pl ace new seal on tool . Garter spri ng on seal
goes toward i nteri or of case.
(b) Start seal i n bore wi th l i ght taps from ham-
mer (Fi g. 86). Once seal i s started, conti nue tap-
pi ng seal i nto bore unti l i nstal l er tool seats agai nst
case.
REAR OUTPUT SHAFT SEAL
REMOVAL
(1) Shi ft the transmi ssi on and transfer case i nto
NEUTRAL.
(2) Rai se and support vehi cl e.
(3) Mark a l i ne across the pi ni on shaft and at each
end of the propel l er shaft for i nstal l ati on reference.
(4) Remove the U-joi nt strap bol ts at the pi ni on
shaft yoke.
(5) Pry open cl amp hol di ng the dust boot to propel -
l er shaft yoke (Fi g. 87).
(6) Sl i de the sl i p yoke off of the transmi ssi on/
transfer case output shaft and remove the propel l er
shaft.
(7) Spread band cl amp whi ch hol ds output shaft
boot to the output shaft sl i nger, or output shaft
damper, wi th a sui tabl e awl , or equi val ent.
NOTE: Vehicles built with a 4.0L engine and a man-
ual transmission use a damper weight on the trans-
fer case output shaft. Be sure to identify the
transfer case before proceeding.
(8) Remove output shaft boot from sl i nger, or out-
put shaft damper, and output shaft.
(9) I f the vehi cl e i s not equi pped wi th an output
shaft damper, remove the output shaft rear sl i nger
usi ng Pul l er MD-998056-A (Fi g. 88).
(10) I f the vehi cl e i s equi pped wi th an output shaft
damper, use Screws 8421 and the pul l er yoke and
forci ng screw from a bol t-gri p pul l er set, such as
those used to remove steeri ng wheel s and harmoni c
bal ancers, to remove the transfer case output shaft
damper.
Fig. 86 Front Output Seal Installation - Typical
1 - INSTALLER 8143-A
2 - TRANSFER CASE
Fig. 87 Dust Boot Clamp
1 - SLINGER
2 - BOOT
3 - AWL
4 - TRANSFER CASE
Fig. 88 Rear Slinger Removal
1 - TRANSFER CASE
2 - SPECIAL TOOL MD-998056-A
3 - SLINGER
21 - 224 TRANSFER CASE - NV231 TJ
FRONT OUTPUT SHAFT SEAL (Continued)
(11) Use a sui tabl e pry tool , or a sl i de hammer
mounted screw, to remove the seal from the rear
retai ner (Fi g. 89).
INSTALLATION
(1) Appl y l i beral quanti ty of petrol eum jel l y to new
rear seal and to output shaft. Petrol eum jel l y i s
needed to protect seal l i ps duri ng i nstal l ati on.
(2) Sl i de seal onto Seal Protector 6992 (Fi g. 90).
Sl i de seal protector and seal onto output shaft.
(3) Sl i de I nstal l er C-4076-B onto seal protector
wi th the recessed si de of the tool toward the seal .
Dri ve seal i nto rear beari ng retai ner wi th I nstal l er
C-4076-B and Handl e MD-998323 (Fi g. 91).
NOTE: Vehicles built with a 4.0L engine and a man-
ual transmission use a damper weight on the trans-
fer case output shaft. Be sure to identify the
transfer case before proceeding.
(4) I nstal l a new output shaft rear sl i nger wi th
I nstal l er 8408, i f the vehi cl e i s not equi pped wi th an
output shaft damper.
(5) I f the vehi cl e i s equi pped wi th an output shaft
damper, i nstal l the output shaft damper as fol l ows:
(a) Posi ti on the damper wei ght on the output
shaft. Start the damper onto the output shaft
chamfer, bei ng careful to keep the wei ght square to
the output shaft. (Fi g. 92)
Fig. 92 Position Damper on Output Shaft
1 - Transfer Case
2 - Output Shaft
3 - Damper Weight
4 - Chamfer
Fig. 89 Rear Output Shaft Seal
1 - REAR RETAINER
2 - OUTPUT SHAFT SEAL
Fig. 90 Output Shaft Seal and Protector
1 - OUTPUT SHAFT SEAL
2 - SPECIAL TOOL 6992
3 - TRANSFER CASE
Fig. 91 Rear Seal Installation
1 - SPECIAL TOOL C-4076-B
2 - SPECIAL TOOL MD-998323
3 - TRANSFER CASE
TJ TRANSFER CASE - NV231 21 - 225
REAR OUTPUT SHAFT SEAL (Continued)
(b) Posi ti on the dri ver porti on of I nstal l er 8422
(Fi g. 93) onto the damper, maki ng sure the l egs of
the damper are posi ti oned through the sl ots of the
damper.
(c) Thread the pul l er screw of I nstal l er 8422 i nto
the output shaft by hand onl y. Make sure the
screw i s ful l y threaded i nto the output shaft.
(d) Usi ng a wrench to hol d the pul l i ng screw sta-
ti onary (Fi g. 94), turn the pul l i ng screw nut unti l
the dri ver l egs contact the rear face of the transfer
case rear retai ner. When the l egs contact the
retai ner, the damper i s properl y posi ti oned on the
output shaft.
(6) I nstal l boot on output shaft sl i nger, or output
shaft damper, and cri mp retai ni ng cl amp wi th tool
C-4975-A (Fi g. 95).
(7) Sl i de the sl i p yoke on the transmi ssi on/transfer
case output shaft. Al i gn i nstal l ati on reference marks
at the axl e yoke and i nstal l the propel l er shaft.
(8) Ti ghten the U-joi nt strap/cl amp bol ts at the
axl e yoke to 19 N·m (14 ft. l bs.).
(9) Cri mp cl amp wi th Cl amp Tool C-4975A to hol d
dust boot to propel l er shaft yoke.
(10) Remove support and l ower the vehi cl e.
Fig. 93 Driver Installer 8422
1 - Pulling Screw
2 - Pulling Screw Nut
3 - Bearing
4 - Driver Legs
5 -Installer Driver
Fig. 94 Install Damper
1 - Damper
2 - Installer Driver
3 - Pulling Screw Nut
4 - Pulling Screw
Fig. 95 Slinger Boot Installation - Typical
1 - SPECIAL TOOL C-4975–A
2 - SLINGER
3 - BOOT
4 - CLAMP
21 - 226 TRANSFER CASE - NV231 TJ
REAR OUTPUT SHAFT SEAL (Continued)
SHIFT LEVER
REMOVAL
(1) Shi ft transfer case i nto 4L.
(2) Rai se vehi cl e.
(3) Loosen adjusti ng trunni on l ocknut and sl i de
shi ft rod out of trunni on (Fi g. 96). I f rod l acks
enough travel to come out of trunni on, push trunni on
out of torque shaft.
(4) Lower vehi cl e.
(5) Remove consol e. (Refer to 23 - BODY/I NTERI -
OR/FLOOR CONSOLE - REMOVAL)
(6) Remove screws attachi ng l ever assembl y to
fl oorpan and remove assembl y and shi ft rod (i f l eft
attached).
INSTALLATION
(1) I f shi ft rod was not removed from l ever assem-
bl y, work rod down through fl oorpan openi ng. Then
posi ti on l ever assembl y on fl oorpan and i nstal l
assembl y attachi ng screws.
(2) I nstal l consol e. (Refer to 23 - BODY/I NTERI -
OR/FLOOR CONSOLE - I NSTALLATI ON)
(3) Rai se vehi cl e.
(4) Connect trunni on to torque shaft arm. Or, sl i de
shi ft rod i nto trunni on on range l ever. Be sure shi ft
rod sl i des freel y i n trunni on.
(5) Veri fy that range l ever i s i n 4L posi ti on. Then
ti ghten trunni on l ock bol t.
(6) Lower vehi cl e and check transfer case shi ft
operati on.
Fig. 96 Shift Linkage
1 - Rivnut (4) 8 - Torque Shaft
2 - Shift Lever Assembly 9 - Transfer Case Shift Lever
3 - Floorpan 10 - Torque Shaft Transfer Case Bracket
4 - Trunnion Lock Bolt A - 3-4 N·m (27-35 in. lbs.)
5 - Selector Rod and Trunnion B - 11-14 N·m (97-123 in. lbs.)
6 - Shift Lever Rod C - 8-14 N·m (72-120 in. lbs.)
7 - Torque Shaft Frame Bracket
TJ TRANSFER CASE - NV231 21 - 227
ADJUSTMENTS - SHIFT LINKAGE
(1) Shi ft transfer case i nto 4L posi ti on.
(2) Rai se vehi cl e.
(3) Loosen l ock bol t on adjusti ng trunni on (Fi g.
97).
(4) Be sure l i nkage rod sl i des freel y i n trunni on.
Cl ean rod and appl y spray l ube i f necessary.
(5) Veri fy that transfer case range l ever i s ful l y
engaged i n 4L posi ti on.
(6) Ti ghten adjusti ng trunni on l ock bol t.
(7) Lower vehi cl e.
SPEEDOMETER DRIVE
ADAPTER
REMOVAL
(1) Rai se vehi cl e.
(2) Di sconnect wi res from vehi cl e speed sensor.
(3) Remove adapter cl amp and screw (Fi g. 98).
(4) Remove speed sensor and speedometer adapter
as an assembl y.
(5) Remove speed sensor retai ni ng screw and
remove sensor from adapter.
(6) Remove speedometer pi ni on from adapter.
Repl ace pi ni on i f chi pped, cracked, or worn.
(7) I nspect sensor and adapter O-ri ngs (Fi g. 98).
Remove and di scard O-ri ngs i f worn or damaged.
(8) I nspect termi nal pi ns i n speed sensor. Cl ean
pi ns wi th Mopar௡ el ectri cal spray cl eaner i f di rty or
oxi di zed. Repl ace sensor i f faul ty, or i f pi ns are l oose,
severel y corroded, or damaged.
INSTALLATION
(1) Thoroughl y cl ean adapter fl ange and adapter
mounti ng surface i n housi ng. Surfaces must be cl ean
for proper adapter al i gnment and speedometer oper-
ati on.
(2) I nstal l new O-ri ngs on speed sensor and speed-
ometer adapter (Fi g. 98), i f necessary.
(3) Lubri cate sensor and adapter O-ri ngs wi th
transmi ssi on fl ui d.
(4) I nstal l vehi cl e speed sensor i n speedometer
adapter. Ti ghten sensor attachi ng screw to 2-3 N·m
(15-27 i n. l bs.) torque.
(5) I nstal l speedometer pi ni on i n adapter.
(6) Count number of teeth on speedometer pi ni on.
Do thi s before i nstal l i ng assembl y i n housi ng. Then
l ubri cate pi ni on teeth wi th transmi ssi on fl ui d.
(7) Note i ndex numbers on adapter body (Fi g. 99).
These numbers wi l l correspond to number of teeth on
pi ni on.
(8) I nstal l speedometer assembl y i n housi ng.
(9) Rotate adapter unti l requi red range numbers
are at 6 o-cl ock posi ti on. Be sure range i ndex num-
bers correspond to number of teeth on pi ni on gear.
Fig. 97 Shift Linkage
1 - TRANSFER CASE SHIFT LEVER SHAFT
2 - SEAL
3 - TRANSFER CASE SHIFT LEVER ASSEMBLY
4 - FLOORPAN
5 - TRUNNION LOCK BOLT
6 - SHIFT ROD
7 - ADJUSTING TRUNNION
8 - TORQUE SHAFT BRACKET
9 - RANGE LEVER
10 - TORQUE SHAFT ROD
11 - TORQUE SHAFT
12 - LINKAGE BRACKET
21 - 228 TRANSFER CASE - NV231 TJ
SHIFT LEVER (Continued)
(10) I nstal l speedometer adapter cl amp and retai n-
i ng screw. Ti ghten cl amp screw to 10-12 N·m (90-110
i n. l bs.) torque.
(11) Connect wi res to vehi cl e speed sensor.
(12) Lower vehi cl e and top off transmi ssi on fl ui d
l evel i f necessary.
VEHICLE SPEED SENSOR
DESCRIPTION
The 3-wi re Vehi cl e Speed Sensor (VSS) i s l ocated
on the speedometer pi ni on gear adapter. I f equi pped
wi th 4WD, thi s adapter i s l ocated on the extensi on
housi ng of the transfer case (dri vers si de). I f
equi pped wi th 2WD, thi s adapter i s l ocated on the
l eft si de of the transmi ssi on extensi on housi ng.
OPERATION
The VSS i s a 3-ci rcui t (3–wi re), magneti c, hal l -ef-
fect sensor.
The 3 ci rcui ts are:
• A 5-vol t power suppl y from the Powertrai n Con-
trol Modul e (PCM).
• A ground i s provi ded for the sensor though a
l ow-noi se sensor return ci rcui t i n the PCM.
• An i nput to the PCM i s used to determi ne vehi -
cl e speed and di stance travel ed.
The speed sensor generates 8 pul ses per sensor
revol uti on. These si gnal s, i n conjuncti on wi th a
cl osed throttl e si gnal from the throttl e posi ti on sen-
sor, i ndi cate a cl osed throttl e decel erati on to the
PCM. When the vehi cl e i s stopped at i dl e, a cl osed
throttl e si gnal i s recei ved by the PCM (but a speed
sensor si gnal i s not recei ved).
Fig. 98 Speedometer
1 - Sensor O-ring 5 - Adapter Clamp
2 - Speedometer Adapter 6 - Vehicle Speed Sensor
3 - Adapter O-ring A - 2-3 N·m (15-27 in. lbs.)
4 - Speedometer Pinion B - 10-12 N·m (90-110 in. lbs.)
Fig. 99 Location Of Index Numbers On Speedometer
Adapter
1 - SPEEDOMETER ADAPTER
2 - INDEX NUMBER LOCATION
TJ TRANSFER CASE - NV231 21 - 229
SPEEDOMETER DRIVE ADAPTER (Continued)
Under decel erati on condi ti ons, the PCM adjusts
the I dl e Ai r Control (I AC) motor to mai ntai n a
desi red MAP val ue. Under i dl e condi ti ons, the PCM
adjusts the I AC motor to mai ntai n a desi red engi ne
speed.
REMOVAL
The Vehi cl e Speed Sensor (VSS) i s l ocated on the
speedometer pi ni on gear adapter. I f equi pped wi th
4WD, thi s adapter i s l ocated on the transfer case
extensi on (l eft si de) (Fi g. 100). I f equi pped wi th 2WD,
thi s adapter i s l ocated on the extensi on housi ng of
the transmi ssi on (l eft si de).
(1) Rai se and support vehi cl e.
(2) Di sconnect el ectri cal connector from sensor by
pushi ng sl i de tab (Fi g. 100). After sl i de tab has been
posi ti oned, push i n on secondary rel ease l ock (Fi g.
100) on si de of connector and pul l connector from
sensor.
(3) Remove sensor mounti ng bol t (Fi g. 101).
(4) Remove sensor (pul l strai ght out) from speed-
ometer pi ni on gear adapter (Fi g. 101). Do not remove
gear adapter from transmi ssi on.
INSTALLATION
(1) Cl ean i nsi de of speedometer pi ni on gear
adapter before i nstal l i ng speed sensor.
(2) I nstal l sensor i nto speedometer gear adapter
and i nstal l mounti ng bol t. Before ti ghteni ng bol t, ver-
i fy speed sensor i s ful l y seated (mounted fl ush) to
speedometer pi ni on gear adapter.
(3) Ti ghten sensor mounti ng bol t to 2.2 N·m (20 i n.
l bs.) torque.
(4) Connect el ectri cal connector to sensor.
Fig. 100 VSS Location
1 - SENSOR ELECTRICAL CONNECTOR
2 - SLIDE TAB
3 - 4WD TRANSFER CASE EXTENSION
4 - VEHICLE SPEED SENSOR
5 - RELEASE LOCK
Fig. 101 VSS Removal/Installation
1 - ELECTRICAL CONNECTOR
2 - SENSOR MOUNTING BOLT
3 - O-RING
4 - SPEEDOMETER PINION GEAR
5 - SPEEDOMETER PINION GEAR ADAPTER
6 - O-RING
7 - VEHICLE SPEED SENSOR
21 - 230 TRANSFER CASE - NV231 TJ
VEHICLE SPEED SENSOR (Continued)
TRANSFER CASE - NV241
TABLE OF CONTENTS
page page
TRANSFER CASE - NV241
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 231
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 232
DIAGNOSIS AND TESTING - TRANSFER
CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 234
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 245
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 258
SPECIFICATIONS
TRANSFER CASE - NV241 . . . . . . . . . . . . . 258
SPECIAL TOOLS
TRANSFER CASE - NV241 . . . . . . . . . . . . . 259
REAR EXTENSION SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 261
FLUID
STANDARD PROCEDURE - FLUID DRAIN AND
FILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
FRONT OUTPUT SHAFT SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 262
POSITION SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 263
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 263
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 263
SHIFT LEVER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 264
ADJUSTMENTS - SHIFT LINKAGE . . . . . . . . . 264
VEHICLE SPEED SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 265
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 265
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 265
TRANSFER CASE - NV241
DESCRIPTION
The NV241 transfer case (Fi g. 1) i s a part-ti me
transfer case wi th a l ow-range gear system. I t pro-
vi des three operati ng ranges pl us a NEUTRAL posi -
ti on. The l ow range posi ti on provi des a gear
reducti on rati o of 4.0:1 for i ncreased l ow speed torque
capabi l i ty.
The gear cases, retai ner and extensi on are al l of
al umi num. Dri ve sprockets and an i nterconnecti ng
dri ve chai n are used to transmi t engi ne torque to the
front/rear propel l er shafts. The mai nshaft, i nput gear
and front output shaft are supported by bal l and nee-
dl e beari ngs.
Fig. 1 NV241 - Front View
TJ TRANSFER CASE - NV241 21 - 231
IDENTIFICATION
An i denti fi cati on tag (Fi g. 2) i s attached to the rear
case of every transfer case. The tag provi des the
transfer case model number, assembl y number, seri al
number, and l ow range rati o.
The transfer case seri al number al so represents
the date of bui l d.
OPERATION
OPERATING RANGES
Transfer case operati ng ranges are:
• 2H (2-wheel dri ve)
• 4H (4-wheel dri ve)
• 4LO (4-wheel dri ve l ow range
The 2H range i s for use on any road surface at any
ti me.
The 4H and 4LO ranges are for off road use onl y.
They are not for use on hard surface roads. The onl y
excepti on bei ng when the road surface i s covered by
i ce and snow.
The l ow range reducti on gear system i s operati ve
i n 4LO range onl y. Thi s range i s for extra pul l i ng
power i n off road si tuati ons. Low range reducti on
rati o i s 4.0:1.
SHIFT MECHANISM
The transfer case i s operated by an adjustabl e fl oor
mounted shi ft l i nkage. The transfer case shi ft l ever
i s di rectl y attached to the shi ft sector. The sector
operates the range and mode forks wi thi n the trans-
fer case.
A strai ght l i ne shi ft pattern i s used wi th a NEU-
TRAL detent. Lever range posi ti ons are i mpri nted i n
the shi ft knob.
SHIFTING
The vehi cl e must have the transmi ssi on pl aced i n
NEUTRAL, or the cl utch depressed i n the case of a
manual transmi ssi on, and be movi ng l ess than 2-3
MPH when shi fti ng i nto the 4L operati ng range.
DIAGNOSIS AND TESTING - TRANSFER CASE
Before begi nni ng repai r on a suspected transfer
case mal functi on, check al l other dri vel i ne compo-
nents beforehand.
The actual cause of a probl em may be rel ated to
such i tems as: front hubs, axl es, propel l er shafts,
wheel s and ti res, transmi ssi on, or cl utch i nstead. I f
al l other dri vel i ne components are i n good condi ti on
and operati ng properl y, refer to the Di agnosi s Chart
for further i nformati on.
Fig. 2 Transfer Case Identification Tag and Fill/Drain
Plugs
1 - IDENTIFICATION TAG
2 - FILL PLUG
3 - DRAIN PLUG
21 - 232 TRANSFER CASE - NV241 TJ
TRANSFER CASE - NV241 (Continued)
DIAGNOSIS CHART
Condition Possible Cause Correction
Transfer Case difficult to shift or will
not shift into desired range.
1) Vehicle speed too great to permit
shifting.
1) Stop vehicle and shift into desired
range. Or, reduce speed to below 3-4
km/h (2-3 mph) before attempting the
shift.
2) If vehicle was operated for an
extended period in 4H on a dry paved
surface, the driveline torque load may
be causing a bind.
2) Stop vehicle and shift the
transmission into neutral. Shift the
transfer case to 2H and operate
vehicle in 2H on dry paved surfaces.
3) Transfer case external shift linkage
binding.
3) Lubricate, repair, or replace linkage
bushings, or tighten loose
components as necessary.
4) Insufficient or incorrect lubricant. 4) Drain and refill to edge of fill hole
with Moparா ATF +4, type 9602,
Automatic Transmission fluid.
5) Internal components binding, worn,
or damaged.
5) Disassemble the transfer case and
replace worn or damaged
components as necessary.
Transfer Case noisy in all operating
ranges.
1) Insufficient or incorrect lubricant. 1) Drain and refill to edge of fill hole
with Moparா ATF +4, type 9602,
Automatic Transmission fluid.
Noisy in, or jumps out of, four wheel
drive low range.
1) Transfer case not completely
engaged in 4L position.
1) With the transmission in
NEUTRAL, or the clutch depressed in
the case of a manual transmission
and the vehicle moving under 3-4
km/h (2-3 mph), shift the transfer case
to NEUTRAL and then shift into the
4L position.
2) Shift linkage out of adjustment. 2) Adjust linkage.
3) Shift linkage loose or binding. 3) Tighten, lubricate, or repair linkage
as necessary.
4) Range fork damaged, inserts worn,
or fork is binding on the shift rail.
4) Disassemble unit and repair as
necessary.
5) Low range gear worn or damaged. 5) Disassemble unit and repair as
necessary.
Lubricant leaking from output shaft
seal or vent.
1) Transfer case overfilled. 1) Drain lubricant to the correct level.
2) Vent closed or restricted. 2) Clear or replace vent as necessary.
3) Output shaft seals damaged or
installed incorrectly.
3) Replace seal as necessary. Check
to ensure that another component, the
propeller shaft slip yoke for example,
is not causing damage to seal.
Abnormal tire wear. 1) Extended operation on hard, dry
surfaces in the 4H position.
1) Operate vehicle in the 2H position
on hard, dry surfaces.
TJ TRANSFER CASE - NV241 21 - 233
TRANSFER CASE - NV241 (Continued)
REMOVAL
(1) Rai se and support vehi cl e.
(2) Remove ski d pl ate, i f equi pped. (Refer to 13 -
FRAMES & BUMPERS/FRAME/TRANSFER CASE
SKI D PLATE - REMOVAL)
(3) Posi ti on drai n oi l contai ner under transfer
case.
(4) Remove transfer case drai n pl ug and drai n
l ubri cant i nto contai ner.
(5) Di sconnect vent hose and vacuum harness at
transfer case swi tch.
(6) Di sconnect shi ft rod from grommet i n transfer
case shi ft l ever, or from fl oor shi ft arm whi chever
provi des easy access. Use channel l ock styl e pl i ers to
press rod out of l ever grommet.
(7) Support transmi ssi on wi th jack stand.
(8) Remove rear crossmember.
(9) Mark front and rear propel l er shafts for assem-
bl y reference.
(10) Remove front and rear propel l er shafts. (Refer
to 3 - DI FFERENTI AL & DRI VELI NE/PROPELLER
SHAFT/PROPELLER SHAFT - REMOVAL)
(11) Support transfer case wi th sui tabl e jack.
Secure transfer case to jack wi th safety chai ns.
(12) Remove nuts attachi ng transfer case to trans-
mi ssi on.
(13) Move transfer case assembl y rearward unti l
free of transmi ssi on output shaft.
(14) Lower jack and move transfer case from
under vehi cl e.
DISASSEMBLY
Posi ti on transfer case i n a shal l ow drai n pan.
Remove drai n pl ug and drai n any remai ni ng l ubri -
cant remai ni ng i n case.
REAR EXTENSION, RETAINER, AND REAR CASE
(1) I nstal l bol ts i nto two threaded hol es i n the rear
propel l er shaft compani on fl ange 180° apart (Fi g. 3).
(2) Pl ace the Hol der 6719 (Fi g. 3) over the two
bol ts and use the Hol der to remove the rear compan-
i on fl ange nut.
(3) Remove the rear compani on fl ange from the
output shaft.
NOTE: The companion flange is a taper fit onto the
output shaft. It may be necessary to use Puller 8992
to remove the companion flange.
(4) There i s a seal sl i nger l ocated on the rear of
the compani on fl ange that can be repl aced i f neces-
sary. Use a sui tabl e col d chi sel to stri ke the sl i nger
hub paral l el to the centerl i ne i n several spots to
expand the sl i nger hub. A new sl i nger can be dri ven
onto the fl ange hub usi ng a sui tabl e pi pe tool .
(5) Remove the speedometer sensor bol t (Fi g. 4).
Fig. 4 Speedometer Sensor Bolt Removal
1 - EXTENSION HOUSING
2 - BOLT
3 - SPEEDOMETER SENSOR
Fig. 3 Rear Companion Flange Nut Removal
1 - TRANSFER CASE
2 - HOLDER 6719
3 - COMPANION FLANGE
4 - BOLTS
21 - 234 TRANSFER CASE - NV241 TJ
TRANSFER CASE - NV241 (Continued)
(6) Remove the speedometer sensor (Fi g. 5) from
the extensi on housi ng.
(7) Remove rear extensi on bol ts (Fi g. 6).
(8) Remove rear extensi on housi ng (Fi g. 7). Tap
extensi on once or twi ce wi th a pl asti c mal l et to break
seal er bead and l oosen i t.
(9) Remove the speedometer sensor tone wheel
(Fi g. 8) from the output shaft.
Fig. 7 Rear Extension Removal
1 - TRANSFER CASE
2 - EXTENSION HOUSING
Fig. 8 Speedometer Sensor Tone Wheel Removal
1 - TRANSFER CASE
2 - OUPUT SHAFT
3 - SENSOR TONE WHEEL
Fig. 5 Speedometer Sensor Removal
1 - EXTENSION HOUSING
2 - SPEEDOMETER SENSOR
Fig. 6 Rear Extension Bolt Removal
1 - EXTENSION HOUSING
2 - BOLTS
TJ TRANSFER CASE - NV241 21 - 235
TRANSFER CASE - NV241 (Continued)
(10) Remove the tone wheel dowel pi n (Fi g. 9) from
the output shaft.
YOKE AND SHIFT LEVER
(1) Shi ft transfer case i nto a 4WD mode.
(2) Use Hol der 6958 to secure the yoke and remove
the yoke nut (Fi g. 10). Di scard nut after removal . I t
i s not reusabl e.
(3) Remove the yoke (Fi g. 11) from the front out-
put shaft.
NOTE: The yoke is a taper fit onto the output shaft.
It may be necessary to use a puller such as C-452
to remove the yoke.
(4) There i s a seal sl i nger l ocated on the rear of
the yoke that can be repl aced i f necessary. Use a
sui tabl e col d chi sel to stri ke the sl i nger hub paral l el
to the centerl i ne i n several spots to expand the
sl i nger hub. A new sl i nger can be dri ven onto the
yoke hub usi ng a sui tabl e pi pe tool .
(5) Remove yoke rubber seal from front output
shaft.
(6) Remove bol t (Fi g. 12) that retai ns the shi ft
l ever to sector shaft.
Fig. 12 Shift Lever Bolt Removal
1 - SHIFT LEVER
2 - BOLT
3 - SECTOR SUPPORT
Fig. 9 Output Shaft Dowel Pin
1 - TRANSFER CASE
2 - OUPUT SHAFT
3 - DOWEL PIN
Fig. 10 Front Yoke Nut Removal
1 - TRANSFER CASE
2 - HOLDER 6958
3 - FRONT YOKE
Fig. 11 Front Yoke Removal
1 - TRANSFER CASE
2 - FRONT YOKE
21 - 236 TRANSFER CASE - NV241 TJ
TRANSFER CASE - NV241 (Continued)
(7) Remove the shi ft l ever (Fi g. 13) from the shi ft
sector.
(8) Remove the detent pl ug (Fi g. 14).
(9) Remove the detent pl ug (Fi g. 15), spri ng, and
pl unger from the transfer case.
(10) Remove the transfer case posi ti on sensor (Fi g.
16).
Fig. 16 Remove Transfer Case Position Sensor
1 - TRANSFER CASE POSITION SENSOR
2 - TRANSFER CASE
Fig. 13 Shift Lever Removal
1 - SHIFT LEVER
2 - SECTOR SUPPORT
3 - SHIFT SECTOR
Fig. 14 Detent Plug Removal
1 - DETENT PLUG
2 - SPRING
Fig. 15 Detent Plug, Spring, and Plunger Removal
1 - DETENT PLUG
2 - SPRING
3 - PLUNGER
TJ TRANSFER CASE - NV241 21 - 237
TRANSFER CASE - NV241 (Continued)
(11) Remove the shi ft sector support (Fi g. 17).
MAINSHAFT, FRONT OUTPUT SHAFT, AND DRIVE
CHAIN
(1) Note posi ti on of bol ts that attach rear case to
front case. Some bol ts are uni que. Mark posi ti on of
these bol ts wi th pai nt or scri ber.
(2) Remove rear case-to-front case bol ts (Fi g. 18).
(3) Loosen rear case wi th pry tool to break seal er
bead.
(4) Unseat rear case from al i gnment dowel s (Fi g.
19).
(5) Remove rear case and oi l pump assembl y from
front case (Fi g. 20).
CAUTION: Do not remove the bolts holding the oil
pump cover to the rear case half. The oil pump
cover is aligned to the rear output shaft bearing
inner race and will become mis-aligned if the bolts
are loosened. If the transfer case failure has gener-
ated any debris which may have become trapped in
the oil pump, the rear case and oil pump assembly
MUST be replaced.
Fig. 17 Shift Sector Support Removal
1 - SHIFT SECTOR SHAFT
2 - SECTOR SUPPORT
Fig. 18 Case Half Bolt Removal
1 - REAR CASE HALF
2 - FRONT CASE HALF
3 - BOLTS
Fig. 19 Case Alignment Dowel
1 - REAR CASE HALF
2 - FRONT CASE HALF
3 - ALIGNMENT DOWEL
Fig. 20 Rear Case Half Removal
1 - REAR CASE HALF
2 - FRONT CASE HALF
21 - 238 TRANSFER CASE - NV241 TJ
TRANSFER CASE - NV241 (Continued)
(6) Remove shi ft rai l cups and spri ng (Fi g. 21).
(7) Remove front dri ve sprocket retai ni ng ri ng
(Fi g. 22).
(8) Remove mai nshaft, front sprocket, and chai n as
an assembl y (Fi g. 23).
SHIFT FORKS
(1) Remove front output shaft from beari ng i n case
(Fi g. 24).
Fig. 21 Shift Rail Cup And Spring Removal
1 - SHIFT RAIL
2 - SPRING
3 - CUPS (2)
Fig. 22 Front Drive Sprocket Snap-Ring Removal
1 - DRIVE CHAIN
2 - FRONT DRIVE SPROCKET
3 - SNAP-RING
Fig. 23 Remove Mainshaft, Drive Chain, and Front
Sprocket
1 - MAINSHAFT
2 - DRIVE CHAIN
3 - DRIVE SPROCKET
Fig. 24 Front Output Shaft Removal
1 - FRONT CASE HALF
2 - FRONT OUTPUT SHAFT
TJ TRANSFER CASE - NV241 21 - 239
TRANSFER CASE - NV241 (Continued)
(2) Remove the shi ft rai l (Fi g. 25) from the shi ft
forks.
(3) Remove mode fork, mode sl eeve (Fi g. 26). Note
whi ch way sl eeve fi ts i n fork (l ong si de of sl eeve goes
to front).
(4) Remove range fork and hub as an assembl y
(Fi g. 27). Note fork posi ti on for i nstal l ati on reference.
(5) Remove shi ft sector (Fi g. 28).
Fig. 25 Shift Fork Rail Removal
1 - FRONT CASE HALF
2 - SHIFT RAIL
Fig. 26 Mode Fork and Sleeve Removal
1 - MODE FORK
2 - MODE SLEEVE
Fig. 27 Range Fork and Hub Removal
1 - RANGE FORK
2 - RANGE HUB
Fig. 28 Shift Sector Removal
1 - FRONT CASE HALF
2 - SHIFT SECTOR
21 - 240 TRANSFER CASE - NV241 TJ
TRANSFER CASE - NV241 (Continued)
MAINSHAFT
(1) Remove the snap-ri ng that secures the chai n
dri ve sprocket onto mai nshaft (Fi g. 29). Use standard
(i nstead of paral l el jaw) snap-ri ng pl i ers to remove
thi s snap-ri ng.
(2) Remove dri ve sprocket (Fi g. 30).
(3) Remove the sl i di ng cl utch gear (Fi g. 31) from
the mai nshaft.
(4) Rotate the mai nshaft 180° and remove the
mode hub snap-ri ng (Fi g. 32).
Fig. 29 Mainshaft Drive Sprocket Snap-Ring
Removal
1 - MAINSHAFT
2 - DRIVE SPROCKET
3 - SNAP-RING
Fig. 30 Mainshaft Drive Sprocket Removal
1 - MAINSHAFT
2 - DRIVE SPROCKET
Fig. 31 Sliding Clutch Gear Removal
1 - MAINSHAFT
2 - SLIDING CLUTCH GEAR
Fig. 32 Mode Hub Snap-Ring Removal
1 - MAINSHAFT
2 - MODE HUB
3 - SNAP-RING
TJ TRANSFER CASE - NV241 21 - 241
TRANSFER CASE - NV241 (Continued)
(5) Remove the mode hub (Fi g. 33) from the mai n-
shaft.
(6) Remove the dri ve sprocket dri ve hub (Fi g. 34)
from the mai nshaft.
INPUT AND PLANETARY GEAR
(1) Remove front i nput retai ner attachi ng bol ts
(Fi g. 35).
(2) Remove the i nput gear seal wi th a sui tabl e
screw and sl i de hammer.
(3) Remove the i nput gear snap-ri ng (Fi g. 36) from
the i nput retai ner.
Fig. 33 Mode Hub Removal
1 - MAINSHAFT
2 - MODE HUB
Fig. 34 Drive Sprocket Drive Hub Removal
1 - MAINSHAFT
2 - DRIVE SPROCKET DRIVE HUB
Fig. 35 Front Input Retainer Bolt Removal
1 - INPUT RETAINER
2 - INPUT GEAR
3 - BOLT
4 - FRONT CASE HALF
Fig. 36 Input Gear Snap-Ring Removal
1 - INPUT RETAINER
2 - INPUT GEAR
3 - SNAP-RING
21 - 242 TRANSFER CASE - NV241 TJ
TRANSFER CASE - NV241 (Continued)
(4) Remove the i nput gear (Fi g. 37) from the i nput
gear beari ng wi th sui tabl e hammer.
(5) Remove front i nput retai ner (Fi g. 38).
(6) Remove the l ow range pl anetary pl asti c spacer
(Fi g. 39) from the pl anetary carri er or back si de of
the i nput retai ner.
(7) Remove the l ow range pl anetary gear set (Fi g.
40) from the front case hal f.
Fig. 37 Input Gear Removal
1 - INPUT RETAINER
2 - INPUT GEAR
Fig. 38 Front Input Retainer Removal
1 - INPUT RETAINER
2 - FRONT CASE HALF
Fig. 39 Low Range Planetary Plastic Spacer
1 - LOW RANGE PLANETARY
2 - PLASTIC SPACER
Fig. 40 Low Range Planetary Removal
1 - FRONT CASE HALF
2 - LOW RANGE PLANETARY
3 - ANNULUS GEAR
TJ TRANSFER CASE - NV241 21 - 243
TRANSFER CASE - NV241 (Continued)
(8) Remove the annul us gear (Fi g. 41) from the
front case hal f.
(9) Support the i nput retai ner on Cup 8148 as
shown (Fi g. 42).
(10) Whi l e usi ng sui tabl e snap-ri ng pl i ers to
spread the i nput gear beari ng snap-ri ng (Fi g. 43),
press downward on the retai ner to remove the bear-
i ng.
(11) Remove the front output shaft beari ng wi th
Handl e C-4171 and I nstal l er 8239 (Fi g. 44).
Fig. 44 Front Output Bearing Removal
1 - HANDLE C-4171
2 - INSTALLER 8239
Fig. 41 Remove Annulus Gear
1 - FRONT CASE HALF
2 - ANNULUS GEAR
Fig. 42 Support Input Gear Bearing For Removal
1 - INPUT RETAINER
2 - CUP 8148
3 - INPUT GEAR BEARING
Fig. 43 Input Gear Bearing Removal
1 - INPUT RETAINER
2 - CUP 8148
3 - INPUT GEAR BEARING
21 - 244 TRANSFER CASE - NV241 TJ
TRANSFER CASE - NV241 (Continued)
(12) Remove the rear output shaft beari ng wi th
Handl e C-4171 and I nstal l er 8239 (Fi g. 45).
CLEANING
Cl ean the transfer case parts wi th a standard
parts cl eani ng sol vent. Remove al l traces of seal er
from the cases and retai ners wi th a scraper and
3M™ al l purpose cl eaner. Use compressed ai r to
remove sol vent resi due from oi l feed passages i n the
case hal ves, retai ners, gears, and shafts.
INSPECTION
MAINSHAFT/SPROCKET/HUB
I nspect the spl i nes on the hub and shaft and the
teeth on the sprocket. Mi nor ni cks and scratches can
be smoothed wi th an oi l stone, however, repl ace any
part that i s damaged.
Check the contact surfaces i n the sprocket bore
and on the mai nshaft. Mi nor ni cks and scratches can
be smoothed wi th 320-400 gri t emery cl oth but do not
try to sal vage the shaft i f ni cks or wear i s severe.
INPUT GEAR AND PLANETARY CARRIER
Check the teeth on the gear. Mi nor ni cks can be
dressed off wi th an oi l stone but repl ace the gear i f
any teeth are broken, cracked, or chi pped. The bear-
i ng surface on the gear can be smoothed wi th
300-400 gri t emery cl oth i f necessary.
Exami ne the carri er body and pi ni on gears for
wear or damage. The carri er wi l l have to be repl aced
as an assembl y i f the body, pi ni on pi ns, or pi ni on
gears are damaged. I nspect the pl asti c washer on the
i nsi de, bottom of the pl anetary carri er. The washer i s
trapped by the pi ni on gears and the compl ete pl ane-
tary wi l l need to be repl aced i f the washer i s worn or
damaged.
SHIFT FORKS/HUBS/SLEEVES
Check condi ti on of the shi ft forks and mode fork
shi ft rai l . Mi nor ni cks on the shi ft rai l can be
smoothed wi th 320-400 gri t emery cl oth.
I nspect the shi ft fork wear pads. The mode and
range fork pads are servi ceabl e and can be repl aced
i f necessary.
Check both of the sl eeves for wear or damage,
especi al l y on the i nteri or teeth. Repl ace the sl eeves i f
wear or damage i s evi dent.
DRIVE CHAIN
Exami ne the dri ve chai n and shaft beari ngs.
repl ace the chai n i f stretched, di storted, or i f any of
the l i nks bi nd. Repl ace the beari ngs i f rough, or
noi sy.
LOW RANGE ANNULUS GEAR
I nspect annul us gear condi ti on careful l y. The gear
can be servi ced separatel y.
FRONT-REAR CASES
I nspect the cases for wear and damage. Repl ace
the i nput retai ner seal , do not reuse i t.
Check case condi ti on. I f l eaks were a probl em, l ook
for gouges and severe scori ng of case seal i ng sur-
faces. Al so make sure the front case mounti ng studs
are i n good condi ti on.
Check the front case mounti ng studs and vent
tube. The tube can be secured wi th Locti te™ 271 or
680 i f l oose. The stud threads can be cl eaned up wi th
a di e i f necessary. Al so check condi ti on of the fi l l /
drai n pl ug threads i n the rear case. The threads can
be repai red wi th a thread chaser or tap i f necessary.
Or the threads can be repai red wi th Hel i coi l ™ stai n-
l ess steel i nserts i f requi red.
OIL PUMP/OIL PICKUP
Exami ne the oi l pump pi ckup parts. Repl ace the
pump i f any evi dence of debri s or damage exi sts. Do
not di sassembl e the pump from the rear case hal f as
i ndi vi dual parts are not avai l abl e and i t wi l l not be
possi bl e to reassembl e the pump cover to the rear
case hal f. The pump i s onl y avai l abl e as part of the
rear case hal f assembl y. The pi ckup screen, hose, and
tube are the onl y servi ceabl e parts and are avai l abl e
separatel y.
Fig. 45 Rear Output Bearing Removal
1 - REAR CASE HALF
2 - HANDLE C-4171
3 - INSTALLER 8239
TJ TRANSFER CASE - NV241 21 - 245
TRANSFER CASE - NV241 (Continued)
ASSEMBLY
BEARINGS AND SEALS
(1) Posi ti on the i nput gear beari ng i n the i nput
retai ner beari ng bore. Spread the snap-ri ng captured
i n the retai ner wi th sui tabl e snap-ri ng pl i ers and
press the beari ng i nto pl ace. Veri fy that the snap-
ri ng has engaged the groove i n the beari ng.
(2) Start front output shaft beari ng i n case (Fi g.
46). Then seat beari ng wi th Handl e C-4171 and
I nstal l er 6953.
(3) I nstal l the front output shaft beari ng retai ni ng
ri ng.
(4) I nstal l the rear output shaft beari ng i nto the
rear case hal f wi th I nstal l er 6953 and Handl e C-4171
(Fi g. 47).
(5) Remove the i nput gear pi l ot beari ng usi ng
Pul l er Jaws 8240 and Cup 8148.
(6) Remove the i nput gear cup pl ug (Fi g. 48) wi th
a sui tabl e dri ft and hammer i nserted from the front
of the i nput gear.
Fig. 46 Front Output Shaft Bearing Installation
1 - HANDLE C-4171
2 - INSTALLER 6953
3 - BEARING
Fig. 47 Rear Output Bearing Installation
1 - REAR CASE HALF
2 - HANDLE C-4171
3 - INSTALLER 6953
Fig. 48 Remove Input Gear Cup Plug
1 - DRIFT
2 - INPUT GEAR
21 - 246 TRANSFER CASE - NV241 TJ
TRANSFER CASE - NV241 (Continued)
(7) I nstal l a new i nput gear cup pl ug wi th
I nstal l er 9045 and Handl e C-4171.
(8) I nstal l new i nput gear pi l ot beari ng wi th
I nstal l er 9047 and Handl e C-4171.
(9) Remove the front output shaft rear beari ng
wi th the screw and jaws from Remover L-4454 and
Cup 8148 (Fi g. 49).
(10) I nstal l new beari ng wi th Tool Handl e C-4171
and I nstal l er 5066 (Fi g. 50). The beari ng bore i s
chamfered at the top. I nstal l the beari ng so i t i s
fl ush wi th the l ower edge of thi s chamfer (Fi g. 51).
Fig. 49 Front Output Shaft Rear Bearing Removal
1 - REAR CASE
2 - SPECIAL TOOL L-4454-1 AND L-4454-3
3 - SPECIAL TOOL 8148
Fig. 50 Output Shaft Rear Bearing Installation
1 - HANDLE C-4171
2 - OUTPUT SHAFT INNER BEARING
3 - INSTALLER 5066
Fig. 51 Output Shaft Rear Bearing Installation Depth
1 - BEARING (SEATED) AT LOWER EDGE OF CHAMFER
2 - CHAMFER
TJ TRANSFER CASE - NV241 21 - 247
TRANSFER CASE - NV241 (Continued)
INPUT AND PLANETARY GEAR
(1) I nstal l the annul us gear (Fi g. 52) i nto the front
case hal f.
(2) Al i gn and i nstal l l ow range pl anetary assembl y
i nto the front case hal f (Fi g. 53). Be sure l ow range
pl anetary pi ni ons are engaged i n annul us gear.
(3) I nstal l the l ow range pl anetary pl asti c spacer
(Fi g. 54) onto the l ow range pl anetary carri er.
(4) Cl ean gasket seal er resi due from retai ner and
i nspect retai ner for cracks or other damage.
(5) Appl y a 3 mm (1/8 i n.) bead of Mopar௡ Gasket
Maker, or equi val ent si l i cone adhesi ve, to seal i ng
surface of retai ner.
(6) I nstal l the front i nput retai ner (Fi g. 55) onto
the front case hal f.
Fig. 55 Front Input Retainer Installation
1 - INPUT RETAINER
2 - FRONT CASE HALF
Fig. 52 Install Annulus Gear
1 - FRONT CASE HALF
2 - ANNULUS GEAR
Fig. 53 Low Range Planetary Installation
1 - FRONT CASE HALF
2 - LOW RANGE PLANETARY
3 - ANNULUS GEAR
Fig. 54 Low Range Planetary Plastic Spacer
1 - LOW RANGE PLANETARY
2 - PLASTIC SPACER
21 - 248 TRANSFER CASE - NV241 TJ
TRANSFER CASE - NV241 (Continued)
(7) I nstal l bol ts to hol d retai ner to transfer case
(Fi g. 56). Ti ghten to 21 N·m (16 ft. l bs.) of torque.
(8) I nstal l the i nput gear to the l ow range pl ane-
tary assembl y and the i nput gear beari ng.
(9) I nstal l the i nput gear retai ni ng snap-ri ng (Fi g.
57) onto the i nput gear.
(10) I nstal l new oi l seal i n front i nput retai ner
wi th I nstal l er 8841 and Handl e C-4171 (Fi g. 58).
SHIFT FORKS AND MAINSHAFT
(1) Lubri cate mai nshaft spl i nes wi th recommended
transmi ssi on fl ui d.
(2) I nstal l the dri ve sprocket dri ve hub onto the
mai nshaft (Fi g. 59). Veri fy that the l ong shoul der i s
towards the front of the mai nshaft.
Fig. 56 Front Input Retainer Bolt Installation
1 - INPUT RETAINER
2 - INPUT GEAR
3 - BOLT
4 - FRONT CASE HALF
Fig. 57 Input Gear Snap-Ring Installation
1 - INPUT RETAINER
2 - INPUT GEAR
3 - SNAP-RING
Fig. 58 Input Gear Seal Installation
1 - HANDLE C-4171
2 - INSTALLER 8841
3 - INPUT RETAINER
Fig. 59 Drive Sprocket Drive Hub Installation
1 - MAINSHAFT
2 - DRIVE SPROCKET DRIVE HUB
TJ TRANSFER CASE - NV241 21 - 249
TRANSFER CASE - NV241 (Continued)
(3) I nstal l the mode hub (Fi g. 60) onto the mai n-
shaft.
(4) I nstal l the mode hub snap-ri ng (Fi g. 61) onto
the mai nshaft.
(5) Rotate the mai nshaft 180° and i nstal l the sl i d-
i ng cl utch gear (Fi g. 62) onto the dri ve sprocket dri ve
hub.
(6) I nstal l the mai nshaft dri ve sprocket (Fi g. 63)
onto the dri ve hub.
Fig. 62 Sliding Clutch Gear Installation
1 - MAINSHAFT
2 - SLIDING CLUTCH GEAR
Fig. 63 Mainshaft Drive Sprocket Installation
1 - MAINSHAFT
2 - DRIVE SPROCKET
Fig. 60 Mode Hub Installation
1 - MAINSHAFT
2 - MODE HUB
Fig. 61 Mode Hub Snap-Ring Installation
1 - MAINSHAFT
2 - MODE HUB
3 - SNAP-RING
21 - 250 TRANSFER CASE - NV241 TJ
TRANSFER CASE - NV241 (Continued)
(7) I nstal l the mai nshaft dri ve sprocket retai ni ng
ri ng (Fi g. 64) onto the dri ve hub.
(8) Support front case on wood bl ocks so case i nte-
ri or i s faci ng up. Pl ace bl ocks between mounti ng
studs on forward surface of case.
(9) Lubri cate mai nshaft components wi th trans-
mi ssi on fl ui d.
(10) Lubri cate sector shaft wi th transmi ssi on fl ui d
and i nstal l shi ft sector i n case (Fi g. 65). Posi ti on sl ot
i n sector so i t wi l l be al i gned wi th shi ft fork pi n
when shi ft forks are i nstal l ed.
(11) Assembl e and i nstal l range fork and hub (Fi g.
66). Be sure hub i s properl y seated i n l ow range gear
and engaged to the i nput gear.
(12) Al i gn and i nsert range fork pi n i n shi ft sector
sl ot.
(13) I nstal l mode fork and mode sl eeve (Fi g. 67).
Veri fy that the l ong si de of the mode sl eeve i s
towards the front of the transfer case.
(14) I nstal l the shi ft rai l (Fi g. 68) through the shi ft
forks and i nto the shi ft rai l pocket i n the front case
hal f.
Fig. 64 Mainshaft Drive Sprocket Snap-Ring
Installation
1 - MAINSHAFT
2 - DRIVE SPROCKET
3 - SNAP-RING
Fig. 65 Shift Sector Installation
1 - FRONT CASE HALF
2 - SHIFT SECTOR
Fig. 66 Range Fork and Hub Installation
1 - RANGE FORK
2 - RANGE HUB
Fig. 67 Mode Fork and Sleeve Installation
1 - MODE FORK
2 - MODE SLEEVE
TJ TRANSFER CASE - NV241 21 - 251
TRANSFER CASE - NV241 (Continued)
FRONT OUTPUT SHAFT AND DRIVE CHAIN
(1) I nstal l front output shaft i nto the font output
shaft beari ng (Fi g. 69).
(2) I nstal l the front output shaft snap-ri ng onto
the front output shaft.
(3) I nstal l new front output seal (Fi g. 70) i n front
case wi th I nstal l er 9041 and Handl e C-4171.
(4) I nsert front sprocket i n dri ve chai n (Fi g. 71).
(5) I nstal l dri ve chai n around mai nshaft dri ve
sprocket (Fi g. 71). Then posi ti on front sprocket over
front output shaft.
(6) I nstal l the mai nshaft i nto the range hub and
mode sl eeve and seat the front dri ve sprocket onto
the front output shaft (Fi g. 71).
Fig. 71 Install Mainshaft, Drive Chain, and Front
Sprocket
1 - MAINSHAFT
2 - DRIVE CHAIN
3 - DRIVE SPROCKET
Fig. 68 Shift Fork Rail Installation
1 - FRONT CASE HALF
2 - SHIFT RAIL
Fig. 69 Front Output Shaft Installation
1 - FRONT CASE HALF
2 - FRONT OUTPUT SHAFT
Fig. 70 Front Output Shaft Seal Installation
1 - HANDLE C-4171
2 - INSTALLER 9041
21 - 252 TRANSFER CASE - NV241 TJ
TRANSFER CASE - NV241 (Continued)
(7) I nstal l the front dri ve sprocket retai ni ng ri ng
(Fi g. 72).
(8) I nstal l spri ng and cups on shi ft rai l (Fi g. 73).
(9) I nsert magnet i n front case pocket (Fi g. 74).
OIL PUMP AND REAR CASE
CAUTION: Do not remove the bolts holding the oil
pump cover to the rear case half. The oil pump
cover is aligned to the rear output shaft inner bear-
ing race and will become mis-aligned if the bolts
are loosened. If the transfer case failure has gener-
ated any debris which may have become trapped in
the oil pump. the rear case and oil pump assembly
MUST be replaced.
Lubri cate the oi l pump components before i nstal l a-
ti on. Pri me the oi l pi ckup tube by pouri ng a l i ttl e oi l
i nto the tube before i nstal l ati on.
(1) I nstal l new o-ri ng i n pi ckup tube i nl et of oi l
pump.
(2) Posi ti on oi l pi ckup tube and fi l ter i n rear case.
Be sure pi ckup fi l ter i s seated i n case pocket and
that pi ckup tube i s al i gned i n case notches. Be sure
hose that connects tube to fi l ter i s securel y posi -
ti oned.
(3) I nstal l the transfer case posi ti on sensor (Fi g.
75). Ti ghten the sensor to 20-34 N·m (16-25 ft.l bs.).
Fig. 75 Install Transfer Case Position Sensor
1 - TRANSFER CASE POSITION SENSOR
2 - TRANSFER CASE
Fig. 72 Front Drive Sprocket Snap-Ring Installation
1 - DRIVE CHAIN
2 - FRONT DRIVE SPROCKET
3 - SNAP-RING
Fig. 73 Shift Rail Spring And Cups Installation
1 - CUPS (2)
2 - SPRING
Fig. 74 Case Magnet Installation
1 - MAGNET
2 - CASE POCKET
TJ TRANSFER CASE - NV241 21 - 253
TRANSFER CASE - NV241 (Continued)
(4) I nstal l the shi ft sector support (Fi g. 76).
Ti ghten the sector support to 27-42 N·m (20-30
ft.l bs.).
(5) I nstal l detent pl unger and spri ng i nto the front
case hal f. (Fi g. 77).
(6) I nstal l new o-ri ng on detent pl ug and i nstal l
pl ug i n front case (Fi g. 77). Ti ghten pl ug to 16-25
N·m (12-18 ft. l bs.).
(7) I nstal l shi ft l ever onto the sector shaft (Fi g.
78).
(8) I nstal l the shi ft l ever bol t (Fi g. 79). Ti ghten the
bol t to 20-34 N·m (15-25 ft.l bs.)
(9) Shi ft the transfer case i nto a 4WD range. Thi s
wi l l rai se the mai nshaft sl i ghtl y and make i nstal l a-
ti on of the rear case hal f much easi er.
(10) Veri fy that the transfer case al i gnment dowel s
are properl y i nstal l ed.
(11) Appl y bead of Mopar௡ Gasket Maker, or
equi val ent, to mati ng surface of front case. Keep
seal er bead wi dth to maxi mum of 3/16 i nch. Do not
use excessi ve amount of seal er as excess wi l l be di s-
pl aced i nto case i nteri or.
Fig. 76 Shift Sector Support Installation
1 - SHIFT SECTOR SHAFT
2 - SECTOR SUPPORT
Fig. 77 Detent Plug, Spring, and Plunger Installation
1 - DETENT PLUG
2 - SPRING
3 - PLUNGER
Fig. 78 Shift Lever Installation
1 - SHIFT LEVER
2 - SECTOR SUPPORT
3 - SHIFT SECTOR
Fig. 79 Shift Lever Bolt Installation
1 - SHIFT LEVER
2 - BOLT
3 - SECTOR SUPPORT
21 - 254 TRANSFER CASE - NV241 TJ
TRANSFER CASE - NV241 (Continued)
(12) Al i gn oi l pump wi th mai nshaft and al i gn shi ft
rai l wi th bore i n rear case. Then i nstal l rear case and
oi l pump assembl y (Fi g. 80). Be sure oi l pi ckup tube
remai ns i n posi ti on duri ng case i nstal l ati on.
(13) I nstal l 4-5 rear case-to front case bol ts to hol d
rear case i n posi ti on. Ti ghten bol ts snug but not to
speci fi ed torque at thi s ti me.
CAUTION: Verify that shift rail, and case alignment
dowels (Fig. 81) are seated before installing any
bolts. Case could be cracked if shaft rail or dowels
are misaligned.
(14) Appl y Locti te™ 242 to remai nder of rear case-
to-front case bol t threads and i nstal l bol ts (Fi g. 82).
Ti ghten al l bol ts to 20-27 N·m (15-20 ft. l bs.).
YOKE
(1) I nstal l yoke seal onto front shaft (Fi g. 83).
Fig. 80 Rear Case Half Installation
1 - REAR CASE HALF
2 - FRONT CASE HALF
Fig. 81 Case Alignment Dowel
1 - REAR CASE HALF
2 - FRONT CASE HALF
3 - ALIGNMENT DOWEL
Fig. 82 Case Half Bolt Installation
1 - REAR CASE HALF
2 - FRONT CASE HALF
3 - BOLTS
Fig. 83 Installing Flange Seal On Front Shaft
1 - FRONT OUTPUT SHAFT
2 - FLANGE SEAL
TJ TRANSFER CASE - NV241 21 - 255
TRANSFER CASE - NV241 (Continued)
(2) I nstal l yoke onto front shaft (Fi g. 84). Then
i nstal l and ti ghten a new yoke nut to 122-176 N·m
(90-130 ft. l bs.) torque. Never re-use a yoke nut.
REAR EXTENSION
(1) Cl ean mati ng surfaces of transfer case housi ng
and the rear retai ner of any ori gi nal gasket materi al .
(2) Appl y bead of Mopar௡ Gasket Maker, or equi v-
al ent, to mati ng surface of rear case. Keep seal er
bead wi dth to maxi mum of 3/16 i nch. Do not use
excessi ve amount of seal er as excess wi l l be di spl aced
i nto case i nteri or.
(3) I nstal l the tone wheel dowel pi n (Fi g. 85) i nto
the output shaft.
(4) I nstal l the speedometer sensor tone wheel (Fi g.
86) onto the output shaft wi th the notch i n the tone
wheel i nner di ameter toward the front of the transfer
case. Make sure the notch fi ts over the dowel pi n i n
the output shaft and the tone wheel i s agai nst the
rear output shaft beari ng i nner race.
Fig. 85 Output Shaft Dowel Pin
1 - TRANSFER CASE
2 - OUPUT SHAFT
3 - DOWEL PIN
Fig. 86 Speedometer Sensor Tone Wheel Installation
1 - TRANSFER CASE
2 - OUPUT SHAFT
3 - SENSOR TONE WHEEL
Fig. 84 Front Yoke Installation
1 - TRANSFER CASE
2 - FRONT YOKE
21 - 256 TRANSFER CASE - NV241 TJ
TRANSFER CASE - NV241 (Continued)
(5) Al i gn and i nstal l rear extensi on on rear case
(Fi g. 87).
(6) Appl y Mopar௡ Si l i cone Seal er to threads of rear
extensi on bol ts. Then i nstal l extensi on bol ts (Fi g. 88).
Ti ghten the extensi on bol ts to 16-25 N·m (12-18
ft.l bs.).
(7) I nstal l new seal i n rear extensi on housi ng wi th
I nstal l er 9041 and Handl e C-4171.
(8) I nstal l the speedometer sensor (Fi g. 89) i nto
the extensi on housi ng.
(9) I nstal l the speedometer sensor bol t (Fi g. 90).
Ti ghten the bol t to 11-16 N·m (8-12 ft.l bs.).
Fig. 87 Rear Extension Installation
1 - TRANSFER CASE
2 - EXTENSION HOUSING
Fig. 88 Rear Extension Bolt Installation
1 - EXTENSION HOUSING
2 - BOLTS
Fig. 89 Speedometer Sensor Installation
1 - EXTENSION HOUSING
2 - SPEEDOMETER SENSOR
Fig. 90 Speedometer Sensor Bolt Installation
1 - EXTENSION HOUSING
2 - BOLT
3 - SPEEDOMETER SENSOR
TJ TRANSFER CASE - NV241 21 - 257
TRANSFER CASE - NV241 (Continued)
(10) I nstal l the rear compani on fl ange onto the
output shaft.
(11) I nstal l bol ts i nto two threaded hol es i n the
rear propel l er shaft compani on fl ange 180° apart
(Fi g. 91).
(12) Pl ace the Hol der 6719 (Fi g. 91) over the two
bol ts and use the Hol der to i nstal l a new rear com-
pani on fl ange nut. Never re-use the compani on
fl ange nut once i t has been i nstal l ed. Ti ghten the
compani on fl ange nut to 122-176 N·m (90-130 ft.l bs.).
INSTALLATION
(1) Al i gn and seat transfer case on transmi ssi on.
Be sure transfer case i nput gear spl i nes are al i gned
wi th transmi ssi on output shaft. Al i gn spl i nes by
rotati ng transfer case rear output shaft yoke i f nec-
essary. Do not i nstal l any transfer case attachi ng
nuts unti l the transfer case i s compl etel y seated
agai nst the transmi ssi on.
(2) I nstal l and ti ghten transfer case attachi ng
nuts. Ti ghten nuts to 30-41 N·m (20-30 ft.l bs.).
(3) I nstal l rear crossmember.
(4) Remove jack stand from under transmi ssi on.
(5) Al i gn and connect propel l er shafts. (Refer to 3 -
DI FFERENTI AL & DRI VELI NE/PROPELLER
SHAFT/PROPELLER SHAFT - I NSTALLATI ON)
(6) Connect vacuum harness and vent hose.
(7) Connect shi ft rod to transfer case l ever or fl oor
shi ft arm. Use channel l ock styl e pl i ers to press rod
back i nto l ever grommet.
(8) Adjust shi ft l i nkage, i f necessary.
(9) Fi l l transfer case wi th recommended transmi s-
si on fl ui d and i nstal l fi l l pl ug.
(10) I nstal l ski d pl ate, i f equi pped. (Refer to 13 -
FRAMES & BUMPERS/FRAME/TRANSFER CASE
SKI D PLATE - I NSTALLATI ON)
(11) Lower vehi cl e
SPECIFICATIONS
TRANSFER CASE - NV241
TORQUE SPECIFICATIONS
DESCRIPTION N·m Ft. Lbs. In. Lbs.
Plug, Detent 16-25 12-18 -
Plug, Drain/Fill 20-34 15-25 -
Bolt, Rear Extension 16-24 12-18 -
Bolt, Front Input Retainer 21 16 -
Bolt, Case Half 20-27 15-20 -
Nut, Front Yoke 122-176 90-130 -
Nut, Rear Companion Flange 258-312 190-230 -
Bolt, Shift Lever 20-34 15-25 -
Nuts, Mounting 30-41 20-30 -
Bolts, U-Joint 19 17 -
Support, Sector 27-42 20-30 -
Sensor, Transfer Case Position 20-34 16-25 -
Bolt, Speed Sensor 11-16 8-12 -
Fig. 91 Rear Companion Flange Nut Removal
1 - TRANSFER CASE
2 - HOLDER 6719
3 - COMPANION FLANGE
4 - BOLTS
21 - 258 TRANSFER CASE - NV241 TJ
TRANSFER CASE - NV241 (Continued)
SPECIAL TOOLS
TRANSFER CASE - NV241
Puller - C-452
Handle, Universal - C-4171
Remover - L-4454
Installer, Bushing - 5066
Holder, Yoke - 6719A
Installer, Bearing - 6953
Spanner Wrench - 6958
Cup - 8148
Installer, Bearing - 8239
TJ TRANSFER CASE - NV241 21 - 259
TRANSFER CASE - NV241 (Continued)
Remover - 8240
Installer, Seal - 8841
Flange Puller - 8992
Installer, Cup Seal - 9045
Installer, Bearing - 9047
21 - 260 TRANSFER CASE - NV241 TJ
TRANSFER CASE - NV241 (Continued)
REAR EXTENSION SEAL
REMOVAL
(1) Rai se and support vehi cl e.
(2) Remove rear propel l er shaft. (Refer to 3 - DI F-
FERENTI AL & DRI VELI NE/PROPELLER SHAFT/
PROPELLER SHAFT - REMOVAL)
(3) Remove the rear compani on fl ange from the
output shaft.
(4) Usi ng a sui tabl e pry tool or sl i de-hammer
mounted screw, remove the rear extensi on seal .
INSTALLATION
(1) Cl ean fl ui d resi due from seal i ng surface and
i nspect for defects.
(2) Usi ng I nstal l er 9041 and Handl e C-4171,
i nstal l seal i n rear extensi on (Fi g. 92).
(3) I nstal l the compani on fl ange onto the output
shaft.
(4) I nstal l a new compani on fl ange nut and ti ghten
to 176-271 N·m (130-200 ft.l bs.).
(5) I nstal l propel l er shaft. (Refer to 3 - DI FFER-
ENTI AL & DRI VELI NE/PROPELLER SHAFT/PRO-
PELLER SHAFT - I NSTALLATI ON)
(6) Veri fy proper transfer case fl ui d l evel .
(7) Lower vehi cl e.
FLUID
STANDARD PROCEDURE - FLUID DRAIN AND
FILL
The fi l l and drai n pl ugs are both i n the rear case
(Fi g. 93). Correct fi l l l evel i s to the bottom edge of
the fi l l pl ug hol e. Be sure the vehi cl e i s l evel to
ensure an accurate fl ui d l evel check.
FRONT OUTPUT SHAFT SEAL
REMOVAL
(1) Shi ft transfer case i nto NEUTRAL.
(2) Rai se vehi cl e.
(3) Remove front propel l er shaft. (Refer to 3 - DI F-
FERENTI AL & DRI VELI NE/PROPELLER SHAFT/
PROPELLER SHAFT - REMOVAL)
(4) Usi ng Spanner Wrench 6958, remove yoke nut
(Fi g. 94). Di scard nut after removal . I t i s not reus-
abl e.
Fig. 92 Install Rear Extension Seal
1 - SPECIAL TOOL C-4171
2 - SPECIAL TOOL 9041
Fig. 93 Transfer Case Identification Tag and
Fill/Drain Plugs
1 - IDENTIFICATION TAG
2 - FILL PLUG
3 - DRAIN PLUG
Fig. 94 Front Yoke Nut Removal
1 - TRANSFER CASE
2 - HOLDER 6958
3 - FRONT YOKE
TJ TRANSFER CASE - NV241 21 - 261
(5) Remove yoke from output shaft (Fi g. 95). Use
pul l er C-452 i f fl ange can not be removed by hand.
(6) Remove yoke rubber seal from front output
shaft (Fi g. 96).
(7) Remove front output shaft seal wi th sui tabl e
pry tool , or a sl i de hammer mounted screw.
INSTALLATION
(1) I nstal l new front output seal i n front case wi th
I nstal l er Tool 9041 and Handl e C-4171 (Fi g. 97).
(2) I nstal l yoke seal on front output shaft (Fi g. 98).
(3) I nstal l yoke on front output shaft (Fi g. 99).
I nstal l a new yoke nut onto the front output shaft.
Fig. 98 Installing Flange Seal On Front Shaft
1 - FRONT OUTPUT SHAFT
2 - FLANGE SEAL
Fig. 99 Front Yoke Installation
1 - TRANSFER CASE
2 - FRONT YOKE
Fig. 95 Front Yoke Removal
1 - TRANSFER CASE
2 - FRONT YOKE
Fig. 96 Yoke Seal Removal
1 - FLANGE SEAL
Fig. 97 Front Output Seal Installation - Typical
1 - SPECIAL TOOL C-4171
2 - SPECIAL TOOL 9041
21 - 262 TRANSFER CASE - NV241 TJ
FRONT OUTPUT SHAFT SEAL (Continued)
(4) Usi ng Spanner Wrench 6958 (Fi g. 100), ti ghten
the yoke nut to 176-271 N·m (130-200 ft. l bs.) torque.
(5) I nstal l propel l er shaft. (Refer to 3 - DI FFER-
ENTI AL & DRI VELI NE/PROPELLER SHAFT/PRO-
PELLER SHAFT - I NSTALLATI ON)
POSITION SENSOR
DESCRIPTION
The transfer case posi ti on sensor i s an el ectroni c
devi ce whose output can be i nterpreted to i ndi cate the
transfer case’s current operati ng mode. The sensor con-
si sts of a fi ve posi ti on, resi sti ve mul ti pl exed ci rcui t
whi ch returns a speci fi c resi stance val ue to the Power-
trai n Control Modul e (PCM) for each transfer case oper-
ati ng mode. The sensor i s l ocated on the top of the
transfer case, just l eft of the transfer case centerl i ne
and ri des agai nst the sector pl ate roostercomb. The
PCM suppl i es 5VDC (+/- 0.5V) to the sensor and moni -
tors the return vol tage to determi ne the sector pl ate,
and therefore the transfer case, posi ti on.
OPERATION
Duri ng normal vehi cl e operati on, the Powertrai n
Control Modul e (PCM) moni tors the transfer case
posi ti on sensor return vol tage to determi ne the oper-
ati ng mode of the transfer case. Refer to the Operat-
i ng Mode Versus Resi stance tabl e for the correct
resi stance for each posi ti on (Fi g. 101).
OPERATING MODE VERSUS RESISTANCE
SENSOR POSITION OPERATING MODE SENSOR RESISTANCE (ohms)
1 2H 1124-1243
2 4H 650-719
3 NEUTRAL 389-431
4 4L 199-221
5 NOT USED 57-64
REMOVAL
(1) Rai se and support the vehi cl e.
(2) Di sengage the transfer case posi ti on sensor
connector from the posi ti on sensor.
(3) Remove the posi ti on sensor from the transfer
case.
INSTALLATION
(1) I nspect the o-ri ng seal on the transfer case
posi ti on sensor. Repl ace the o-ri ng i f necessary.
(2) I nstal l the transfer case posi ti on sensor i nto
the transfer case. Torque the sensor to 20-34 N·m
(15-25 ft.l bs.).
(3) Engage the transfer case posi ti on sensor con-
nector to the posi ti on sensor.
(4) Lower vehi cl e.
(5) Veri fy proper sensor operati on.
Fig. 100 Front Yoke Nut Installation
1 - TRANSFER CASE
2 - HOLDER 6958
3 - FRONT YOKE
Fig. 101 Position Sensor Linear Movement
1 - POSITION 1 - 10mm ±0.5mm
2 - POSITION 2 - 12mm ±0.5mm
3 - POSITION 3 - 14mm ±0.5mm
4 - POSITION 4 - 16mm ±0.5mm
5 - POSITION 5 - 18mm ±0.5mm
6 - POSITION 6 - 20mm±0.5mm - FULL EXTENSION
TJ TRANSFER CASE - NV241 21 - 263
FRONT OUTPUT SHAFT SEAL (Continued)
SHIFT LEVER
REMOVAL
(1) Shi ft transfer case i nto 4L.
(2) Rai se vehi cl e.
(3) Loosen adjusti ng trunni on l ocknut and sl i de
shi ft rod out of trunni on (Fi g. 102). I f rod l acks
enough travel to come out of trunni on, push trunni on
out of torque shaft.
(4) Lower vehi cl e.
(5) Remove consol e. (Refer to 23 - BODY/I NTERI -
OR/FLOOR CONSOLE - REMOVAL)
(6) Remove screws attachi ng l ever assembl y to
fl oorpan and remove assembl y and shi ft rod (i f l eft
attached).
INSTALLATION
(1) I f shi ft rod was not removed from l ever assem-
bl y, work rod down through fl oorpan openi ng. Then
posi ti on l ever assembl y on fl oorpan and i nstal l
assembl y attachi ng screws.
(2) I nstal l consol e. (Refer to 23 - BODY/I NTERI -
OR/FLOOR CONSOLE - I NSTALLATI ON)
(3) Rai se vehi cl e.
(4) Connect trunni on to torque shaft arm. Or, sl i de
shi ft rod i nto trunni on on range l ever. Be sure shi ft
rod sl i des freel y i n trunni on.
(5) Veri fy that range l ever i s i n 4L posi ti on. Then
ti ghten trunni on l ock bol t.
(6) Lower vehi cl e and check transfer case shi ft
operati on.
ADJUSTMENTS - SHIFT LINKAGE
(1) Shi ft transfer case i nto 4L posi ti on.
(2) Rai se vehi cl e.
(3) Loosen l ock bol t on adjusti ng trunni on (Fi g.
103).
(4) Be sure l i nkage rod sl i des freel y i n trunni on.
Cl ean rod and appl y spray l ube i f necessary.
Fig. 102 Shift Linkage
1 - Rivnut (4) 8 - Torque Shaft
2 - Shift Lever Assembly 9 - Transfer Case Shift Lever
3 - Floorpan 10 - Torque Shaft Transfer Case Bracket
4 - Trunnion Lock Bolt A - 3-4 N·m (27-35 in. lbs.)
5 - Selector Rod and Trunnion B - 11-14 N·m (97-123 in. lbs.)
6 - Shift Lever Rod C - 8-14 N·m (72-120 in. lbs.)
7 - Torque Shaft Frame Bracket
21 - 264 TRANSFER CASE - NV241 TJ
(5) Veri fy that transfer case range l ever i s ful l y
engaged i n 4L posi ti on.
(6) Ti ghten adjusti ng trunni on l ock bol t.
(7) Lower vehi cl e.
VEHICLE SPEED SENSOR
DESCRIPTION
The 3-wi re Vehi cl e Speed Sensor (VSS) (Fi g. 104) i s
l ocated i n the transfer case rear extensi on.
OPERATION
The VSS i s a 3-ci rcui t (3–wi re), magneti c, hal l -ef-
fect sensor.
The 3 ci rcui ts are:
• A 5-vol t power suppl y from the Powertrai n Con-
trol Modul e (PCM).
• A ground i s provi ded for the sensor though a
l ow-noi se sensor return ci rcui t i n the PCM.
• An i nput to the PCM i s used to determi ne vehi -
cl e speed and di stance travel ed.
The speed sensor generates 8 pul ses per sensor
revol uti on. These si gnal s, i n conjuncti on wi th a
cl osed throttl e si gnal from the throttl e posi ti on sen-
sor, i ndi cate a cl osed throttl e decel erati on to the
PCM. When the vehi cl e i s stopped at i dl e, a cl osed
throttl e si gnal i s recei ved by the PCM (but a speed
sensor si gnal i s not recei ved).
Under decel erati on condi ti ons, the PCM adjusts
the I dl e Ai r Control (I AC) motor to mai ntai n a
desi red MAP val ue. Under i dl e condi ti ons, the PCM
adjusts the I AC motor to mai ntai n a desi red engi ne
speed.
REMOVAL
The Vehi cl e Speed Sensor (VSS) i s l ocated i n the
transfer case rear extensi on.
(1) Rai se and support vehi cl e.
(2) Di sconnect el ectri cal connector from sensor by
pushi ng sl i de tab. After sl i de tab has been posi ti oned,
push i n on secondary rel ease l ock on si de of connec-
tor and pul l connector from sensor.
(3) Remove sensor mounti ng bol t.
(4) Remove sensor (pul l strai ght out) from rear
extensi on.
INSTALLATION
(1) I nstal l sensor i nto transfer case rear extensi on
and i nstal l mounti ng bol t. Before ti ghteni ng bol t, ver-
i fy speed sensor i s ful l y seated (mounted fl ush) to
rear extensi on.
(2) Ti ghten sensor mounti ng bol t to 11-16 N·m
(8-12 ft. l bs.) torque.
(3) Connect el ectri cal connector to sensor.
Fig. 103 Shift Linkage
1 - TRANSFER CASE SHIFT LEVER SHAFT
2 - SEAL
3 - TRANSFER CASE SHIFT LEVER ASSEMBLY
4 - FLOORPAN
5 - TRUNNION LOCK BOLT
6 - SHIFT ROD
7 - ADJUSTING TRUNNION
8 - TORQUE SHAFT BRACKET
9 - RANGE LEVER
10 - TORQUE SHAFT ROD
11 - TORQUE SHAFT
12 - LINKAGE BRACKET
Fig. 104 Speedometer Sensor
1 - EXTENSION HOUSING
2 - SPEEDOMETER SENSOR
TJ TRANSFER CASE - NV241 21 - 265
SHIFT LEVER (Continued)
TIRES/WHEELS
TABLE OF CONTENTS
page page
TIRES/WHEELS
DIAGNOSIS AND TESTING - TIRE AND
WHEEL RUNOUT . . . . . . . . . . . . . . . . . . . . . . 1
STANDARD PROCEDURE
STANDARD PROCEDURE - ROTATION . . . . . . 2
STANDARD PROCEDURE - MATCH
MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
STANDARD PROCEDURE - TIRE AND
WHEEL BALANCE . . . . . . . . . . . . . . . . . . . . . . 4
TIRES
DESCRIPTION
DESCRIPTION - TIRES . . . . . . . . . . . . . . . . . . 5
DESCRIPTION - RADIAL-PLY TIRES . . . . . . . . 6
DESCRIPTION - TIRE INFLATION
PRESSURES . . . . . . . . . . . . . . . . . . . . . . . . . . 6
DESCRIPTION - TIRE PRESSURE FOR
HIGH SPEED. . . . . . . . . . . . . . . . . . . . . . . . . . 7
DESCRIPTION - REPLACEMENT TIRES . . . . . 7
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - PRESSURE
GAUGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DIAGNOSIS AND TESTING - TREAD WEAR
INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DIAGNOSIS AND TESTING - TIRE WEAR
PATTERNS . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DIAGNOSIS AND TESTING - TIRE NOISE
OR VIBRATION . . . . . . . . . . . . . . . . . . . . . . . . 8
DIAGNOSIS AND TESTING - TIRE/VEHICLE
LEAD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
STANDARD PROCEDURE - REPAIRING
LEAKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
CLEANING - TIRES . . . . . . . . . . . . . . . . . . . . . 10
SPECIFICATIONS
TIRE SIZE . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SPARE TIRE
DESCRIPTION
DESCRIPTION - SPARE/TEMPORARY . . . . . 10
DESCRIPTION - FULL SIZE, SPARE WHEEL
WITH MATCHING TIRE . . . . . . . . . . . . . . . . . 10
SPARE TIRE CARRIER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11
WHEELS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 11
DIAGNOSIS AND TESTING - WHEEL
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 12
STANDARD PROCEDURE
STANDARD PROCEDURE - WHEEL
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 12
STANDARD PROCEDURE - WHEEL
REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . 12
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . 13
STUDS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 13
TIRES/WHEELS
DIAGNOSIS AND TESTING - TIRE AND WHEEL
RUNOUT
Radi al runout i s the di fference between the hi gh
and l ow poi nts on the ti re or wheel (Fi g. 1).
Lateral runout i s the wobble of the ti re or wheel .
Radi al runout of more than 1.5 mm (.060 i nch)
measured at the center l i ne of the tread may cause
the vehi cl e to shake.
Lateral runout of more than 2.0 mm (.080 i nch)
measured near the shoul der of the ti re may cause the
vehi cl e to shake.
Someti mes radi al runout can be reduced. Rel ocate
the wheel and ti re assembl y on the mounti ng studs
(See Method 1). I f thi s does not reduce runout to an
acceptabl e l evel , the ti re can be rotated on the wheel .
(See Method 2).
METHOD 1 (RELOCATE WHEEL ON HUB)
(1) Dri ve vehi cl e a short di stance to el i mi nate ti re
fl at spotti ng from a parked posi ti on.
(2) Check wheel beari ngs and adjust i f adjustabl e
or repl ace i f necessary.
(3) Check the wheel mounti ng surface.
(4) Rel ocate wheel on the mounti ng, two studs
over from the ori gi nal posi ti on.
(5) Ti ghten wheel nuts unti l al l are properl y
torqued, to el i mi nate brake di storti on.
(6) Check radi al runout. I f sti l l excessi ve, mark
ti re si dewal l , wheel , and stud at poi nt of maxi mum
runout and proceed to Method 2.
METHOD 2 (RELOCATE TIRE ON WHEEL)
NOTE: Rotating the tire on wheel is particularly
effective when there is runout in both tire and
wheel.
TJ TIRES/WHEELS 22 - 1
(1) Remove ti re from wheel and mount wheel on
servi ce dynami c bal ance machi ne.
(2) Check wheel radi al runout (Fi g. 2) and l ateral
runout (Fi g. 3).
• STEEL WHEELS: Radi al runout 0.040 i n., Lat-
eral runout 0.045 i n. (average-maxi mum)
• ALUMI NUM WHEELS: Radi al runout 0.030 i n.,
Lateral runout 0.035 i n. (average-maxi mum)
(3) I f poi nt of greatest wheel l ateral runout i s near
ori gi nal chal k mark, remount ti re 180 degrees.
Recheck runout or match mount, (Refer to 22 -
TI RES/WHEELS - STANDARD PROCEDURE).
STANDARD PROCEDURE
STANDARD PROCEDURE - ROTATION
Ti res on the front and rear operate at di fferent
l oads and perform di fferent steeri ng, dri vi ng, and
braki ng functi ons. For these reasons they wear at
unequal rates and tend to devel op i rregul ar wear
patterns. These effects can be reduced by rotati ng
the ti res at regul ar i nterval s. The benefi ts of ti re
rotati on are:
• I ncrease tread l i fe
• Mai ntai n tracti on l evel s
• A smooth, qui et ri de
The suggested method of ti re rotati on i s (Fi g. 4).
Other rotati on methods can be used, but they wi l l
not provi de al l the ti re l ongevi ty benefi ts.
Fig. 1 Checking Tire/Wheel/Hub Runout
1 - RADIAL RUNOUT
2 - LATERAL RUNOUT
Fig. 2 RADIAL RUNOUT
1 - DIAL INDICATORS
2 - MOUNTING CONE
3 - SPINDLE SHAFT
4 - WING NUT
5 - PLASTIC CUP
6 - WHEEL
Fig. 3 LATERAL RUNOUT
1 - DIAL INDICATORS
2 - MOUNTING CONE
3 - SPINDLE SHAFT
4 - WING NUT
5 - PLASTIC CUP
6 - WHEEL
Fig. 4 Tire Rotation Pattern
22 - 2 TIRES/WHEELS TJ
TIRES/WHEELS (Continued)
STANDARD PROCEDURE - MATCH MOUNTING
Ti res and wheel s are currentl y match mounted at
the factory. Match mounti ng i s a techni que used to
reduce runout i n the wheel /ti re assembl y. Thi s means
that the hi gh spot of the ti re i s al i gned wi th the l ow
spot on the wheel ri m. The hi gh spot on the ti re i s
marked wi th a pai nt mark or a bri ght col ored adhe-
si ve l abel on the outboard si dewal l . The l ow spot on
the ri m i s i denti fi ed wi th a l abel on the outsi de of the
ri m and a dot on the i nsi de of the ri m. I f the outsi de
l abel has been removed the ti re wi l l have to be
removed to l ocate the dot on the i nsi de of the ri m.
Before di smounti ng a ti re from i ts wheel , a refer-
ence mark shoul d be pl aced on the ti re at the val ve
stem l ocati on. Thi s reference wi l l ensure that i t i s
remounted i n the ori gi nal posi ti on on the wheel .
(1) Use a di al i ndi cator to l ocate the hi gh spot of
the ti re on the center tread ri b (Fi g. 5). Record the
i ndi cator readi ng and mark the hi gh spot on the ti re.
Pl ace a mark on the ti re at the val ve stem l ocati on
(Fi g. 6).
(2) Break down the ti re and remount i t 180
degrees on the ri m (Fi g. 7).
(3) Measure the total runout agai n and mark the
ti re to i ndi cate the hi gh spot.
(4) I f runout i s sti l l excessi ve use the fol l owi ng
procedures.
(a) I f the hi gh spot i s wi thi n 101.6 mm (4.0 i n.)
of the fi rst spot and i s sti l l excessi ve, repl ace the
ti re.
(b) I f the hi gh spot i s wi thi n 101.6 mm (4.0 i n.)
of the fi rst spot on the wheel , the wheel may be out
of speci fi cati ons. (Refer to 22 - TI RES/WHEELS -
DI AGNOSI S AND TESTI NG).
(c) I f the hi gh spot i s NOT wi thi n 101.6 mm (4.0
i n.) of ei ther hi gh spot, draw an arrow on the tread
from second hi gh spot to fi rst. Break down the ti re
and remount i t 90 degrees on ri m i n that di recti on
(Fi g. 8). Thi s procedure wi l l normal l y reduce the
runout to an acceptabl e amount.
Fig. 5 Dial Indicator
Fig. 6 First Measurement On Tire
1 - REFERENCE MARK
2 - 1ST MEASUREMENT
HIGH SPOT MARK TIRE AND RIM
3 - WHEEL
4 - VALVE STEM
Fig. 7 Remount Tire 180 Degrees
1 - VALVE STEM
2 - REFERENCE MARK
TJ TIRES/WHEELS 22 - 3
TIRES/WHEELS (Continued)
STANDARD PROCEDURE - TIRE AND WHEEL
BALANCE
I t i s recommended that a two pl ane servi ce
dynami c bal ancer be used when a ti re and wheel
assembl y requi re bal anci ng. Refer to bal ancer opera-
ti on i nstructi ons for proper cone mounti ng proce-
dures. Typi cal l y use front cone mounti ng method for
steel wheel s. For al umi num wheel use back cone
mounti ng method wi thout cone spri ng.
NOTE: Static should be used only when a two plane
balancer is not available.
NOTE: Cast aluminum and forged aluminum wheels
require coated balance weights and special align-
ment equipment.
Wheel bal anci ng can be accompl i shed wi th ei ther
on or off vehi cl e equi pment. When usi ng on-vehi cl e
bal anci ng equi pment, remove the opposi te wheel /ti re.
Off-vehi cl e bal anci ng i s recommended.
For stati c bal anci ng, fi nd l ocati on of heavy spot
causi ng the i mbal ance. Counter bal ance wheel
di rectl y opposi te the heavy spot. Determi ne wei ght
requi red to counter bal ance the area of i mbal ance.
Pl ace hal f of thi s wei ght on the inner ri m fl ange and
the other hal f on the outer ri m fl ange (Fi g. 9).
For dynami c bal anci ng, the bal anci ng equi pment i s
desi gned to l ocate the amount of wei ght to be appl i ed
to both the i nner and outer ri m fl ange (Fi g. 10).
Fig. 9 Static Unbalance & Balance
1 - HEAVY SPOT
2 - CENTER LINE OF SPINDLE
3 - ADD BALANCE WEIGHTS HERE
4 - CORRECTIVE WEIGHT LOCATION
5 - TIRE OR WHEEL TRAMP, OR WHEEL HOP
Fig. 8 Remount Tire 90 Degrees In Direction of
Arrow
1 - 2ND HIGH SPOT ON TIRE
2 - 1ST HIGH SPOT ON TIRE
22 - 4 TIRES/WHEELS TJ
TIRES/WHEELS (Continued)
TIRES
DESCRIPTION
DESCRIPTION - TIRES
Ti res are desi gned and engi neered for each speci fi c
vehi cl e. They provi de the best overal l performance
for normal operati on. The ri de and handl i ng charac-
teri sti cs match the vehi cl e’s requi rements. Wi th
proper care they wi l l gi ve excel l ent rel i abi l i ty, trac-
ti on, ski d resi stance, and tread l i fe.
Dri vi ng habi ts have more effect on ti re l i fe than
any other factor. Careful dri vers wi l l obtai n i n most
cases, much greater mi l eage than severe use or care-
l ess dri vers. A few of the dri vi ng habi ts whi ch wi l l
shorten the l i fe of any ti re are:
• Rapi d accel erati on
• Severe brake appl i cati ons
• Hi gh speed dri vi ng
• Excessi ve speeds on turns
• Stri ki ng curbs and other obstacl es
Radi al -pl y ti res are more prone to i rregul ar tread
wear. I t i s i mportant to fol l ow the ti re rotati on i nter-
val (Refer to 22 - TI RES/WHEELS - STANDARD
PROCEDURE). Thi s wi l l hel p to achi eve a greater
tread l i fe.
TIRE IDENTIFICATION
Ti re type, si ze, aspect rati o and speed rati ng are
encoded i n the l etters and numbers i mpri nted on the
si de wal l of the ti re. Refer to the chart to deci pher
the ti re i denti fi cati on code (Fi g. 11).
Performance ti res have a speed rati ng l etter after
the aspect rati o number.
LETTER SPEED RATING
P 150 km/h (93 mph)
S 180 km/h (112 mph)
T 190 km/h (118 mph)
U 200 km/h (124 mph)
H 210 km/h (130 mph)
V 240 km/h (149 mph)
W 270 km/h (168 mph)
Y 300 km/h (186 mph)
The speed rati ng i s not al ways pri nted on the ti re
si dewal l .
TIRE CHAINS
Ti re snow chai ns may be used on certain model s.
Refer to the Owner’s Manual for more i nformati on.
Fig. 10 Dynamic Unbalance & Balance
1 - CENTER LINE OF SPINDLE
2 - ADD BALANCE WEIGHTS HERE
3 - CORRECTIVE WEIGHT LOCATION
4 - HEAVY SPOT WHEEL SHIMMY AND VIBRATION
TJ TIRES/WHEELS 22 - 5
TIRES/WHEELS (Continued)
DESCRIPTION - RADIAL-PLY TIRES
Radi al -pl y ti res i mprove handl i ng, tread l i fe and
ri de qual i ty, and decrease rol l i ng resi stance.
Radi al -pl y ti res must al ways be used i n sets of
four. Under no ci rcumstances shoul d they be used on
the front onl y. They may be mi xed wi th temporary
spare ti res when necessary. A maxi mum speed of 50
MPH i s recommended whi l e a temporary spare i s i n
use.
Radi al -pl y ti res have the same l oad-carryi ng capac-
i ty as other types of ti res of the same si ze. They al so
use the same recommended i nfl ati on pressures.
The use of oversi zed ti res, ei ther i n the front or
rear of the vehi cl e, can cause vehi cl e dri ve trai n fai l -
ure. Thi s coul d al so cause i naccurate wheel speed
si gnal s when the vehi cl e i s equi pped wi th Anti -Lock
Brakes.
The use of ti res from di fferent manufactures on the
same vehi cl e i s NOT recommended. The proper ti re
pressure shoul d be mai ntai ned on al l four ti res.
DESCRIPTION - TIRE INFLATION PRESSURES
Under i nfl ati on wi l l cause rapi d shoul der wear, ti re
fl exi ng, and possi bl e ti re fai l ure (Fi g. 12).
Over i nfl ati on wi l l cause rapi d center wear and
l oss of the ti re’s abi l i ty to cushi on shocks (Fi g. 13).
I mproper i nfl ati on can cause:
• Uneven wear patterns
• Reduced tread l i fe
• Reduced fuel economy
• Unsati sfactory ri de
• Vehi cl e dri ft
For proper ti re pressure speci fi cati on refer to the
Ti re I nfl ati on Pressure Chart provi ded wi th the vehi -
cl es Owners Manual . A Certi fi cati on Label on the
dri vers si de door pi l l ar provi des the mi ni mum ti re
and ri m si ze for the vehi cl e. The l abel al so l i st the
col d i nfl ati on pressure for these ti res at ful l l oad
operati on
Ti re pressures have been chosen to provi de safe
operati on, vehi cl e stabi l i ty, and a smooth ri de. Ti re
pressure shoul d be checked col d once a month. Ti re
pressure decreases as the ambi ent temperature
drops. Check ti re pressure frequentl y when ambi ent
temperature vari es wi del y.
Fig. 11 Tire Identification
Fig. 12 Under Inflation Wear
1 - THIN TIRE THREAD AREAS
Fig. 13 Over Inflation Wear
1 - THIN TIRE THREAD AREA
22 - 6 TIRES/WHEELS TJ
TIRES (Continued)
Ti re i nfl ati on pressures are col d i nfl ati on pressure.
The vehi cl e must si t for at l east 3 hours to obtai n the
correct col d i nfl ati on pressure readi ng. Or be dri ven
l ess than one mi l e after si tti ng for 3 hours. Ti re
i nfl ati on pressures may i ncrease from 2 to 6 pounds
per square i nch (psi ) duri ng operati on. Do not reduce
thi s normal pressure bui l d-up.
WARNING: OVER OR UNDER INFLATED TIRES CAN
AFFECT VEHICLE HANDLING AND TREAD WEAR.
THIS MAY CAUSE THE TIRE TO FAIL SUDDENLY,
RESULTING IN LOSS OF VEHICLE CONTROL.
DESCRIPTION - TIRE PRESSURE FOR HIGH
SPEED
Where speed l i mi ts al l ow the vehi cl e to be dri ven
at hi gh speeds, correct ti re i nfl ati on pressure i s very
i mportant. For speeds up to and i ncl udi ng 120 km/h
(75 mph), ti res must be i nfl ated to the pressures
shown on the ti re pl acard. For conti nuous speeds i n
excess of 120 km/h (75 mph), ti res must be i nfl ated
to the maxi mum pressure speci fi ed on the ti re si de-
wal l .
Vehi cl es l oaded to the maxi mum capaci ty shoul d
not be dri ven at conti nuous speeds above 75 mph
(120 km/h).
For emergency vehi cl es that are dri ven at speeds
over 90 mph (144 km/h), speci al hi gh speed ti res
must be used. Consul t ti re manufacturer for correct
i nfl ati on pressure recommendati ons.
DESCRIPTION - REPLACEMENT TIRES
The ori gi nal equi pment ti res provi de a proper bal -
ance of many characteri sti cs such as:
• Ri de
• Noi se
• Handl i ng
• Durabi l i ty
• Tread l i fe
• Tracti on
• Rol l i ng resi stance
• Speed capabi l i ty
I t i s recommended that ti res equi val ent to the ori g-
i nal equi pment ti res be used when repl acement i s
needed.
Fai l ure to use equi val ent repl acement ti res may
adversel y affect the safety and handl i ng of the vehi -
cl e.
The use of oversi ze ti res may cause i nterference
wi th vehi cl e components. Under extremes of suspen-
si on and steeri ng travel , i nterference wi th vehi cl e
components may cause ti re damage.
WARNING: FAILURE TO EQUIP THE VEHICLE WITH
TIRES HAVING ADEQUATE SPEED CAPABILITY
CAN RESULT IN SUDDEN TIRE FAILURE.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - PRESSURE
GAUGES
A qual i ty ai r pressure gauge i s recommended to
check ti re pressure. After checki ng the ai r pressure,
repl ace val ve cap fi nger ti ght.
DIAGNOSIS AND TESTING - TREAD WEAR
INDICATORS
Tread wear i ndi cators are mol ded i nto the bottom
of the tread grooves. When tread depth i s 1.6 mm
(1/16 i n.), the tread wear i ndi cators wi l l appear as a
13 mm (1/2 i n.) band (Fi g. 14).
Ti re repl acement i s necessary when i ndi cators
appear i n two or more grooves or i f l ocal i zed bal di ng
occurs.
DIAGNOSIS AND TESTING - TIRE WEAR
PATTERNS
Under i nfl ati on wi l l cause wear on the shoul ders of
ti re. Over i nfl ati on wi l l cause wear at the center of
ti re.
Excessi ve camber causes the ti re to run at an
angl e to the road. One si de of tread i s then worn
more than the other (Fi g. 15).
Fig. 14 Tread Wear Indicators
1 - TREAD ACCEPTABLE
2 - TREAD UNACCEPTABLE
3 - WEAR INDICATOR
TJ TIRES/WHEELS 22 - 7
TIRES (Continued)
Excessi ve toe-i n or toe-out causes wear on the
tread edges and a feathered effect across the tread
(Fi g. 15).
DIAGNOSIS AND TESTING - TIRE NOISE OR
VIBRATION
Radi al -pl y ti res are sensi ti ve to force i mpul ses
caused by i mproper mounti ng, vi brati on, wheel
defects, or possi bl y ti re i mbal ance.
To fi nd out i f ti res are causi ng the noi se or vi bra-
ti on, dri ve the vehi cl e over a smooth road at varyi ng
speeds. Note the noi se l evel duri ng accel erati on and
decel erati on. The engi ne, di fferenti al and exhaust
noi ses wi l l change as speed vari es, whi l e the ti re
noi se wi l l usual l y remai n constant.
DIAGNOSIS AND TESTING - TIRE/VEHICLE
LEAD
Use the fol l owi ng Vehi cl e Lead Di agnosi s And Cor-
recti on Chart to di agnose and correct a vehi cl e l ead
or dri ft probl em (Fi g. 16).
Fig. 15 Tire Wear Patterns
22 - 8 TIRES/WHEELS TJ
TIRES (Continued)
Fig. 16 VEHICLE LEAD DIAGNOSIS AND CORRECTION CHART
TJ TIRES/WHEELS 22 - 9
TIRES (Continued)
STANDARD PROCEDURE - REPAIRING LEAKS
For proper repai ri ng, a radi al ti re must be removed
from the wheel . Repai rs shoul d onl y be made i f the
defect, or puncture, i s i n the tread area (Fi g. 17). The
ti re shoul d be repl aced i f the puncture i s l ocated i n
the si dewal l .
Defl ate ti re compl etel y before removi ng the ti re
from the wheel . Use l ubri cati on such as a mi l d soap
sol uti on when di smounti ng or mounti ng ti re. Use
tool s free of burrs or sharp edges whi ch coul d dam-
age the ti re or wheel ri m.
Before mounti ng ti re on wheel , make sure al l rust
i s removed from the ri m bead and repai nt i f neces-
sary.
I nstal l wheel on vehi cl e, and ti ghten to proper
torque speci fi cati on. (Refer to 22 - TI RES/WHEELS/
WHEELS - STANDARD PROCEDURE).
CLEANING - TIRES
Remove the protecti ve coati ng on the ti res before
del i very of a vehi cl e. Thi s coati ng may cause deteri -
orati on of the ti res.
To remove the protecti ve coati ng, appl y warm
water and l et i t soak for a few mi nutes. Afterwards,
scrub the coati ng away wi th a soft bri stl e brush.
Steam cl eani ng may al so be used to remove the coat-
i ng.
NOTE: DO NOT use gasoline, mineral oil, oil-based
solvent or a wire brush for cleaning.
SPECIFICATIONS
TIRE SIZE
DESCRIPTION SPECIFICATION
TIRE P215/75R15
TIRE P225/75R15
TIRE LT245/75R16
TIRE 30x9.50R15
SPARE TIRE
DESCRIPTION
DESCRIPTION - SPARE/TEMPORARY
The temporary spare ti re i s desi gned for emer-
gency use onl y. The ori gi nal ti re shoul d be repai red
or repl aced at the fi rst opportuni ty, then rei nstal l ed.
Do not exceed speeds of 50 M.P.H. when usi ng the
temporary spare ti re. Refer to Owner’s Manual for
compl ete detai l s.
DESCRIPTION - FULL SIZE, SPARE WHEEL
WITH MATCHING TIRE
The spare i s a ful l usage wheel wi th a matchi ng
ti re, I t can be used wi thi n the (posted l egal ) speed
l i mi ts or di stance l i mi tati ons as of the rest of the
vehi cl es four ti res. Refer to Owner’s Manual for com-
pl ete detai l s.
Fig. 17 Tire Repair Area
1 - REPAIRABLE AREA
22 - 10 TIRES/WHEELS TJ
TIRES (Continued)
SPARE TIRE CARRIER
REMOVAL
(1) Remove the spare ti re from the wheel bracket
(Fi g. 18).
(2) Remove the bol ts that attach the ti re bracket
to the tai l gate (Fi g. 19).
(3) Di sconnect CHMSL.
(4) Remove the bracket and the gaskets from the
tai l gate.
INSTALLATION
(1) Posi ti on the gaskets and the ti re bracket on the
tai l gate and i nstal l the bol ts. Ti ghten the bol ts to 24
N·m (17 ft. l bs.) torque.
(2) Connect CHMSL connector.
(3) I nstal l the spare ti re on the ti re bracket.
WHEELS
DESCRIPTION
The ri m si ze i s on the vehi cl e safety certi fi cati on
l abel l ocated on the dri vers door shut face. The si ze
of the ri m i s determi ned by the dri vetrai n package.
Ori gi nal equi pment wheel s/ri ms are desi gned for
operati on up to the speci fi ed maxi mum vehi cl e capac-
i ty.
Al l model s use stamped steel , cast al umi num or
forged al umi num wheel s. Every wheel has rai sed sec-
ti ons between the ri m fl anges and ri m drop wel l
cal l ed safety humps (Fi g. 20).
I ni ti al i nfl ati on of the ti re forces the bead over
these rai sed secti ons. I n case of rapi d l oss of ai r pres-
sure, the rai sed secti ons hel p hol d the ti re on the
wheel .
The wheel studs and nuts are desi gned for speci fi c
appl i cati ons. Al l al umi num and some steel wheel s
have wheel stud nuts wi th an enl arged nose. Thi s
enl arged nose i s necessary to ensure proper retenti on
of the wheel s. Do not use repl acement studs or nuts
wi th a di fferent desi gn or l esser qual i ty.
Fig. 18 Spare Tire
1 - WHEEL NUT
2 - CHMSL
3 - LOCK NUT
Fig. 19 Spare Tire Bracket
1 - BUMPER
2 - GASKET
3 - TAILGATE
4 - SPARE TIRE BRACKET
Fig. 20 Safety Rim
1 - FLANGE
2 - RIDGE
3 - WELL
TJ TIRES/WHEELS 22 - 11
DIAGNOSIS AND TESTING - WHEEL
INSPECTION
I nspect wheel s for:
• Excessi ve run out
• Dents or cracks
• Damaged wheel l ug nut hol es
• Ai r Leaks from any area or surface of the ri m
NOTE: Do not attempt to repair a wheel by hammer-
ing, heating or welding.
I f a wheel i s damaged an ori gi nal equi pment
repl acement wheel shoul d be used. When obtai ni ng
repl acement wheel s, they shoul d be equi val ent i n
l oad carryi ng capaci ty. The di ameter, wi dth, offset,
pi l ot hol e and bol t ci rcl e of the wheel shoul d be the
same as the ori gi nal wheel .
WARNING: FAILURE TO USE EQUIVALENT
REPLACEMENT WHEELS MAY ADVERSELY
AFFECT THE SAFETY AND HANDLING OF THE
VEHICLE. USED WHEELS ARE NOT RECOM-
MENDED. THE SERVICE HISTORY OF THE WHEEL
MAY HAVE INCLUDED SEVERE TREATMENT OR
VERY HIGH MILEAGE. THE RIM COULD FAIL WITH-
OUT WARNING.
STANDARD PROCEDURE
STANDARD PROCEDURE - WHEEL
INSTALLATION
The wheel studs and nuts are desi gned for speci fi c
appl i cati ons. They must be repl aced wi th equi val ent
parts. Do not use repl acement parts of l esser qual i ty
or a substi tute desi gn. Al l al umi num and some steel
wheel s have wheel stud nuts whi ch feature an
enl arged nose. Thi s enl arged nose i s necessary to
ensure proper retenti on of the al umi num wheel s.
Before i nstal l i ng the wheel , be sure to remove any
bui l d up of corrosi on on the wheel mounti ng surfaces.
Ensure wheel s are i nstal l ed wi th good metal -to-metal
contact.
To i nstal l the wheel , fi rst posi ti on i t properl y on
the mounti ng surface. Al l wheel nuts shoul d then be
ti ghtened just snug. Gradual l y ti ghten them i n
sequence to the proper torque speci fi cati on (Fi g. 21).
WARNING: NEVER USE OIL OR GREASE ON
STUDS OR NUTS. INSTALLING WHEELS WITHOUT
GOOD METAL-TO-METAL CONTACT OR USING
CHROME PLATED LUG NUTS WITH CHROME
PLATED WHEELS COULD CAUSE LOOSENING OF
WHEEL NUTS. THIS COULD AFFECT THE SAFETY
AND HANDLING OF THE VEHICLE.
WHEEL REPLACEMENT
Wheel s must be repl aced i f they have:
• Excessi ve runout
• Bent or dented
• Leak ai r through wel ds
• Have damaged bol t hol es
Wheel repai rs empl oyi ng hammeri ng, heati ng, or
wel di ng are not al l owed.
Ori gi nal equi pment wheel s are avai l abl e through
your deal er. Repl acement wheel s from any other
source shoul d be equi val ent i n:
• Load carryi ng capaci ty
• Di ameter
• Wi dth
• Offset
• Mounti ng confi gurati on
Fai l ure to use equi val ent repl acement wheel s may
affect the safety and handl i ng of your vehi cl e.
Repl acement wi th used wheel s i s not recommended.
Thei r servi ce hi story may have i ncl uded severe treat-
ment.
STANDARD PROCEDURE - WHEEL
REPLACEMENT
The wheel studs and nuts are desi gned for speci fi c
appl i cati ons. They must be repl aced wi th equi val ent
parts. Do not use repl acement parts of l esser qual i ty
or a substi tute desi gn. Al l al umi num and some steel
wheel s have wheel stud nuts whi ch feature an
enl arged nose. Thi s enl arged nose i s necessary to
ensure proper retenti on of the al umi num wheel s.
Wheel s must be repl aced i f they have:
• Excessi ve runout
• Bent or dented
• Leak ai r through wel ds
• Have damaged bol t hol es
Wheel repai rs empl oyi ng hammeri ng, heati ng, or
wel di ng are not al l owed.
Fig. 21 Lug Nut Tightening Pattern
22 - 12 TIRES/WHEELS TJ
WHEELS (Continued)
Ori gi nal equi pment wheel s are avai l abl e through
your deal er. Repl acement wheel s from any other
source shoul d be equi val ent i n:
• Load carryi ng capaci ty
• Di ameter
• Wi dth
• Offset
• Mounti ng confi gurati on
Fai l ure to use equi val ent repl acement wheel s may
affect the safety and handl i ng of your vehi cl e.
Repl acement wi th used wheel s i s not recommended.
Thei r servi ce hi story may have i ncl uded severe treat-
ment.
SPECIFICATIONS
TORQUE CHART
TORQUE SPECIFICATIONS
DESCRIPTION N·m Ft. Lbs. In. Lbs.
Lug Nut
1/2 X 20 with 60°Cone
115-156 85-115 —
STUDS
REMOVAL
(1) Rai se and support vehi cl e.
(2) Remove wheel and ti re assembl y.
(3) Remove brake cal i per, cal i per adapter and
rotor, (Refer to 5 - BRAKES/HYDRAULI C/MECHAN-
I CAL/ROTORS - REMOVAL).
(4) Remove stud from hub wi th Remover C-4150A
(Fi g. 22).
INSTALLATION
(1) I nstal l new stud i nto hub fl ange.
(2) I nstal l three washers onto stud, then i nstal l
l ug nut wi th the fl at si de of the nut agai nst the
washers.
(3) Ti ghten l ug nut unti l the stud i s pul l ed i nto
the hub fl ange. Veri fy that the stud i s properl y
seated i nto the fl ange.
(4) Remove l ug nut and washers.
(5) I nstal l the brake rotor, cal i per adapter, and cal -
i per, (Refer to 5 - BRAKES/HYDRAULI C/MECHAN-
I CAL/ROTORS - I NSTALLATI ON).
(6) I nstal l wheel and ti re assembl y, use new l ug
nut on stud or studs that were repl aced. (Refer to 22
- TI RES/WHEELS/WHEELS - STANDARD PROCE-
DURE).
(7) Remove support and l ower vehi cl e.
Fig. 22 Wheel Stud Removal
1 - REMOVER
2 - WHEEL STUD
TJ TIRES/WHEELS 22 - 13
WHEELS (Continued)
BODY
TABLE OF CONTENTS
page page
BODY
WARNING
SAFETY PRECAUTIONS AND WARNINGS . . . 1
STANDARD PROCEDURE
STANDARD PROCEDURE - BODY
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . 1
STANDARD PROCEDURE - PLASTIC BODY
PANEL REPAIR . . . . . . . . . . . . . . . . . . . . . . . . 2
STANDARD PROCEDURE - BUZZ, SQUEAK
& RATTLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SPECIFICATIONS - TORQUE . . . . . . . . . . . . . . 10
SPECIAL TOOLS
BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
TAILGATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
FULL DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
HALF DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
EXTERIOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . 36
INTERIOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
PAINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
REMOVEABLE TOP . . . . . . . . . . . . . . . . . . . . . . 63
SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
STATIONARY GLASS . . . . . . . . . . . . . . . . . . . . . 77
WEATHERSTRIP/SEALS . . . . . . . . . . . . . . . . . . . 82
BODY STRUCTURE . . . . . . . . . . . . . . . . . . . . . . 86
BODY
WARNING
SAFETY PRECAUTIONS AND WARNINGS
WARNING: USE AN OSHA APPROVED BREATHING
FILTER WHEN SPRAYING PAINT OR SOLVENTS IN
A CONFINED AREA. PERSONAL INJURY CAN
RESULT.
• AVOID PROLONGED SKIN CONTACT WITH
PETROLEUM OR ALCOHOL – BASED CLEANING
SOLVENTS. PERSONAL INJURY CAN RESULT.
• DO NOT STAND UNDER A HOISTED VEHICLE
THAT IS NOT PROPERLY SUPPORTED ON SAFETY
STANDS. PERSONAL INJURY CAN RESULT.
CAUTION: When holes must be drilled or punched
in an inner body panel, verify depth of space to the
outer body panel, electrical wiring, or other compo-
nents. Damage to vehicle can result.
• Do not weld exterior panels unless combustible
material on the interior of vehicle is removed from
the repair area. Fire or hazardous conditions, can
result.
• Always have a fire extinguisher ready for use
when welding.
• Disconnect the negative (-) cable clamp from
the battery when servicing electrical components
that are live when the ignition is OFF. Damage to
electrical system can result.
• Do not use abrasive chemicals or compounds
on painted surfaces. Damage to finish can result.
• Do not use harsh alkaline based cleaning sol-
vents on painted or upholstered surfaces. Damage
to finish or color can result.
• Do not hammer or pound on plastic trim panel
when servicing interior trim. Plastic panels can
break.
STANDARD PROCEDURE
STANDARD PROCEDURE - BODY LUBRICATION
Al l mechani sms and l i nkages shoul d be l ubri cated
when necessary. Thi s wi l l mai ntai n ease of operati on
and provi de protecti on agai nst rust and excessi ve
wear. The weatherstri p seal s shoul d be l ubri cated to
prol ong thei r l i fe as wel l as to i mprove door seal i ng.
Al l appl i cabl e exteri or and i nteri or vehi cl e operat-
i ng mechani sms shoul d be i nspected and cl eaned.
Pi vot/sl i di ng contact areas on the mechani sms shoul d
then be l ubri cated.
(1) When necessary, l ubri cate the operati ng mech-
ani sms wi th the speci fi ed l ubri cants.
(2) Appl y si l i cone l ubri cant to a cl oth and wi pe i t
on door seal s to avoi d over-spray that can soi l pas-
senger’s cl othi ng.
(3) Before appl yi ng l ubri cant, the component
shoul d be wi ped cl ean. After l ubri cati on, any excess
l ubri cant shoul d be removed.
(4) The hood l atch, l atch rel ease mechani sm, l atch
stri ker, and safety l atch shoul d be l ubri cated peri od-
i cal l y.
(5) The door l ock cyl i nders shoul d be l ubri cated
twi ce each year (preferabl y autumn and spri ng):
• Spray a smal l amount of l ock cyl i nder l ubri cant
di rectl y i nto the l ock cyl i nder.
TJ BODY 23 - 1
• Appl y a smal l amount to the key and i nsert i t
i nto the l ock cyl i nder.
• Rotate i t to the l ocked posi ti on and then back to
the unl ocked posi ti on several ti mes.
• Remove the key. Wi pe the l ubri cant from i t wi th
a cl ean cl oth to avoi d soi l i ng of cl othi ng.
Component Fluid, Lubricant, or Genuine Part
Hinges:
Door And
Hood
Moparா Engine Oil
Liftgate Moparா Multi-Purpose Lube NLGI
Grade 2 EP, GC-LB
Latches:
Door,
Hood/Safety
Catch, Liftgate
Moparா Multi-Purpose Lube NLG
Grade 2 EP, GC-LB
Seat
Regulator &
Track
Moparா Multi-Purpose Lube NLGI
Grade 2 EP, GC-LB
Window
System
Components
Moparா Spray White Lube
Lock
Cylinders
Moparா Lock Cylinder Lube
Parking Brake
Mechanism
Moparா Wheel Brg. Grease NLGI
Grade 1, GC-LBB
Soft Top Moparா Soft Top Zipper Cleaner &
Lubricant
STANDARD PROCEDURE - PLASTIC BODY
PANEL REPAIR
There are many di fferent types of pl asti cs used i n
today’s automoti ve envi ronment. We group pl asti cs i n
three di fferent categori es: Ri gi d, Semi -Ri gi d, and
Fl exi bl e. Any of these pl asti cs may requi re the use of
an adhesi on promoter for repai r. These types of pl as-
ti c are used extensi vel y on Dai ml erChrysl er Motors
vehi cl es. Al ways fol l ow repai r materi al manufactur-
er’s pl asti c i denti fi cati on and repai r procedures.
Rigid Plastics:
Exampl es of ri gi d pl asti c use: Fasci as, Hoods,
Doors, and other Body Panel s, whi ch i ncl ude SMC,
ABS, and Pol ycarbonates.
Semi-Rigid Plastics:
Exampl es of semi -ri gi d pl asti c use: I nteri or Panel s,
Under Hood Panel s, and other Body Tri m Panel s.
Flexible Plastics:
Exampl es of fl exi bl e pl asti c use: Fasci as, Body
Mol di ngs, and upper and l ower Fasci a Covers.
Repair Procedure:
The repai r procedure for al l three categori es of
pl asti cs i s basi cal l y the same. The one di fference i s
the materi al used for the repai r. The materi al s must
be speci fi c for each substrate, ri gi d repai r materi al
for ri gi d pl asti c repai r, semi -ri gi d repai r materi al for
semi -ri gi d pl asti c repai r and fl exi bl e repai r materi al
for fl exi bl e pl asti c repai r.
Adhesion Promoter/Surface Modifier:
Adhesi on Promoters/Surface Modi fi ers are requi red
for certai n pl asti cs. Al l three categori es may have
pl asti cs that requi re the use of adhesi on promoter/
surface modi fi ers. Al ways fol l ow repai r materi al man-
ufacturer’s pl asti c i denti fi cati on and repai r
procedures.
SAFETY PRECAUTION AND WARNINGS
WARNING:
• EYE PROTECTION SHOULD BE USED WHEN
SERVICING COMPONENTS. PERSONAL INJURY
CAN RESULT.
• USE AN OSHA APPROVED BREATHING MASK
WHEN MIXING EPOXY, GRINDING, AND SPRAYING
PAINT OR SOLVENTS IN A CONFINED AREA. PER-
SONAL INJURY CAN RESULT.
• AVOID PROLONGED SKIN CONTACT WITH
RESIN, PETROLEUM, OR ALCOHOL BASED SOL-
VENTS. PERSONAL INJURY CAN RESULT.
• DO NOT VENTURE UNDER A HOISTED VEHI-
CLE THAT IS NOT PROPERLY SUPPORTED ON
SAFETY STANDS. PERSONAL INJURY CAN
RESULT.
NOTE:
• When holes must be drilled or cut in body pan-
els, verify locations of internal body components
and electrical wiring. Damage to vehicle can result.
• Do not use abrasive chemicals or compounds
on undamaged painted surfaces around repair
areas. Damage to finish can result.
23 - 2 BODY TJ
BODY (Continued)
RIGID, SEMI-RIGID, AND FLEXIBLE PLASTIC PARTS TYPES
CODE FAMILY NAME COMMON TRADE NAME TYPICAL APPLICATION
ASA ACRYLONITRILE STYRENE
ACRYLITE
LURAN S CONSOLES, GRILLES
ABS ACRYLONITRILE
BUTADIENE STYRENE
TERLURAN ЉAЉ PILLARS, CONSOLES,
GRILLES
ABS/PC ABS/PC ALLOY PULSE, PROLOY, BAYBLEND DOORS, INSTRUMENT
PANELS
ABS/PVC ABS/PV ALLOY PROLOY, PULSE, LUSTRAN,
CYCLOVIN
DOOR PANELS, GRILLES,
TRIM
BMC BULK MOLDING
COMPOUND
BMC FENDER EXTENSIONS
EMA EHTYLENE METHYL
ACRYLATE/IONOMER
SURLYN, EMA, IONOMER BUMPER GUARDS, PADS
METTON METTON METTON GRILLES, KICK PANELS,
RUNNING BOARDS
MPPO MODIFIED
POLYPHENYLENE OXIDE
MPPO SPOILER ASSEMBLY
PA POLYAMID ZYTEL, VYDYNE, PA,
MINLON
FENDERS, QUARTER
PANELS
PET THERMOPLASTIC
POLYESTER
RYNITE TRIM
PBT/PPO PBT/PPO ALLOY GERMAX CLADDINGS
PBTP POLYBUTYLENE
THEREPTHALATE
PBT, PBTP, POCAN, VALOX WHEEL COVERS, FENDERS,
GRILLES
PBTP/EEBC POLYBUTYLENE
THEREPTHALATE/EEBC
ALLOY
BEXLOY, ЉMЉ, PBTP/EEBC FASCIAS, ROCKER PANEL,
MOLDINGS
PC POLYCARBONATE LEXAN, MERLON, CALIBRE,
MAKROLON PC
TAIL LIGHT LENSES, IP TRIM,
VALANCE PANELS
PC/ABS PC/ABS ALLOY GERMAX, BAY BLENDS,
PULSE
DOORS, INSTRUMENT
PANELS
PPO POLYPHENYLENE OXIDE AZDEL, HOSTALEN,
MARLEX, PRFAX, NORYL,
GTX, PPO
INTERIOR TRIM, DOOR
PANELS, SPLASH SHIELDS,
STEERING COLUMN
SHROUD
PPO/PA POLYPHENYLENE/
POLYAMID
PPO/PA, GTX 910 FENDERS, QUARTER
PANELS
PR/FV FIBERGLASS REINFORCED
PLASTIC
FIBERGLASS, FV, PR/FV BODY PANELS
PS POLYSTYRENE LUSTREX, STYRON, PS DOOR PANELS, DASH
PANELS
RTM RESIN TRANSFER
MOLDING COMPOUND
RTM BODY PANELS
SMC SHEET MOLDED
COMPOUND
SMC BODY PANELS
TMC TRANSFER MOLDING
COMPOUND
TMC GRILLES
TJ BODY 23 - 3
BODY (Continued)
CODE FAMILY NAME COMMON TRADE NAME TYPICAL APPLICATION
UP UNSATURATED
POLYESTER
(THERMOSETTING)
SMC, BMC, TMC, ZMC, IMC,
XSMC, UP
GRILLE OPENING PANEL,
LIFTGATES, FLARESIDE
FENDERS, FENDER
EXTENSIONS
EEBC ETHER/ESTER BLOCKED
CO-POLYMER
EEBC BUMPERS
EEBC/PBTP EEBC/POLYBUTYLENE
TEREPTHALATE
EEBC, PBTP, BEXLOY BUMPER, ROCKER PANELS
EMPP ETHYLENE MODIFIED
POLYPROPYLENE
EMPP BUMPER COVERS
EPDM ETHYLENE/
PROPROPYLENE DIENE
MONOMER
EPDM, NORDEL, VISTALON BUMPERS
EPM ETHYLENE/
PROPROPYLENE CO-
POLYMER
EPM FENDERS
MPU FOAM POLYURETHANE MPU SPOILERS
PE POLYETHYLENE ALATHON, DYLAN,
LUPOLEN, MARLEX
-
PP POLYPROPYLENE
(BLENDS)
NORYL, AZDEL, MARLOX,
DYLON, PRAVEX
INNER FENDER, SPOILERS,
KICK PANELS,A-PILLARS,
DOOR PANELS, B-PILLARS,
QUARTER PANELS, SPORT
BAR TRIM, LIFTGATE TRIM,
DECKLID TRIM SCUFF
PLATES, KICK PANELS,
CONSOLES
PP/EPDM PP/EPDM ALLOY PP/EPDM SPOILERS, GRILLES
PUR POLYURETHANE COLONELS, PUR, PU FASCIAS, BUMPERS
PUR/PC PUR/PC ALLOY TEXIN BUMPERS
PVC POLYVINYL CHLORIDE APEX, GEON, VINYLITE BODY MOLDINGS, WIRE
INSULATION, STEERING
WHEELS
RIM REACTION INJECTED
MOLDED POLYURETHANE
RIM, BAYFLEX FRONT FASCIAS, MODULAR
WINDOWS
RRIM REINFORCED REACTION
INJECTED MOLDED
PUR, RRIM FASCIAS, BODY PANELS,
BODY TRIMS
TPE THERMO POLYETHYLENE TPE, HYTREL, BEXLOY-V FASCIAS, BUMPERS,
CLADDINGS
TPO THERMOPOLYOLEFIN POLYTROPE, RENFLEX,
SANTOPRENE, VISAFLEX,
ETA, APEX, TPO, SHIELDS,
CLADDINGS
BUMPERS, END CAPS,
TELCAR, RUBBER, STRIPS,
SIGHT, INTERIOR B POST
TPP THERMO-POLYPROPYLENE TPP BUMPERS
TPU THERMOPOLYURETHANE,
POLYESTER
TPU, HYTREL, TEXIN,
ESTANE
BUMPERS, BODY SIDE,
MOLDINGS, FENDERS,
FASCIAS
23 - 4 BODY TJ
BODY (Continued)
PANEL SECTIONING
I f i t i s requi red to secti on a l arge panel for a pl as-
ti c repai r, i t wi l l be necessary to rei nforce the panel
(Fi g. 1). To bond two pl asti c panel s together, a rei n-
forcement must overl ap both panel s. The panel s
must be “V’d” at a 20 degree angl e. The area to be
rei nforced shoul d be washed, then sanded. Be sure to
wi pe off any excess soap and water when fi ni shed.
Li ghtl y sand or abrade the pl asti c wi th an abrasi ve
pad or sandpaper. Bl ow off any dust wi th compressed
ai r or wi pe wi th a cl ean dry rag.
When bondi ng pl asti c panel s, Fol l ow repai r mate-
ri al manufacturers recommendati ons. Be sure that
enough adhesi ve has been appl i ed to al l ow squeeze
out and to fi l l the ful l bond l i ne. Once the pi eces
have been brought together, do not move them unti l
the adhesi ve i s cured. The assembl y can be hel d
together wi th cl amps, ri vets, etc. A faster cure can be
obtai ned by heati ng wi th a heat l amp or heat gun.
After the parts have been bonded and have had ti me
to cure, rough sand the seam and appl y the fi nal
adhesi ve fi l l er to the area bei ng repai red. Smooth the
fi l l er wi th a spreader, wooden tongue depressor, or
squeegee. For fi ne texturi ng, a smal l amount of
water can be appl i ed to the fi l l er surface whi l e
smoothi ng. The cured fi l l er can be sanded as neces-
sary and, as a fi nal step, cl eanup can be done wi th
soapy water. Wi pe the surface cl ean wi th a dry cl oth
al l owi ng ti me for the panel to dry before movi ng on
wi th the repai r.
PANEL REINFORCEMENT
Structural repai r procedures for ri gi d panel s wi th
l arge cracks and hol es wi l l requi re a rei nforcement
backi ng. Rei nforcements can be made wi th several
appl i cati ons of gl ass cl oth saturated wi th structural
adhesi ve. Semi -ri gi d or fl exi bl e repai r materi al s
shoul d be used for semi -ri gi d or fl exi bl e backi ng rei n-
forcement (Fi g. 2) and (Fi g. 3). Open meshed fi ber-
gl ass dry wal l tape can be used to form a
rei nforcement. The dry wal l tape al l ows the resi n to
penetrate through and make a good bond between
the panel and the adhesi ve. Structural l y, the more
dry wal l tape used, the stronger the repai r.
Another ki nd of repai r that can be done to repai r
l arge cracks and hol es i s to use a scrap pi ece of si m-
i l ar pl asti c and bond wi th structural adhesi ve. The
rei nforcement shoul d cover the enti re break and
shoul d have a generous amount of overl ap on ei ther
si de of the cracked or broken area.
When repai ri ng pl asti c, the damaged area i s fi rst
“V’d” out, or bevel ed. Large bondi ng areas are desi r-
abl e when repai ri ng pl asti c because smal l repai rs are
l ess l i kel y to hol d permanentl y. Bevel i ng the area
around a crack at a 20 degree angl e wi l l i ncrease the
bondi ng surface for a repai r (Fi g. 4). I t i s recom-
mended that sharp edges be avoi ded because the
joi nt may show through after the panel i s refi ni shed.
Fig. 1 PANEL SECTIONING
1 - EXISTING PANEL
2 - NEW PANEL
3 - PANEL ADHESIVE
4 - BONDING STRIP
Fig. 2 SOFTENED EDGES
1 - SOFTENED EDGES
2 - PANEL ADHESIVE
3 - BONDING STRIP
Fig. 3 PANEL REINFORCEMENT
1 - PANEL ADHESIVE
2 - REINFORCEMENT
TJ BODY 23 - 5
BODY (Continued)
• Panel repai r for both fl exi bl e and ri gi d panel s
are basi cal l y the same. The pri mary di fference
between fl exi bl e panel repai r and ri gi d panel repai r
i s i n the adhesi ve materi al s used (Fi g. 5).
• The techni ci an shoul d fi rst deci de what needs to
be done when worki ng on any type of body panel .
One shoul d determi ne i f i t i s possi bl e to return the
damage part to i ts ori gi nal strength and appearance
wi thout exceedi ng the val ue of the repl acement part.
• When pl asti c repai rs are requi red, i t i s recom-
mended that the part be l eft on the vehi cl e when
every possi bl e. That wi l l save ti me, and the panel
wi l l remai n stati onary duri ng the repai r. Mi sal i gn-
ment can cause stress i n the repai r areas and can
resul t i n future fai l ure.
VISUAL INSPECTION
Composi te materi al s can mask the severi ty of an
acci dent. Adhesi ve bond l i nes, i nteri or structure of
the doors, and steel structures need to be i nspected
careful l y to get a true damage assessment. Cl ose
i nspecti on may requi re parti al removal of i nteri or
tri m or i nner panel s.
I denti fy the type of repai r: Puncture or Crack -
Damage that has penetrated compl etel y through the
panel . Damage i s confi ned to one general area; a
panel secti on i s not requi red. However, a backer
panel , open fi bergl ass tape, or matted materi al must
be bonded from behi nd (Fi g. 7) (Fi g. 6).
PANEL SURFACE PREPARATION
I f a body panel has been punctured, cracked, or
crushed, the damaged area must be removed from
the panel to achi eve a successful repai r. Al l spi der
web cracks l eadi ng away from a damaged area must
be stopped or removed. To stop a runni ng crack i n a
panel , dri l l a 6 mm (0.250 i n.) hol e at the end of the
crack farthest away from the damage. I f spi der web
cracks can not be stopped, the panel woul d requi re
repl acement. The surfaces around the damaged area
shoul d be stri pped of pai nt and freed from wax and
oi l . Scuff surfaces around repai r area wi th 360 gri t
wet/dry sandpaper, or equi val ent, to assure adhesi on
of repai r materi al s.
PATCHING PANELS
An panel that has extensi ve puncture type damage
can be repai red by cutti ng out the damaged materi al
(Fi g. 7). Use a sui tabl e reci procati ng saw or cut off
wheel to remove the secti on of the panel that i s dam-
aged. The pi ece cut out can be used as a templ ate to
shape the new patch. I t i s not necessary to have
access to the back of the panel to i nstal l a patch.
Bevel edges of cutout at 20 degrees to expose a l arger
bondi ng area on the outer si de. Thi s wi l l al l ow for an
i ncreased rei nforcement areas.
PANEL PATCH FABRICATIONS
A patch can be fabri cated from any ri gi d fi bergl ass
panel that has comparabl e contour wi th the repai r
area. Li ft gates and fenders can be used to suppl y
patch materi al . I f exi sti ng materi al i s not avai l abl e
or compati bl e, a patch can be constructed wi th adhe-
si ve and rei nforcement mesh (dry wal l tape). Perform
the fol l owi ng operati on i f requi red:
Fig. 4 BEVELING ANGLE - 20 DEGREE
Fig. 5 FIBERGLASS TAPE
Fig. 6 DAMAGE COMPONENT
1 - PUNCTURE
23 - 6 BODY TJ
BODY (Continued)
(1) Cover waxed paper or pl asti c wi th adhesi ve
backed nyl on mesh (dry wal l tape) l arger than the
patch requi red (Fi g. 8).
(2) Tape waxed paper or pl asti c sheet wi th mesh to
a surface that has a compati bl e contour to the repai r
area.
(3) Appl y a l i beral coat of adhesi ve over the rei n-
forcement mesh (Fi g. 8). I f necessary appl y a second
or thi rd coat of adhesi ve and mesh after fi rst coat
has cured. The thi ckness of the patch shoul d be the
same as the repai r area.
(4) After patch has cured, peel waxed paper or
pl asti c from the back of the patch.
(5) I f desi red, a thi n fi l m coat of adhesi ve can be
appl i ed to the back of the patch to cover mesh for
added strength.
PANEL PATCH INSTALLATION
(1) Make a paper or cardboard pattern the si ze
and shape of the cutout hol e i n the panel .
(2) Tri m 3 mm (0.125 i n.) from edges of pattern so
patch wi l l have a gap between connecti ng surfaces.
(3) Usi ng the pattern as a gui de, cut the patch to
si ze.
(4) Cut scrap pi eces of patch materi al i nto 50 mm
(2 i n.) squares to use as patch supports to sustai n
the patch i n the cutout.
(5) Dri l l 4 mm (0.160 i n.) hol es 13 mm (0.5 i n.) i n
from edge of cutout hol e (Fi g. 7).
(6) Dri l l 4 mm (0.160 i n.) hol es 13 mm (0.5 i n.)
away from edge of patch across from hol es dri l l ed
around cutout.
(7) Dri l l 3 mm (0.125 i n.) hol es i n the support
squares 13 mm (0.5 i n.) from the edge i n the center
of one si de.
(8) Scuff the backsi de of the body panel around the
cutout hol e wi th a scuff pad or sandpaper.
(9) Mi x enough adhesi ve to cover one si de of al l
support squares.
(10) Appl y adhesi ve to cover one si de of al l support
squares.
(11) Usi ng number 8 sheet metal screws, secure
support squares to back si de of body panel wi th
adhesi ve sandwi ched between the panel and squares
(Fi g. 9).
(12) Posi ti on patch i n cutout agai nst support
squares and adjust patch unti l the gap i s equal al ong
al l si des (Fi g. 10).
(13) Dri l l 3 mm (0.125 i n.) hol es i n the support
squares through the pre-dri l l ed hol es i n the patch.
Fig. 7 DAMAGED PANEL CUTOUT AND PATCH
1 - CUTOUT
2 - DAMAGED BODY PANEL
3 - 4 MM (0.160 IN.) HOLES
4 - PATCH CUT TO SIZE
Fig. 8 FABRICATED PANEL
1 - STRUCTURAL ADHESIVE
2 - FIBERGLASS CLOTH OR FIBERGLASS MESH TAPE
3 - WIDTH OF V-GROOVE
4 - WAXED PAPER
Fig. 9 SECURE SUPPORT SQUARES TO BODY
PANEL
1 - SUPPORT SQUARES
2 - SCREWS
3 - DAMAGED BODY PANEL
TJ BODY 23 - 7
BODY (Continued)
(14) Appl y a coat of adhesi ve to the exposed ends
of the support squares (Fi g. 11).
(15) I nstal l screws to hol d the patch to support
squares (Fi g. 12). Ti ghten screws unti l patch surface
i s fl ush wi th panel surface.
(16) Al l ow adhesi ve to cure, and remove al l screws.
(17) Usi ng a 125 mm (5 i n.) 24 gri t di sc gri nder,
gri nd a 50 mm (2 i n.) to 75 mm (3 i n.) wi de and 2
mm (0.080 i n.) deep path across the gaps around the
patch (Fi g. 13). Wi th compressed ai r, bl ow dust from
around patch.
(18) Appl y adhesi ve backed nyl on mesh (dry wal l
tape) over gaps around patch (Fi g. 14).
(19) Mi x enough adhesi ve to cover the enti re patch
area.
(20) Appl y adhesi ve over the mesh around patch,
and smooth epoxy wi th a wi de spreader to reduce fi n-
i sh gri ndi ng. Use two to three l ayers of mesh and
adhesi ve to create a stronger repai r (Fi g. 15).
PATCHED PANEL SURFACING
After patch panel i s i nstal l ed, the patch area can
be fi ni shed usi ng the same methods as fi ni shi ng
other types of body panel s. I f mesh materi al i s
exposed i n the patched area, gri nd surface down, and
appl y a coat of hi gh qual i ty ri gi d pl asti c body fi l l er.
Pri me, bl ock sand, and pai nt as requi red.
Fig. 10 POSITION PATCH IN CUTOUT AND ALIGN
1 - CUTOUT
2 - SUPPORT SQUARES
Fig. 11 APPLY ADHESIVE TO SUPPORT SQUARES
1 - APPLICATOR
2 - SUPPORT SQUARES
3 - ADHESIVE
Fig. 12 INSTALL SCREWS
1 - PATCH
2 - GAP
23 - 8 BODY TJ
BODY (Continued)
STANDARD PROCEDURE - BUZZ, SQUEAK &
RATTLE
Buzz, Squeak & Rattl es (BSR) may be caused by
any one or more of the fol l owi ng and may be cor-
rected as i ndi cated:
• Loose fasteners shoul d be ti ghtened to speci fi ca-
ti ons.
• Damaged or mi ssi ng cl i ps shoul d be repl aced.
• Damaged tri m panel s shoul d be repl aced.
• I ncorrectl y i nstal l ed tri m panel s shoul d be rei n-
stal l ed properl y.
Many BSR compl ai nts such as l oose tri m, can be
servi ced usi ng the Mopar௡ Parts BSR Noi se Reduc-
ti on Ki t. Thi s ki t contai ns vari ous tapes i ncl udi ng
foam, fl ock and anti -squeak used to el i mi nate noi ses
caused by metal , pl asti c and vi nyl components. Long
l i fe l ubri cants and greases can al so be used on a vari -
ety of components. Refer to the Buzz, Squeak & Rat-
tl e Ki t tabl e for materi al contents and usage.
BUZZ, SQUEAK & RATTLE KIT
ITEM FEATURES APPLICATIONS SERVICE TEMP
Itch And Squeak
Tape
An abrasion resistant material
thin enough to conform to most
irregular surfaces. Stops most
itches and squeaks.
Between metal and metal,
metal and plastic, metal and
vinyl, vinyl and plastic. Interior.
Examples: Trim panels and
bezels.
-40°to 225°
Fahrenheit
(-40°to 107°
Celsius)
Fig. 13 GRIND SURFACE
1 - PATCH
2 - GAP
3 - DISC GRINDER
Fig. 14 COVER GAPS WITH MESH
1 - GROUND DOWN AREA
2 - PATCH
3 - MESH
Fig. 15 COVER MESH WITH ADHESIVE
1 - ADHESIVE
2 - MESH
3 - PATCH
4 - SPREADER
TJ BODY 23 - 9
BODY (Continued)
ITEM FEATURES APPLICATIONS SERVICE TEMP
Black Nylon Flock Nylon Flock with an aggressive
acrylic adhesive. Provides for
cushioning and compression fit,
also isolates components.
Water-resistant.
Between metal and metal,
metal and plastic, vinyl and
plastic.
Examples: Pull cups, bezels,
clips, ducts, top cover to glass,
cowl panel.
-40°to 180°
Fahrenheit
(-40°to 82°Celsius)
High Density
Urethane Foam
Tear resistant, highly resilient
and durable.
Between metal and metal,
metal and plastic. Water-
resistant.
Examples: I/P, heavy metal
rattles, isolating brackets.
-40°to 180°
Fahrenheit
(-40°to 82°Celsius)
Open Cell Foam
Tape
Soft foam conforms to irregular
surfaces.
Wire harness and connector
wrap.
Examples: Seals, gasket,
wiring, heat ducts.
-40°to 180°
Fahrenheit
(-40°to 82°Celsius)
Closed Cell Low
Density Foam Tape
Soft, conformable. Water-
resistant.
Wherever bulk is needed.
Prevents closing flutters and
rattles when applied to door
watershield.
Examples: Door, I/P.
-40°to 180°
Fahrenheit
(-40°to 82°Celsius)
NYEா Grease 880 Long life. Suspensions.
Examples: Strut busings, sway
bars.
-40°to 390°
Fahrenheit
(-40°to 200°
Celsius)
Krytoxா Oil Long life. Will not dry out or
harm plastics or rubber.
When access is not possible, oil
will migrate to condition. Vinyl,
rubber, plastic, metal.
Examples: Convertible top
bushings, pull cups trim panel
inserts.
-30°to 400°
Fahrenheit
(-34°to 205°
Celsius)
Krytoxா Grease Long life. Will not dry out or
harm plastics or rubber.
Vinyl, rubber, plastic, metal,
glass.
Examples: Weather-strips,
backlite and windshield
moldings.
-30°to 400°
Fahrenheit
(-34°to 205°
Celsius)
SPECIFICATIONS - TORQUE
TORQUE SPECIFICATIONS
DESCRIPTION N·m Ft. Lbs. In. Lbs.
Body side guard/side bolts 5 — 45
Body side guard/support tab bolts 11 8 —
Hood assist spring bolt 3 — 25
Hood catch nuts 18 13 —
Hood catch bracket nuts 11 8 —
Hood hinge screws 24 18 —
Hood safety latch bolt 9 — 80
Bucket seat front anchor bolt 47 35 —
23 - 10 BODY TJ
BODY (Continued)
DESCRIPTION N·m Ft. Lbs. In. Lbs.
Bucket seat rear inboard anchor bolt 74 55 —
Bucket seat rear outboard anchor bolt 33 25 —
Liftgate glass ball stud nut 13 10 —
Liftgate glass hinge nut 6 — 53
Liftgate hinge to hardtop bolt 11 8 95
Front turning loop bolt 47 35 —
Front retractor bolt 47 35 —
Rear retractor bolt 47 35 —
Rear turning loop bolt 47 35 —
Rear belt anchor bolt 47 35 —
Rearview mirror set screw 1 — 9
Rear buckle anchor bolt 43 32 —
Side support bar to sport bar bolts 20 15 —
Side support sport bar to windshield frame bolts 32 24 —
Sport bar bracket bolt 68 50 —
Sport bar speaker pod bolts 68 50 —
Sport bar to wheelhouse bolts 40 30 —
Sport bar to cargo floor bolts 40 30 —
Tailgate hinge screws 23 17 —
Tailgate striker 71 52 —
SPECIAL TOOLS
BODY
Trim Stick C-4755
TORX BIT SET C-4794-B
REMOVER, MOLDINGS C-4829-A
TJ BODY 23 - 11
BODY (Continued)
TAILGATE
TABLE OF CONTENTS
page page
TAILGATE OUTSIDE HANDLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12
TAILGATE HINGE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12
TAILGATE LATCH
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 13
TAILGATE LATCH STRIKER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 13
LIFTGATE GLASS HINGE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 13
LIFTGATE GLASS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14
LIFTGATE GLASS WEATHERSTRIP
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 14
TAILGATE LOCK CYLINDER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14
LIFTGATE GLASS SUPPORT CYLINDER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 15
TAILGATE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 16
ADJUSTMENTS
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . 16
TAILGATE OUTSIDE HANDLE
REMOVAL
(1) Remove the l atch from the tai l gate. (Refer to
23 - BODY/TAI LGATE/LATCH - REMOVAL)
(2) Remove the screws attachi ng the outsi de han-
dl e to the tai l gate (Fi g. 1).
(3) Separate the outsi de handl e and seal from the
tai l gate.
INSTALLATION
(1) Posi ti on the seal and outsi de rel ease handl e on
the tai l gate. and i nstal l screws.
(2) I nstal l the screws attachi ng the outsi de handl e
to the tai l gate.
(3) I nstal l the l atch. (Refer to 23 - BODY/TAI L-
GATE/LATCH - I NSTALLATI ON)
TAILGATE HINGE
REMOVAL
NOTE: Hinges may be serviced individually. If both
are to be serviced, remove/install hinges one at a
time.
(1) Usi ng a grease penci l or equi val ent, mark the
posi ti on of the hi nge on the body.
(2) Remove the screws attachi ng the hi nge to the
body and tai l gate (Fi g. 2).
(3) Separate the hi nge from the tai l gate.
INSTALLATION
NOTE: Hinges may be serviced individually. If both
are to be serviced, remove/install hinges one at a
time.
(1) Prepare and pai nt the repl acement hi nge to
match the body pai nt col or.
Fig. 1 TAILGATE OUTSIDE HANDLE
1 - OUTSIDE HANDLE
2 - SEAL
3 - TAILGATE
23 - 12 TAILGATE TJ
(2) Lubri cate the hi nge wi th spray l ubri cant.
(3) Al i gn and posi ti on the hi nge on the body and
tai l gate.
(4) I nstal l the screws and ti ghten the screws to 23
N·m (200 i n. l bs.).
TAILGATE LATCH
REMOVAL
(1) Open the tai l gate and remove the l atch tri m
cover (Fi g. 3).
(2) Di sconnect the outsi de handl e to l atch rod.
(3) Di sconnect the l ock cyl i nder to l atch rod.
(4) Remove the screw attachi ng l atch to tai l gate.
(5) Separate the l atch from the tai l gate.
INSTALLATION
(1) Posi ti on the l atch i n the tai l gate.
(2) I nstal l the screw attachi ng l atch to tai l gate. Do
not ti ghten screw.
(3) Connect the l ock cyl i nder to l atch rod.
(4) Connect the outsi de handl e to l atch rod.
(5) I nstal l the l atch tri m cover.
TAILGATE LATCH STRIKER
REMOVAL
(1) Remove the stri ker from the bracket.
(2) Remove the shi m washers from the bracket.
(3) Remove the screws attachi ng the stri ker
bracket to the body.
INSTALLATION
(1) Posi ti on the stri ker bracket on the body and
i nstal l the screws.
(2) Posi ti on the stri ker and shi m washers on the
stri ker bracket.
(3) I nstal l the stri ker i n the bracket and ti ghten
the stri ker to 71 N·m (52 ft. l bs.).
LIFTGATE GLASS HINGE
REMOVAL
(1) Open tai l gate.
(2) Open and support l i ftgate gl ass.
(3) Remove wi per motor cover (ri ght hi nge onl y).
(Refer to 8 - ELECTRI CAL/REAR WI PERS/WASH-
ERS/REAR WI PER MOTOR TRI M COVER -
REMOVAL)
(4) Remove the wi per bl ade. (Refer to 8 - ELEC-
TRI CAL/REAR WI PERS/WASHERS/REAR WI PER
BLADE - REMOVAL)
(5) Remove the nut attachi ng the l i ftgate hi nge to
the l i ftgate gl ass.
(6) Mark the posi ti on of the hi nge i n the top and
remove the bol ts attachi ng the hi nge to the top (Fi g.
4).
INSTALLATION
(1) Al i gn and posi ti on the hi nge on the top and
i nstal l the bol ts.
Fig. 2 TAILGATE HINGE
1 - TAILGATE
2 - NUT PLATE
3 - HINGE
Fig. 3 TAILGATE LATCH
1 - TAILGATE
2 - OUTSIDE HANDLE ROD
3 - OUTSIDE HANDLE
4 - LATCH
5 - STRIKER
6 - STRIKER MOUNTING BRACKET
7 - LOCK CYLINDER
8 - LOCK CYLINDER ROD
9 - LOCK CYLINDER RETAINER CLIP
10 - LATCH COVER
TJ TAILGATE 23 - 13
TAILGATE HINGE (Continued)
(2) I nstal l the nut attachi ng the l i ftgate hi nge to
the l i ftgate gl ass and ti ghten to 6 N·m (53 i n. l bs.).
(3) I nstal l wi per motor cover. (Refer to 8 - ELEC-
TRI CAL/REAR WI PERS/WASHERS/REAR WI PER
MOTOR TRI M COVER - I NSTALLATI ON)
(4) I nstal l the wi per bl ade. (Refer to 8 - ELECTRI -
CAL/REAR WI PERS/WASHERS/REAR WI PER
BLADE - I NSTALLATI ON)
LIFTGATE GLASS
REMOVAL
(1) Di sconnect the rear defroster harness connec-
tors.
(2) Di sconnect the wi per motor harness connectors.
WARNING: DO NOT REMOVE THE LIFTGATE SUP-
PORT RODS WITH THE LIFTGATE CLOSED. THE
SUPPORT ROD PISTONS ARE OPERATED BY HIGH
PRESSURE GAS AND COULD CAUSE PERSONAL
INJURY AND/OR VEHICLE DAMAGE IF THEY ARE
REMOVED WITH THE PISTONS COMPRESSED
(LIFTGATE CLOSED). ONCE REMOVED, DO NOT
ATTEMPT TO DISASSEMBLE OR REPAIR THE SUP-
PORT RODS.
(3) Open the tai l gate and l i ftgate.
(4) Remove support rod cyl i nders. (Refer to 23 -
BODY/TAI LGATE/SUPPORT CYLI NDER -
REMOVAL)
(5) Remove the bol ts attachi ng the l i ftgate hi nge to
the hardtop (Fi g. 5).
(6) Separate the l i ftgate gl ass from the hard top.
INSTALLATION
Transfer al l rel ated components.
(1) I f removed, i nstal l support rod bal l studs and
ti ghten the nut to 12 N·m (112 i n. l bs.).
(2) Posi ti on the l i ftgate gl ass at the hard top.
(3) I nstal l the bol ts attachi ng the l i ftgate hi nge to
the hardtop and ti ghten to 10 N·m (95 i n. l bs.).
(4) I nstal l the support rod cyl i nders. (Refer to 23 -
BODY/TAI LGATE/SUPPORT CYLI NDER - I NSTAL-
LATI ON)
LIFTGATE GLASS
WEATHERSTRIP
DESCRIPTION
The l i ftgate gl ass weatherstri p i s attached to the
l i ftgate gl ass and i s not servi ceabl e. I f the l i ftgate
gl ass weatherstri p needs to be repl aced, repl ace the
l i ftgate gl ass. (Refer to 23 - BODY/LI FTGATE
GLASS - REMOVAL)
TAILGATE LOCK CYLINDER
REMOVAL
(1) Open the tai l gate.
(2) Remove the l atch cover.
(3) Remove the l ock cyl i nder retai ner cl i p.
(4) Remove the l ock cyl i nder from the tai l gate
openi ng.
INSTALLATION
(1) Posi ti on the l ock cyl i nder i n the tai l gate openi ng.
(2) Connect the l ock cyl i nder to l atch rod.
(3) I nstal l the l ock cyl i nder retai ner cl i p.
(4) I nstal l the l atch cover.
Fig. 4 LIFTGATE HINGE
1 - LIFTGATE HINGE
2 - LIFTGATE GLASS
Fig. 5 LIFTGATE GLASS
1 - LIFTGATE REAR WINDOW
2 - HARD TOP
23 - 14 TAILGATE TJ
LIFTGATE GLASS HINGE (Continued)
LIFTGATE GLASS SUPPORT
CYLINDER
REMOVAL
WARNING: DO NOT REMOVE THE LIFTGATE SUP-
PORT RODS WITH THE LIFTGATE CLOSED. THE
SUPPORT ROD PISTONS ARE OPERATED BY HIGH
PRESSURE GAS AND COULD CAUSE PERSONAL
INJURY AND/OR VEHICLE DAMAGE IF THEY ARE
REMOVED WITH THE PISTONS COMPRESSED
(LIFTGATE CLOSED). ONCE REMOVED, DO NOT
ATTEMPT TO DISASSEMBLE OR REPAIR THE SUP-
PORT RODS.
(1) Open and support the l i ftgate gl ass.
(2) Rel ease the support rod cyl i nder retai ni ng cl i ps
at both ends of each support rod cyl i nder. (Fi g. 6)
(3) Pul l the support rods off the bal l studs (Fi g. 7).
INSTALLATION
(1) Posi ti on the support rod cyl i nders on the bal l
studs.
(2) I nstal l the support rod cyl i nder retai ner cl i ps.
TAILGATE
REMOVAL
(1) Remove the spare ti re.
(2) Open the tai l gate and remove the center hi gh
mounted stop l amp (CHMSL) contact cover (Fi g. 8).
(3) Di sengage the CHMSL el ectri cal connectors.
(4) Remove the screws that attach the tai l gate
hi nge to the tai l gate.
(5) Separate the tai l gate from the vehi cl e.
Fig. 6 SUPPORT ROD CYLINDER CONNECTION
1 - CLIP
2 - BALL STUD
3 - SUPPORT ROD END
Fig. 7 SUPPORT ROD CYLINDER REMOVAL
1 - REAR WINDOW LIFT GLASS
2 - SUPPORT CYLINDER
Fig. 8 CHMSL CONTACT COVER
1 - TAILGATE
2 - COVER
3 - CHMSL CONTACT COVER BRACKET
TJ TAILGATE 23 - 15
INSTALLATION
NOTE: If necessary, transfer tailgate related compo-
nents.
(1) I nstal l the screws that attach the tai l gate
hi nge to the tai l gate.
(2) Engage the CHMSL el ectri cal connectors.
(3) I nstal l the CHMSL contact cover.
(4) Cl ose the tai l gate and i nstal l the spare ti re.
ADJ USTMENTS
ADJUSTMENT
(1) Loosen the tai l gate hi nge-to-body screws.
(2) Al i gn the tai l gate i n the body openi ng and
ti ghten the hi nge screws. (Refer to 23 - BODY/BODY
STRUCTURE/GAP AND FLUSH - SPECI FI CA-
TI ONS)
23 - 16 TAILGATE TJ
TAILGATE (Continued)
FULL DOOR
TABLE OF CONTENTS
page page
DOOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 17
ADJUSTMENTS
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . 17
DOOR GLASS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 18
WINDOW REGULATOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 18
EXTERIOR HANDLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 19
GLASS RUN CHANNEL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 20
HINGE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 20
INSIDE HANDLE ACTUATOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 21
LATCH
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 21
LATCH STRIKER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 22
LOCK CYLINDER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 22
TRIM PANEL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 22
DOOR
REMOVAL
(1) Open the door.
(2) Di sconnect the door restrai nt strap from the
pi n (Fi g. 1).
(3) Remove the nuts at the door hi nge pi vots and
l i ft the door from the body.
INSTALLATION
(1) Posi ti on the door i n the hi nge and i nstal l the
nuts.
(2) Connect the door restrai nt strap at the pi n.
ADJ USTMENTS
ADJUSTMENT
The doors are adjusted at the hi nge attachi ng l oca-
ti ons on ei ther the body or the door. Enl arged hol es
are l ocated i n the body (l ower hi nge onl y) for fore, aft
and ti l t adjustments. Enl arged hol es are al so l ocated
i n the door (upper and l ower hi nges) for up, down,
fore, aft and ti l t adjustments.
Pri or to door adjustment or al i gnment, the door
l atch must be removed to al l ow the door to cl ose
freel y and be properl y al i gned.
The door l atch stri ker shoul d be adjusted i n or out
to al l ow the door l atch to be ful l y engaged. The door
shoul d be fl ush wi th the adjacent body panel s.
DOOR GLASS
REMOVAL
(1) Remove the door tri m panel and the waterdam.
(Refer to 23 - BODY/FULL DOOR/TRI M PANEL -
REMOVAL)
Fig. 1 RESTRAINT STRAP
1 - BODY
2 - FOOTMAN LOOP
3 - STRAP
4 - RESTRAINT PIN
TJ FULL DOOR 23 - 17
(2) Pul l the door gl ass run channel from the door
sai l .
(3) Rol l gl ass ful l y downward.
(4) Usi ng a tri m sti ck C-4755 or equi val ent,
remove the screws and remove the door sai l panel
(Fi g. 2) and (Fi g. 3).
(5) Rol l gl ass 1/4 upward to access regul ator arm
gui de.
(6) Remove the screws that attach the regul ator
arm gui de to the gl ass.
(7) Li ft the gl ass upward whi l e ti l ti ng i nward and
remove from the door.
INSTALLATION
(1) Posi ti on the gl ass i n the door ensuri ng the
gl ass i s al i gned i n the gl ass run channel .
(2) I nstal l the screws that attach the regul ator
arm gui de to the gl ass.
(3) I nstal l the door sai l panel .
(4) I nstal l the run channel i n the door sai l .
(5) I nstal l the waterdam and the door tri m panel .
(Refer to 23 - BODY/FULL DOOR/TRI M PANEL -
I NSTALLATI ON)
WINDOW REGULATOR
REMOVAL
(1) Remove door gl ass. (Refer to 23 - BODY/FULL
DOOR/DOOR GLASS - REMOVAL)
(2) Loosen the bol ts i n the sl otted hol es (Fi g. 4).
(3) Remove the bol ts attachi ng the regul ator to the
door i nner panel .
(4) Li ft the regul ator upward to free i t from the
sl otted hol es i n the door i nner panel .
(5) Lower the regul ator and remove i t through the
access hol e i n the door i nner panel (Fi g. 5).
INSTALLATION
(1) Posi ti on the regul ator i n the door.
(2) Al i gn regul ator bol ts i nto sl otted hol es.
(3) I nstal l bol ts attachi ng regul ator to the i nner
door panel .
(4) Ti ghten the bol ts i n the sl otted hol es.
(5) I nstal l door gl ass. (Refer to 23 - BODY/FULL
DOOR/DOOR GLASS - I NSTALLATI ON)
Fig. 2 DOOR SAIL SCREWS
1 - DOOR SAIL
2 - DOOR
Fig. 3 DOOR SAIL REMOVAL
1 - DOOR FRAME
2 - TRIM STICK
3 - DOOR SAIL
Fig. 4 WINDOW REGULATOR BOLTS
1 - LOOSEN BOLTS
2 - REMOVE BOLTS
23 - 18 FULL DOOR TJ
DOOR GLASS (Continued)
EXTERIOR HANDLE
REMOVAL
(1) Remove the door tri m panel . (Refer to 23 -
BODY/FULL DOOR/TRI M PANEL - REMOVAL)
(2) Posi ti on the wi ndow i n the ful l upward posi -
ti on.
(3) Remove the grab handl e support bracket (Fi g.
6).
(4) Peel back the waterdam from the door i nner
panel to access the door l atch.
(5) Di sconnect from the l atch, the i nsi de l ock knob
to l atch rod and, the outsi de rel ease handl e to l atch
rod.
(6) Di sengage tai l of retai ner from handl e keeper.
(7) Usi ng a l ong fl at bl ade, tap the handl e keepers
upward and remove from the door handl e (Fi g. 7).
(8) Remove the l atch rel ease rod from the door
handl e.
(9) Separate the handl e and gasket from the door.
INSTALLATION
(1) Engage the l atch rel ease rod to the door han-
dl e.
(2) Posi ti on the gasket and handl e i n the door.
(3) Sl i de the keepers i nto the door handl e from the
top.
(4) Lower the wi ndow.
(5) Usi ng a l ong fl at bl ade, l i ghtl y tap the handl e
keepers downward to secure the handl e. The tai l of
the retai ner must be posi ti oned on the 2nd or 3rd
step from the bottom on the handl e keeper.
(6) Rai se the wi ndow.
(7) Connect to the l atch, the i nsi de l ock knob to
l atch rod and, the outsi de rel ease handl e to l atch rod.
(8) Reposi ti on the waterdam
(9) I nstal l the grab handl e support bracket.
(10) I nstal l the door tri m panel . (Refer to 23 -
BODY/FULL DOOR/TRI M PANEL - I NSTALLA-
TI ON)
Fig. 5 REGULATOR REMOVAL
1 - DOOR
2 - REGULATOR ASSEMBLY
Fig. 6 GRAB HANDLE SUPPORT BRACKET
1 - FULL DOOR
2 - GRAB HANDLE BRACKET
3 - TRIM PANEL
4 - NUT
Fig. 7 OUTSIDE DOOR HANDLE REMOVAL
1 - TAIL
2 - OUTSIDE HANDLE
3 - RETAINER
4 - HANDLE KEEPER
5 - DOOR
TJ FULL DOOR 23 - 19
WINDOW REGULATOR (Continued)
GLASS RUN CHANNEL
REMOVAL
(1) Lower the wi ndow.
(2) Usi ng a tri m sti ck C-4755 or equi val ent, care-
ful l y pry the gl ass run channel weatherstri p from the
wi ndow openi ng frame.
(3) Remove the door gl ass. (Refer to 23 - BODY/
FULL DOOR/DOOR GLASS - REMOVAL)
(4) Grasp the gl ass run channel weatherstri p i n
the door (Fi g. 8) and pul l from the channel .
INSTALLATION
NOTE: Applying a small amount of lubricant to the
weatherstrip may ease the installation.
(1) Posi ti on the weatherstri p i n the l ower door
channel s and press i nto pl ace.
(2) I nstal l the door gl ass. (Refer to 23 - BODY/
FULL DOOR/DOOR GLASS - I NSTALLATI ON)
(3) Posi ti on the weatherstri p i n the wi ndow open-
i ng frame and press i nto pl ace.
NOTE: Ensure that the glass is seated properly.
Improperly seated door glass will result in high
glass roll-up/roll-down effort.
HINGE
REMOVAL
(1) Remove the door. (Refer to 23 - BODY/FULL
DOOR/DOOR - REMOVAL)
(2) Usi ng a grease penci l or equi val ent, mark the
outl i ne of the exi sti ng hi nge on the body and the door
for i nstal l ati on al i gnment reference.
(3) Remove the nut from the upper hi nge pi n (Fi g.
9).
NOTE: When removing the door or hinge DO NOT
discard the plastic shims or the hinge pin.
(4) Remove the hi nge-to-body screws and the
hi nge-to-door screws. Remove the hi nge from the
door and body. Support the door as necessary. The
upper hi nge i s i ntegrated wi th the wi ndshi el d hi nge.
When removi ng i t, support the wi ndshi el d frame
wi th an appropri ate devi ce pri or to removal .
INSTALLATION
(1) Cl ean the repl acement hi nge wi th an appropri -
ate sol vent and dry i t wi th compressed ai r.
(2) Pai nt the hi nge to match the vehi cl e body.
(3) Lubri cate the hi nge wi th spray l ubri cant.
(4) Posi ti on the hi nge on the door, al i gn careful l y
wi th the wax penci l i nstal l ati on al i gnment reference
marks, and i nstal l the screws.
Fig. 8 FULL DOOR GLASS RUN CHANNEL
WEATHERSTRIP
1 - WINDOW GLASS
2 - REGULATOR
3 - GROMMET
4 - GLASS RUN CHANNEL WEATHERSTRIP
5 - DOOR
Fig. 9 FULL DOOR HINGE
1 - HINGE HALF
2 - HINGE HALF
3 - TAPPING PLATE
4 - HINGE HALF
5 - HINGE HALF
23 - 20 FULL DOOR TJ
(5) Posi ti on the hi nge on the vehi cl e body. Al i gn
the wax penci l marks i nstal l ati on al i gnment refer-
ence marks. I nstal l the screws.
(6) I nstal l the door. (Refer to 23 - BODY/FULL
DOOR/DOOR - I NSTALLATI ON)
(7) I nspect the wi ndshi el d al i gnment after hi nge
i nstal l ati on.
(8) I nspect the door al i gnment and adjust, i f nec-
essary. (Refer to 23 - BODY/FULL DOOR/DOOR -
ADJUSTMENTS)
INSIDE HANDLE ACTUATOR
REMOVAL
(1) Remove the torx screw attachi ng the i nsi de
handl e to the door.
(2) Careful l y pul l the handl e from the door.
(3) Di sconnect the l atch rods from the handl e (Fi g.
10).
INSTALLATION
(1) Connect the l atch rods to the handl e.
(2) Posi ti on handl e and seal i n door.
(3) I nstal l the torx screw attachi ng the i nsi de han-
dl e the to door.
LATCH
REMOVAL
(1) Remove tri m panel . (Refer to 23 - BODY/FULL
DOOR/TRI M PANEL - REMOVAL)
(2) Rol l wi ndow to ful l upward posi ti on.
(3) Di sconnect the l ock cyl i nder to l atch rod. (Fi g.
11)
(4) Di sconnect the l ock knob to l atch rod.
(5) Di sconnect the outsi de handl e to l atch rel ease
rod.
(6) Remove the screws attachi ng the l atch to the
door.
(7) Lower the l atch i n the door and di sconnect the
i nsi de handl e to l atch rod.
(8) Remove the l atch from the door.
INSTALLATION
(1) Posi ti on the l atch i n the door.
(2) Connect the i nsi de handl e to l atch rod.
(3) I nstal l the screws attachi ng the l atch to the
door.
(4) Posi ti on the door weatherstri p i n pl ace, appl y
adhesi ve as necessary.
(5) Connect the outsi de handl e to l atch rod.
(6) Connect the l ock knob to l atch rod.
(7) Connect the l ock cyl i nder to l atch rod.
(8) I nstal l tri m panel . (Refer to 23 - BODY/FULL
DOOR/TRI M PANEL - I NSTALLATI ON)
Fig. 10 INSIDE HANDLE ACTUATOR
1 - LOCK KNOB TO LATCH ROD
2 - U-NUT
3 - HALF DOOR TRIM PANEL
4 - INSIDE RELEASE HANDLE TO LATCH ROD
Fig. 11 DOOR LATCH ASSEMBLY
1 - RELEASE ROD
2 - SCREWS (3)
3 - LATCH ASSEMBLY
4 - LOCK ROD
TJ FULL DOOR 23 - 21
HINGE (Continued)
LATCH STRIKER
REMOVAL
(1) Remove the screws attachi ng the stri ker to the
body.
(2) Separate the stri ker and the spacer from the
body (Fi g. 12).
INSTALLATION
(1) Posi ti on the stri ker and the spacer on the body.
(2) I nstal l the screws attachi ng the stri ker and
spacer to the body.
LOCK CYLINDER
REMOVAL
(1) Remove tri m panel . (Refer to 23 - BODY/FULL
DOOR/TRI M PANEL - REMOVAL)
(2) Peel back waterdam.
(3) Di sconnect l ock cyl i nder to l atch rod.
(4) Remove l ock cyl i nder retai ni ng cl i p.
(5) Remove the l ock cyl i nder from the door.
INSTALLATION
(1) I nstal l the l ock cyl i nder i n the door.
(2) I nstal l l ock cyl i nder retai ni ng cl i p.
(3) Connect l ock cyl i nder to l atch rod.
(4) Secure the waterdam to the door.
(5) I nstal l tri m panel . (Refer to 23 - BODY/FULL
DOOR/LOCK CYLI NDER - I NSTALLATI ON)
TRIM PANEL
REMOVAL
(1) Lower the wi ndow.
(2) Remove the cl i p attachi ng the wi ndow gl ass
regul ator handl e to the regul ator. Remove the han-
dl e.
(3) Remove the screws attachi ng tri m panel to
door (Fi g. 13).
(4) Usi ng a speci al tool C-4829 or equi val ent,
remove push-i n fasteners attachi ng tri m panel to
door.
(5) Li ft the tri m panel upward and separate the
tri m panel from the door.
INSTALLATION
(1) Posi ti on the tri m panel on the door.
(2) Press the push-i n fasteners attachi ng tri m
panel to door i nto pl ace.
(3) I nstal l the screws attachi ng tri m panel to door.
(4) Posi ti on the cl i p on regul ator handl e and
i nstal l the handl e on the regul ator.
Fig. 12 LATCH STRIKER
1 - STRIKER
2 - SPACER
3 - BODY
Fig. 13 FULL
1 - FULL DOOR
2 - GRAB HANDLE BRACKET
3 - TRIM PANEL
4 - NUT
23 - 22 FULL DOOR TJ
HALF DOOR
TABLE OF CONTENTS
page page
DOOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 23
WINDOW
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 23
EXTERIOR HANDLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 24
HINGE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 24
INSIDE HANDLE ACTUATOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 24
LATCH
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 25
LATCH STRIKER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 25
LOCK CYLINDER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 25
TRIM PANEL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 25
DOOR
REMOVAL
(1) Open the door.
(2) Di sconnect the door restrai nt strap from the
pi n (Fi g. 1).
(3) Remove the nuts at the door hi nge pi vots and
l i ft the door from the body.
INSTALLATION
(1) Posi ti on the door i n the hi nge and i nstal l the
nuts.
(2) Connect the door restrai nt strap at the pi n.
(3) Check for proper operati on.
WINDOW
REMOVAL
(1) Open the door.
(2) Grasp the wi ndow at both front and rear edges
and fi rml y l i ft upward (Fi g. 2).
INSTALLATION
(1) Starti ng at the most forward al i gnment pi n,
posi ti on the wi ndow al i gnment pi ns i nto the restrai nt
sl eeves and push downward unti l seated.
Fig. 1 RESTRAINT STRAP
1 - BODY
2 - FOOTMAN LOOP
3 - STRAP
4 - RESTRAINT PIN
Fig. 2 HALF WINDOW
TJ HALF DOOR 23 - 23
EXTERIOR HANDLE
REMOVAL
(1) Remove tri m panel . (Refer to 23 - BODY/HALF
DOOR/TRI M PANEL - REMOVAL)
(2) Di sconnect the outsi de handl e to l atch rod.
(3) Remove screws attachi ng the outsi de handl e to
the door.
(4) Separate the outsi de handl e and seal from the
door.
INSTALLATION
(1) Posi ti on the outsi de handl e and seal i n the
door.
(2) I nstal l screws attachi ng the outsi de handl e to
the door.
(3) Connect the outsi de handl e to l atch rod.
(4) I nstal l tri m panel . (Refer to 23 - BODY/HALF
DOOR/TRI M PANEL - I NSTALLATI ON)
HINGE
DESCRIPTION
The servi ce procedures for the hal f door hi nge are
the same as the ful l door hi nge. (Refer to 23 - BODY/
FULL DOOR/HI NGE - REMOVAL) and (Refer to 23 -
BODY/FULL DOOR/HI NGE - I NSTALLATI ON).
INSIDE HANDLE ACTUATOR
REMOVAL
(1) Remove the torx screw attachi ng the i nsi de
handl e to the door.
(2) Careful l y pul l handl e from door.
(3) Di sconnect the l atch rods from the handl e (Fi g.
3).
INSTALLATION
(1) Connect the l atch rods to the handl e.
(2) Posi ti on handl e and seal i n door.
(3) I nstal l the torx screw attachi ng the i nsi de han-
dl e the to door.
LATCH
REMOVAL
(1) Remove tri m panel . (Refer to 23 - BODY/HALF
DOOR/TRI M PANEL - REMOVAL)
(2) Di sconnect the l ock cyl i nder to l atch rod (Fi g.
4).
(3) Di sconnect the l ock knob to l atch rod.
(4) Di sconnect the outsi de handl e to l atch rod.
(5) Usi ng a tri m sti ck or equi val ent, pry back the
door weatherstri p at the l atch to access the screw
attachi ng the l atch to the door.
(6) Remove the screws attachi ng the l atch to the
door (Fi g. 5).
(7) Lower the l atch i n the door and di sconnect the
i nsi de handl e to l atch rod.
(8) Remove the l atch from the door.
Fig. 3 INSIDE HANDLE ACTUATOR
1 - LOCK KNOB TO LATCH ROD
2 - U-NUT
3 - HALF DOOR TRIM PANEL
4 - INSIDE RELEASE HANDLE TO LATCH ROD
Fig. 4 HALF DOOR LATCH RODS
1 - LOCK CYLINDER
2 - HALF DOOR
3 - HALF DOOR
4 - LATCH
5 - LOCK CYLINDER TO LATCH ROD
6 - LOCK CYLINDER
7 - RETAINER
8 - OUTSIDE HANDLE
9 - INSIDE HANDLE TO LATCH ROD
10 - INSIDE LOCK TO LATCH ROD
23 - 24 HALF DOOR TJ
INSTALLATION
(1) Posi ti on the l atch i n the door.
(2) Connect the i nsi de handl e to l atch rod.
(3) I nstal l the screws attachi ng the l atch to the
door.
(4) Posi ti on the door weatherstri p i n pl ace, appl y
adhesi ve as necessary.
(5) Connect the outsi de handl e to l atch rod.
(6) Connect the l ock knob to l atch rod.
(7) Connect the l ock cyl i nder to l atch rod (Fi g. 4).
(8) I nstal l tri m panel . (Refer to 23 - BODY/HALF
DOOR/TRI M PANEL - I NSTALLATI ON)
LATCH STRIKER
REMOVAL
(1) Remove the screws attachi ng the stri ker to the
body.
(2) Separate the stri ker and the spacer from the
body (Fi g. 6).
INSTALLATION
(1) Posi ti on the stri ker and the spacer on the body.
(2) I nstal l the screws attachi ng the stri ker and
spacer to the body.
LOCK CYLINDER
REMOVAL
(1) Remove tri m panel . (Refer to 23 - BODY/HALF
DOOR/TRI M PANEL - REMOVAL)
(2) Di sconnect l ock cyl i nder to l atch rod (Fi g. 4).
(3) Remove l ock cyl i nder retai ni ng cl i p.
(4) Remove the l ock cyl i nder from the door.
INSTALLATION
(1) I nstal l the l ock cyl i nder i n the door.
(2) I nstal l l ock cyl i nder retai ni ng cl i p.
(3) Connect l ock cyl i nder to l atch rod.
(4) I nstal l tri m panel . (Refer to 23 - BODY/HALF
DOOR/TRI M PANEL - I NSTALLATI ON)
TRIM PANEL
REMOVAL
(1) Remove hal f door wi ndow. (Refer to 23 - BODY/
HALF DOOR/WI NDOW - REMOVAL)
(2) Rotate wi ndow retai ner sl eeves 90°. Usi ng a
tri m sti ck C-4755 or equi val ent, pry sl eeve retai ners
from door.
(3) Remove the screws attachi ng tri m panel to
door.
(4) Usi ng a tri m sti ck C-4829 or equi val ent,
remove push-i n fasteners attachi ng tri m panel to
door.
(5) Separate the tri m panel from the door.
INSTALLATION
(1) Posi ti on the tri m panel on the door.
(2) Press the push-i n fasteners attachi ng tri m
panel to door i nto pl ace.
(3) I nstal l the screws attachi ng tri m panel to door.
(4) Posi ti on retai ner sl eeves i nto door. Rotate
retai ner sl eeves 90° to secure i nto pl ace.
(5) I nstal l hal f door wi ndow. (Refer to 23 - BODY/
HALF DOOR/WI NDOW - I NSTALLATI ON)
Fig. 5 DOOR LATCH
1 - LATCH
2 - HALF DOOR
Fig. 6 LATCH STRIKER
1 - STRIKER
2 - SPACER
3 - BODY
TJ HALF DOOR 23 - 25
LATCH (Continued)
EXTERIOR
TABLE OF CONTENTS
page page
BODY DECALS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 26
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 26
COWL GRILLE AND SCREEN
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 27
RIGHT FRONT FENDER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 27
LEFT FRONT FENDER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 28
RADIATOR GRILLE PANEL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 30
WHEELHOUSE SPLASH SHIELD
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 30
SIDE VIEW MIRROR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 30
WHEEL OPENING FLARE MOLDING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 31
EXHAUSTER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 32
BODY SIDE GUARD
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 32
SIDE STEP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 33
LICENSE PLATE BRACKET
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 33
BODY DECALS
DESCRIPTION
TJ decal s are durabl e tape decal s wi th a adhesi ve
backi ng.
To el i mi nate bl i sters and ai r bubbl es i n a decal ,
pi erce them wi th a needl e or pi n. Force the trapped
ai r out of the hol e.
A heat gun can al so be used to remove smal l wri n-
kl es and i rregul ari ti es i n a decal .
REMOVAL
NOTE: The key to successful decal removal is to
apply heat to area and slowly peel the decal from
panel.
(1) Cl ean the surface as necessary.
(2) Pl ace a pi ece of maski ng tape above or bel ow
the decal as a reference mark.
(3) Start at one end of the decal and appl y heat
wi th a heat gun. Sl owl y peel the decal from the panel
by pul l i ng i t back. Do not pull the decal outward
from the panel.
INSTALLATION
(1) The area that wi l l be covered by the decal must
be cl eaned wi th an cl eani ng sol uti on to remove any
resi due pai nt. Freshl y pai nted surfaces must be thor-
oughl y dry.
(2) Cl ean pai nted surface wi th a commerci al wax
and si l i cone removal sol uti on. Wi pe surface wi th a
cl ean cl oth and al l ow to dry.
(3) Posi ti on decal and carri er on panel and hol d i t
i n-pl ace wi th pi eces maski ng tape.
(4) Li ft the bottom edge of the decal and carri er,
use the tape secti ons as hi nges, and reverse the posi -
ti on of the decal and carri er.
CAUTION: Always remove the carrier from the tape
stripe/decal, never remove the tape stripe/decal
from the carrier.
(5) Bend a corner of the carri er outward, separate
the corner of the carri er from the decal .
(6) Usi ng the maski ng tape on the body panel ,
al i gn the decal .
(7) Separate the carri er from one end of the decal .
(8) Hol d tape decal fi rml y agai nst the panel sur-
face whi l e separati ng the carri er from the decal .
(9) I nspect tape decal wi th refl ected l i ght to check
for defects that coul d have devel oped duri ng the
i nstal l ati on process. Remove al l ai r and/or moi sture
bubbl es.
23 - 26 EXTERIOR TJ
COWL GRILLE AND SCREEN
REMOVAL
(1) Remove the wi per arms. (Refer to 8 - ELEC-
TRI CAL/WI PERS/WASHERS/WI PER ARMS -
REMOVAL)
CAUTION: Use masking tape or equivalent on the
wiper arm pivots to prevent damage to the cowl
grille paint.
(2) Remove the four screws at the rear of the cowl
gri l l e.
(3) Open the hood and remove the screws that
attach the cowl gri l l e and screen to the cowl (Fi g. 1).
(4) Remove the gri l l e and screen from the cowl .
INSTALLATION
NOTE: When installing the cowl grille, ensure the
snorkels on the cowl are positioned correctly and in
good condition. Misaligned or damaged seals may
allow water to enter the HVAC.
(1) Posi ti on the cowl screen and gri l l e on the cowl .
(2) I nstal l the screws that attach the gri l l e and
screen to the cowl .
(3) Remove the tape from the wi per pi vots and
i nstal l the wi per arms. (Refer to 8 - ELECTRI CAL/
WI PERS/WASHERS/WI PER ARMS - I NSTALLA-
TI ON)
RIGHT FRONT FENDER
REMOVAL
(1) Remove the battery tray. (Refer to 8 - ELEC-
TRI CAL/BATTERY SYSTEM/TRAY - REMOVAL)
(2) Remove the ai r cl eaner housi ng.
(3) Remove the bol ts attachi ng the Power Di stri bu-
ti on Center (PDC) to the fender.
(4) Di sengage the PDC wi re harness retai ners on
the battery tray and fender.
(5) Move and secure the PDC.
(6) Di sengage the hi gh pressure ai r condi ti oni ng
l i ne retai ner on the fender.
(7) Di sengage the front end l i ghti ng wi re harness
retai ners on the fender.
(8) Di sengage the battery temperature sensor con-
nector.
(9) Di sengage the vacuum l i ne at the reservoi r
under the battery tray rei nforcement bracket.
(10) Di sengage the headl amp wi re connector.
(11) Route the fog l amp (i f equi pped), park l amp
and si de marker wi re harness through the access
hol e i n the fender wel l .
(12) I f equi pped, remove the fender fl are exten-
si on.
(13) Remove the bol ts attachi ng the fender to the
cowl (Fi g. 2).
(14) Remove the bol ts attachi ng the fender to the
battery tray rei nforcement bracket.
(15) Remove the bol ts attachi ng the fender to the
gri l l e.
(16) Separate the fender from the vehi cl e.
INSTALLATION
Transfer al l rel ated components. Repl ace harness
retai ners i f damaged.
(1) Posi ti on the fender on the vehi cl e.
(2) I nstal l the bol ts attachi ng the fender to the
gri l l e.
(3) I nstal l the bol ts attachi ng the fender to the
battery tray rei nforcement bracket.
(4) I nstal l the bol ts attachi ng the fender to the
cowl .
(5) I f equi pped, i nstal l the fender fl are extensi on
and body si de mol di ng.
(6) Route the fog l amp (i f equi pped), park l amp
and si de marker wi re harness through the access
hol e i n the fender wel l . Seat the grommet.
(7) Engage the headl amp wi re connector.
(8) Engage the battery temperature sensor connec-
tor.
(9) Engage the vacuum l i ne at the reservoi r under
the battery tray rei nforcement bracket.
(10) Posi ti on the front end l i ghti ng wi re harness
i nto the retai ners on the fender. Engage the retai ners
to secure.
Fig. 1 COWL GRILLE AND SCREEN
1 - COWL GRILLE
2 - COWL GRILLE SCREEN
3 - COWL
4 - U NUT
5 - DASH PANEL TIE ROD
6 - U NUT
TJ EXTERIOR 23 - 27
(11) Posi ti on the hi gh pressure ai r condi ti oni ng
l i ne i nto the retai ner on the fender. Engage the
retai ner to secure.
(12) Posi ti on the PDC on the fender and i nstal l the
bol ts.
(13) Posi ti on the PDC wi re harness i nto the
retai ners on the fender and battery tray. Engage the
retai ners to secure.
(14) I nstal l the ai r cl eaner housi ng.
(15) I nstal l the battery tray. (Refer to 8 - ELEC-
TRI CAL/BATTERY SYSTEM/TRAY - I NSTALLA-
TI ON)
LEFT FRONT FENDER
REMOVAL
(1) Di sconnect the negati ve termi nal on the bat-
tery. (Refer to 8 - ELECTRI CAL/BATTERY SYSTEM/
CABLES - REMOVAL)
(2) Remove the wi ndshi el d washer reservoi r.
(3) Remove horns. (Refer to 8 - ELECTRI CAL/
HORN/HORN - REMOVAL)
(4) Remove EVAP cani ster.
(5) Remove the bol ts attachi ng the ABS Hydraul i c
Control Uni t (HCU) to the support tray.
(6) Secure the HCU.
(7) Remove the HCU tray.
(8) Di sengage the front end l i ghti ng wi re harness
retai ners on the fender.
(9) Di sengage the headl amp wi re connector.
(10) Route the fog l amp (i f equi pped), park l amp
and si de marker wi re harness through the access
hol e i n the fender wel l .
(11) Remove the bol ts attachi ng the fender to the
cowl (Fi g. 3).
(12) Remove the bol ts attachi ng the fender to the
HCU tray rei nforcement bracket.
(13) Remove the bol ts attachi ng the fender to the
gri l l e.
(14) Separate the fender from the vehi cl e.
INSTALLATION
Transfer al l rel ated components. Repl ace harness
retai ners i f damaged.
(1) Posi ti on the fender on the vehi cl e.
(2) I nstal l the bol ts attachi ng the fender to the
gri l l e.
Fig. 2 FRONT FENDER
1 - REINFORCEMENT
2 - BATTERY TRAY
3 - BODY
4 - REINFORCEMENT
5 - FENDER
6 - TRAY
7 - RADIATOR GRILLE PANEL
23 - 28 EXTERIOR TJ
RIGHT FRONT FENDER (Continued)
(3) Posi ti on the front end l i ghti ng wi re harness
i nto the retai ners on the fender. Engage the retai ners
to secure.
(4) I nstal l the bol ts attachi ng the fender to the
HCU tray rei nforcement bracket.
(5) I nstal l the bol ts attachi ng the fender to the
cowl .
(6) I f equi pped, i nstal l the body si de mol di ng.
(7) Route the fog l amp (i f equi pped), park l amp
and si de marker wi re harness through the access
hol e i n the fender wel l . Seat the grommet.
(8) Engage the headl amp wi re connector.
(9) I nstal l the HCU tray.
(10) Posi ti on the HCU on the support tray and
i nstal l the bol ts.
(11) I nstal l EVAP cani ster.
(12) I nstal l horns. (Refer to 8 - ELECTRI CAL/
HORN/HORN - I NSTALLATI ON)
(13) Engage horn wi re connectors.
(14) I nstal l the wi ndshi el d washer reservoi r.
(15) Connect the negati ve termi nal on the battery.
(Refer to 8 - ELECTRI CAL/BATTERY SYSTEM/CA-
BLES - I NSTALLATI ON)
RADIATOR GRILLE PANEL
REMOVAL
(1) Remove the front crossmember cover.
(2) Remove the crossmember val ence cover.
(3) Remove the radi ator overfl ow bottl e.
(4) Remove the bol ts that attach the radi ator and
shroud from the gri l l e panel .
(5) I f A/C equi pped:
(a) Evacuate the system.
(b) Di sconnect the hi gh and l ow pressure l i nes
at the qui ck di sconnect coupl i ngs.
(c) Cover (cap) the l i nes to prevent contami na-
ti on.
(6) Remove the bol ts attachi ng the radi ator sup-
port rods to the gri l l e panel .
(7) Di sconnect the head l amp, turn si gnal , marker
l amp and horn wi re harness connectors.
(8) Remove the bol ts attachi ng the fenders to the
gri l l e panel .
(9) Remove the bol t attachi ng the gri l l e to the
frame mount.
(10) Separate the gri l l e from the vehi cl e.
Fig. 3 FRONT FENDER
1 - REINFORCEMENT
2 - BATTERY TRAY
3 - BODY
4 - REINFORCEMENT
5 - FENDER
6 - TRAY
7 - RADIATOR GRILLE PANEL
TJ EXTERIOR 23 - 29
LEFT FRONT FENDER (Continued)
INSTALLATION
Transfer al l rel ated components.
(1) Posi ti on the gri l l e panel on the vehi cl e. Ensure
the rubber support bumpers are al i gned (Fi g. 4).
(2) I nstal l the bol t attachi ng the gri l l e to the frame
mount.
(3) I nstal l the bol ts attachi ng the fenders to the
gri l l e panel .
(4) Connect the head l amp, turn si gnal , marker
l amp and horn wi re harness connectors.
(5) I nstal l the bol ts attachi ng the radi ator support
rods to the gri l l e panel .
(6) I f A/C equi pped:
(a) Connect the hi gh and l ow pressure l i nes at
the qui ck di sconnect coupl i ngs.
(b) Evacuate and charge the system.
(7) I nstal l the radi ator and shroud to the gri l l e
panel .
(8) I nstal l the radi ator overfl ow bottl e.
(9) I nstal l the crossmember val ence cover.
(10) I nstal l the front crossmember cover.
WHEELHOUSE SPLASH
SHIELD
REMOVAL
(1) Remove the pl asti c push pi ns that attach the
spl ash shi el d to the wheel house (Fi g. 5).
(2) Remove the push-i n fasteners attachi ng the
spl ash shi el d to the wheel house. (The push-i n fasten-
ers are mol ded i nto the spl ash shi el d.)
(3) Remove the spl ash shi el d from the wheel house.
INSTALLATION
(1) Posi ti on the spl ash shi el d i n the wheel house.
(2) Press the spl ash shi el d push-i n fasteners i nto
pl ace.
(3) Attach the spl ash shi el d to the wheel house
wi th push pi ns.
SIDE VIEW MIRROR
REMOVAL
(1) Remove the screws attachi ng the mi rror to the
door hi nge (Fi g. 6).
(2) Remove the mi rror from the door hi nge.
(3) Di sconnect the el ectri cal connector, i f equi pped.
INSTALLATION
(1) Cl ean the door hi nge-mi rror base contact sur-
face.
(2) Posi ti on the mi rror base at the door hi nge.
(3) I nstal l the three screws attachi ng the mi rror
base to the door hi nge.
Fig. 4 GRILLE BUMPERS
1 - GRILLE PANEL
2 - BUMPER
Fig. 5 Wheelhouse Splash Shield
1 - BODY
2 - WHEELHOUSE SPLASH SHIELD
3 - PUSH-IN FASTENERS
4 - RIVET
23 - 30 EXTERIOR TJ
RADIATOR GRILLE PANEL (Continued)
WHEEL OPENING FLARE
MOLDING
REMOVAL
(1) Remove the si de marker l amp. (Refer to 8 -
ELECTRI CAL/LAMPS/LI GHTI NG - EXTERI OR/
MARKER LAMP UNI T - REMOVAL)
(2) Remove the screws that attach the fl are to the
front fender or rear wheel house (Fi g. 7).
(3) Separate the fl are from the body.
INSTALLATION
(1) Cl ean the contact surface on the body.
(2) Cl ean the contact surface on the fl are and posi -
ti on i t on the front fender or wheel house.
(3) I nstal l the screws attachi ng the fl ares to the
front fender or wheel house.
(4) I f removed, i nstal l the si de marker l amp.
Fig. 7 FENDER FLARES
1 - U-NUT
2 - FENDER FLARE
3 - NUTSERT
4 - SPLASH SHIELD
5 - RIVET
6 - NUTSERT
7 - FENDER FLARE
8 - U-NUT
Fig. 6 SIDE VIEW MIRROR
1 - MIRROR ASSEMBLY
2 - SCREWS (3)
TJ EXTERIOR 23 - 31
WHEEL OPENING FLARE MOLDING (Continued)
EXHAUSTER
REMOVAL
(1) Remove the spare ti re carri er. (Refer to 22 -
TI RES/WHEELS/TI RES/SPARE TI RE CARRI ER -
REMOVAL)
(2) Usi ng a tri m sti ck C-4755 or equi val ent, sepa-
rate the exhauster from the tai l gate. (Fi g. 8)
INSTALLATION
(1) I nstal l the exhauster and seat ful l y.
(2) I nstal l the spare ti re carri er. (Refer to 22 -
TI RES/WHEELS/TI RES/SPARE TI RE CARRI ER -
I NSTALLATI ON)
BODY SIDE GUARD
REMOVAL
(1) Remove the bol ts from the l ower support tabs.
(Fi g. 9)
(2) Remove the si de bol ts and remove the si de
guard. (Fi g. 10)
INSTALLATION
(1) I nstal l the body si de guard and i nstal l the si de
bol ts.
(2) Ti ghten the bol ts to 5 N·m (45 i n. l bs.).
(3) I nstal l the support tab bol ts and ti ghten to 11
N·m (8 ft. l bs.).
SIDE STEP
REMOVAL
(1) Remove the bol ts that attach the si de step to
the frame (Fi g. 11).
(2) Ti l t the step down and di sengage the tabs from
the frame sl ots.
Fig. 8 BODY EXHAUSTER
1 - TAILGATE HANDLE
2 - EXHAUSTER OPENING
3 - EXHAUSTER
Fig. 9 SIDE GUARD - LOWER
1 - BODY SIDE GUARD
2 - SUPPORT TABS (5)
3 - BODY FLOOR SILL
4 - BOLTS (5)
Fig. 10 SIDE GUARD - UPPER
1 - DOOR
2 - SIDE GUARD BOLTS (5)
3 - BODY SIDE GUARD
23 - 32 EXTERIOR TJ
INSTALLATION
(1) Posi ti on the si de step on the frame and engage
the mounti ng tabs i nto the frame sl ots.
(2) I nstal l the bol ts that attach the si de step to the
frame and ti ghten to 21 N·m (15 ft. l bs.).
LICENSE PLATE BRACKET
REMOVAL
(1) I f i nstal l ed, remove the l i cense pl ate.
(2) Remove the four screws attachi ng the l i cense
pl ate bracket to the body (Fi g. 12).
(3) On export model s remove the bol ts and nuts.
(Fi g. 13)
(4) Separate the bracket from the body.
(5) Di sconnect the el ectri cal connectors, i f
equi pped.
INSTALLATION
(1) Connect the el ectri cal connectors, i f equi pped.
(2) Posi ti on the bracket on the body.
(3) I nstal l the four screws attachi ng the l i cense
pl ate bracket to the body.
(4) On export model s, i nstal l the si x bol ts and four
nuts.
(5) I f removed, i nstal l the l i cense pl ate.
Fig. 11 SIDE STEP
1 - FRAME SLOTS
2 - SIDE STEP
3 - BOLTS
4 - STEP MOUNTING TABS
Fig. 12 LICENSE PLATE BRACKET
1 - BOLTS (4)
2 - BRACKET
Fig. 13 LICENSE PLATE BRACKET - EXPORT
1 - NUTS (4)
2 - BOLTS (2)
3 - BUMPER
4 - ELECTRICAL CONNECTORS
5 - LICENSE PLATE BRACKET
6 - BOLTS (4)
TJ EXTERIOR 23 - 33
SIDE STEP (Continued)
HOOD
TABLE OF CONTENTS
page page
HINGE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 34
HOOD
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 34
ADJUSTMENTS
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . 34
HOOD SAFETY LATCH
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 35
HINGE
REMOVAL
(1) Remove the wi per arms. (Refer to 8 - ELEC-
TRI CAL/WI PERS/WASHERS/WI PER ARMS -
REMOVAL)
(2) Remove the cowl panel and screen. (Refer to 23
- BODY/EXTERI OR/COWL GRI LLE AND SCREEN -
REMOVAL)
(3) Remove the bol ts attachi ng the hi nge to the
cowl .
(4) Usi ng a wax penci l , mark the posi ti on of the
hi nge on the hood for i nstal l ati on al i gnment refer-
ence.
(5) Remove the screws attachi ng the hi nge to the
hood (Fi g. 1).
(6) Separate the hi nge from the hood.
INSTALLATION
(1) Prepare and pai nt the repl acement hi nge to
match the body pai nt col or.
(2) Al i gn the hi nge wi th the i nstal l ati on reference
marks on the hood
(3) I nstal l the screws attachi ng the hi nge to the
hood and cowl and ti ghten the to 24 N·m (18 ft. l bs.).
(4) I nstal l the bol ts attachi ng the hi nge to the
cowl .
(5) I nstal l the cowl panel and screen. (Refer to 23 -
BODY/EXTERI OR/COWL GRI LLE AND SCREEN -
I NSTALLATI ON)
(6) I nstal l the wi per arms. (Refer to 8 - ELECTRI -
CAL/WI PERS/WASHERS/WI PER ARMS - I NSTAL-
LATI ON)
HOOD
REMOVAL
(1) Rai se and support the hood.
(2) Di sconnect the underhood l amp wi re harness
connector.
(3) Di sconnect the wi ndshi el d washer nozzl es.
(4) Di sconnect the ground strap.
(5) Mark the posi ti on of the hi nges on the hood for
i nstal l ati on al i gnment reference.
(6) Remove the screws attachi ng the hood to the
hi nge and remove the hood (Fi g. 1).
(7) I f the hood must be repl aced, remove and
transfer the i nsul ator panel , hi nges, l atches,
bumpers, brackets, footman l oop, hood l amp, support
rod, and safety l atch to the repl acement hood (Fi g.
1).
INSTALLATION
(1) Posi ti on the hood on the vehi cl e and i nstal l the
screws attachi ng the hi nge to the hood.
(2) Al i gn the hi nges wi th the i nstal l ati on reference
marks on the hood and ti ghten the hi nge screws to
24 N·m (18 ft. l bs.).
(3) Connect the underhood l amp wi re harness con-
nector.
(4) Connect the wi ndshi el d washer nozzl es.
(5) Connect the ground strap.
ADJ USTMENTS
ADJUSTMENT
The hood hi nge screw hol es are oversi zed to faci l i -
tate hood adjustment movement.
(1) Loosen the screws.
(2) Move the hood i n the di recti on(s) requi red for
correct al i gnment.
(3) Ti ghten the screws.
23 - 34 HOOD TJ
HOOD SAFETY LATCH
REMOVAL
(1) Rai se and support the hood.
(2) Remove the bol t attachi ng the safety l atch to
the hood (Fi g. 2).
(3) Remove the l atch from the hood.
INSTALLATION
(1) Posi ti on the l atch on the hood.
(2) I nstal l the bol t attachi ng the safety l atch to the
hood and ti ghten to 9 N·m (80 i n. l bs.).
(3) Remove the support rod and cl ose the hood.
Fig. 1 HOOD COMPONENTS
1 - WINDSHIELD REST BUMPER
2 - HOOD HINGE
3 - HOOD
4 - HOOD CATCH BRACKET
5 - HOOD CATCH
6 - PROP ROD
7 - WINDSHIELD HOOD DOWN LOOP
Fig. 2 HOOD SAFETY LATCH
1 - SAFETY LATCH
2 - HOOD
TJ HOOD 23 - 35
HOOD (Continued)
INSTRUMENT PANEL
TABLE OF CONTENTS
page page
ACCESSORY SWITCH BEZEL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 37
AXLE LOCK SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 37
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
DIAGNOSIS AND TESTING - AXLE LOCK
SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 38
BASE TRIM
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 39
CENTER BEZEL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 40
CLUSTER BEZEL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 41
GLOVE BOX
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 42
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 43
GLOVE BOX CHECK STRAP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 44
GLOVE BOX LATCH STRIKER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 45
GRAB HANDLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 45
GRAB HANDLE BEZEL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 46
INSTRUMENT PANEL ASSEMBLY
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 48
STEERING COLUMN OPENING COVER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 49
TOP COVER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 50
ACCESSORY SWITCH BEZEL
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the center bezel from the i nstrument
panel . (Refer to 23 - BODY/I NSTRUMENT PANEL/
CENTER BEZEL - REMOVAL).
(3) Remove the four screws that secure the acces-
sory swi tch bezel to the i nstrument panel (Fi g. 1).
Fig. 1 ACCESSORY SWITCH BEZEL
1 - BEZEL SCREWS (4)
2 - BEZEL
3 - WIRE HARNESS
4 - ELECTRICAL CONNECTORS (7)
23 - 36 INSTRUMENT PANEL TJ
(4) Pul l the accessory swi tch bezel away from the
i nstrument panel far enough to access the i nstru-
ment panel wi re harness connectors.
(5) Di sconnect the i nstrument panel wi re harness
connectors from the connector receptacl es for the
accessory swi tches and the ci gar l i ghter/power outl et
on the back of the accessory swi tch bezel .
(6) Remove the accessory swi tch bezel from the
i nstrument panel .
INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Posi ti on the accessory swi tch bezel to the
i nstrument panel .
(2) Reconnect the i nstrument panel wi re harness
connectors to the connector receptacl es for the acces-
sory swi tches and the ci gar l i ghter/power outl et on
the back of the accessory swi tch bezel .
(3) Posi ti on the accessory swi tch bezel onto the
i nstrument panel .
(4) I nstal l and ti ghten the four screws that secure
the accessory swi tch bezel to the i nstrument panel .
Ti ghten the screws to 2 N·m (20 i n. l bs.).
(5) Rei nstal l the center bezel onto the i nstrument
panel . (Refer to 23 - BODY/I NSTRUMENT PANEL/
CENTER BEZEL - I NSTALLATI ON).
(6) Reconnect the battery negati ve cabl e.
AXLE LOCK SWITCH
DESCRIPTION
I f equi pped, the Axl e Lock swi tch i s l ocated i n the
Accessory Swi tch Bezel , bel ow the HVAC control s.
The swi tch wi l l acti vate the Rear Axl e l ocker and
Rear/Front Axl e l ocker. The swi tch i s a doubl e-acti on
momentary rocker type. The Axl e Lock Swi tch i s
secured by a snap fi t wi thi n the bezel . The axl e Lock
Swi tch cannot be repai red and, i f faul ty or damaged,
the enti re swi tch must be repl aced.
OPERATION
The Axl e Lock swi tch recei ves battery current on a
fused B(+) ci rcui t from a fuse i n the Power Di stri bu-
ti on Center (PDC). The swi tch i s grounded at al l
ti mes. The Axl e Lock swi tch i s onl y operati onal when
the i nstrument cl uster sends an acti vati on si gnal to
the swi tch l ogi c.
Wi th the transfer case i n the 4WD Low Range and
the vehi cl e speed bel ow 10 MPH (16kph), a momen-
tary push to the l ower porti on of the rocker swi tch to
Lock:
• 1st Push: Rear Axl e Locked
• 2nd Push: Rear and Front Axl e Locked
Momentary pushes, wi l l toggl e between Rear Axl e
Locked or Rear/Front Axl e Locked. A momentary
push to the upper porti on of the rocker swi tch to
“OFF”, (both axl es unl ocked).
DIAGNOSIS AND TESTING - AXLE LOCK
SWITCH
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Check the fused B(+) fuse i n the Power Di stri -
buti on Center (PDC). I f OK, go to step 2. I f not,
repai r the shorted ci rcui t or component requi red and
repl ace the fuse.
(2) Check for battery vol tage at the fused B(+) fuse
i n the PDC. I f OK, go to step 3. I f not, repai r the
open B(+) ci rcui t to the fuse.
(3) Turn the i gni ti on to the off posi ti on. Di sconnect
and i sol ate the negati ve battery cabl e. Remove the
Axl e Lock swi tch. Di sconnect the swi tch harness con-
nector. Check for conti nui ty between the fuse cavi ty
i n the PDC and the Fused B(+) ci rcui t i n the swi tch
harness connector. I f OK got to step 4. I f not OK,
repai r the open Fused B(+) ci rcui t.
(4) Turn the i gni ti on to the off posi ti on. Di sconnect
and i sol ate the negati ve battery cabl e. Remove the
Axl e Lock swi tch. di sconnect the swi tch harness con-
nector. check for conti nui ty between the swi tch
ground and a known good ground. I f OK got to step
5. I f not OK, repai r open ground ci rcui t.
TJ INSTRUMENT PANEL 23 - 37
ACCESSORY SWITCH BEZEL (Continued)
(5) Turn the i gni ti on to the OFF posi ti on. Di scon-
nect and i sol ate the negati ve battery cabl e. Remove
the I nstrument Cl uster. Di sconnect the cl uster har-
ness connectors C1 and C2. Check for conti nui ty
between each of the Enabl e ci rcui ts and each of the
request ci rcui ts between the swi tch harness connec-
tor and the cl uster harness connectors. I f OK go to
step 6. I f not OK, repai r the ci rcui ts as requi red.
(6) Turn the i gni ti on to the OFF posi ti on. Di scon-
nect and i sol ate the negati ve battery cabl e. Remove
the axl e Lock swi tch. Di sconnect the swi tch harness
connector. Check for conti nui ty between each of the
Request ci rcui ts, between the swi tch harness connec-
tor and each of the Locker rel ays i n the PDC. I f OK,
refer to Axl e Lock I ndi cator Probl ems i n the I nstru-
ment Cl uster secti on of the appropri ate Body Manual
or the Chassi s Di agnosti c Manual and perform the
appropri ate symptom. I f not OK, repai r the ci rcui t(s)
as requi red.
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, DRIVER AIRBAG,
PASSENGER AIRBAG, OR INSTRUMENT PANEL
COMPONENT DIAGNOSIS OR SERVICE. DISCON-
NECT AND ISOLATE THE BATTERY NEGATIVE
(GROUND) CABLE, THEN WAIT TWO MINUTES FOR
THE SYSTEM CAPACITOR TO DISCHARGE BEFORE
PERFORMING FURTHER DIAGNOSIS OR SERVICE.
THIS IS THE ONLY SURE WAY TO DISABLE THE
SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO
TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the accessory swi tch bezel from the
i nstrument panel center bezel from the i nstrument
panel (Refer to 23 - BODY/I NSTRUMENT PANEL/
ACCESSORY SWI TCH BEZEL - REMOVAL)
(3) Usi ng a tri m sti ck or another sui tabl e wi de
fl at-bl aded tool , gentl y pry the l atch tabs at the top
and bottom of the axl e l ock swi tch on the back of the
accessory swi tch bezel far enough to di sengage the
snap features on the swi tch housi ng then pul l the
swi tch out of the receptacl e (Fi g. 2).
INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, DRIVER AIRBAG,
PASSENGER AIRBAG, OR INSTRUMENT PANEL
COMPONENT DIAGNOSIS OR SERVICE. DISCON-
NECT AND ISOLATE THE BATTERY NEGATIVE
(GROUND) CABLE, THEN WAIT TWO MINUTES FOR
THE SYSTEM CAPACITOR TO DISCHARGE BEFORE
PERFORMING FURTHER DIAGNOSIS OR SERVICE.
THIS IS THE ONLY SURE WAY TO DISABLE THE
SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO
TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
(1) Posi ti on the axl e l ock swi tch over the proper
receptacl e on the back of the accessory swi tch bezel
(Fi g. 2).
(2) Evenl y push the axl e l ock swi tch i nto the
receptacl e unti l the snap features on the top and bot-
tom of the swi tch housi ng are ful l y engaged to the
receptacl e.
(3) Rei nstal l the accessory swi tch bezel onto the
i nstrument panel (Refer to 23 - BODY/I NSTRU-
MENT PANEL/ACCESSORY SWI TCH BEZEL -
I NSTALLATI ON).
(4) Reconnect the battery negati ve cabl e.
Fig. 2 ACCESSORY SWITCH REMOVE
1 - TRIM STICK
2 - REAR WIPER/WASHER SWITCH
3 - OVERDRIVE-OFF SWITCH
4 - AXLE LOCKER SWITCH
5 - ACCESSORY SWITCH BEZEL
6 - REAR WINDOW DEFOGGER SWITCH
23 - 38 INSTRUMENT PANEL TJ
AXLE LOCK SWITCH (Continued)
BASE TRIM
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the i nstrument cl uster from the i nstru-
ment panel . (Refer to 8 - ELECTRI CAL/I NSTRU-
MENT CLUSTER - REMOVAL).
(3) Remove the accessory swi tch bezel from the
i nstrument panel . (Refer to 23 - BODY/I NSTRU-
MENT PANEL/ACCESSORY SWI TCH BEZEL -
REMOVAL).
(4) Remove the grab handl e bezel from the i nstru-
ment panel . (Refer to 23 - BODY/I NSTRUMENT
PANEL/GRAB HANDLE BEZEL - REMOVAL).
(5) Remove the speakers from the i nstrument
panel . (Refer to 8 - ELECTRI CAL/AUDI O/SPEAKER
- REMOVAL).
(6) Remove the radi o from the i nstrument panel .
(Refer to 8 - ELECTRI CAL/AUDI O/RADI O -
REMOVAL).
(7) Remove the heater-A/C control from the i nstru-
ment panel . (Refer to 24 - HEATI NG & AI R CONDI -
TI ONI NG/CONTROLS/A/C-HEATER CONTROL -
REMOVAL).
(8) Remove the outboard heater-A/C panel outl et
barrel s from the i nstrument panel . (Refer to 24 -
HEATI NG & AI R CONDI TI ONI NG/DI STRI BUTI ON/
PANEL OUTLET BARRELS - REMOVAL).
(9) Remove the i nstrument panel from the vehi cl e.
(Refer to 23 - BODY/I NSTRUMENT PANEL -
REMOVAL).
(10) Pl ace the i nstrument panel on a sui tabl e work
surface. Be certai n to take the proper precauti ons to
protect the i nstrument panel from any possi bl e cos-
meti c damage.
(11) Remove the passenger ai rbag door from the
i nstrument panel . (Refer to 8 - ELECTRI CAL/RE-
STRAI NTS/PASSENGER AI RBAG DOOR -
REMOVAL).
(12) Remove the two screws that secure the
16-way data l i nk connector to the i nstrument panel .
(13) Remove al l of the screws around the peri me-
ter of the i nstrument panel that secure the base tri m
to the structural support.
(14) Remove the base tri m from the i nstrument
panel structural support.
INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Posi ti on the base tri m onto the i nstrument
panel structural support.
(2) I nstal l and ti ghten al l of the screws around the
peri meter of the i nstrument panel that secure the
base tri m to the structural support. Ti ghten the
screws to 2 N·m (20 i n. l bs.).
(3) I nstal l and ti ghten the two screws that secure
the 16-way data l i nk connector to the i nstrument
panel . Ti ghten the screws to 2 N·m (20 i n. l bs.).
(4) Rei nstal l the passenger ai rbag door i nto the
i nstrument panel . (Refer to 8 - ELECTRI CAL/RE-
STRAI NTS/PASSENGER AI RBAG DOOR - I NSTAL-
LATI ON).
(5) Rei nstal l the i nstrument panel i nto the vehi cl e.
(Refer to 23 - BODY/I NSTRUMENT PANEL -
I NSTALLATI ON).
(6) Rei nstal l the outboard heater-A/C panel outl et
barrel s i nto the i nstrument panel . (Refer to 24 -
HEATI NG & AI R CONDI TI ONI NG/DI STRI BUTI ON/
PANEL OUTLET BARRELS - I NSTALLATI ON).
(7) Rei nstal l the heater-A/C control i nto the i nstru-
ment panel . (Refer to 24 - HEATI NG & AI R CONDI -
TI ONI NG/CONTROLS/A/C-HEATER CONTROL -
I NSTALLATI ON).
(8) Rei nstal l the radi o i nto the i nstrument panel .
(Refer to 8 - ELECTRI CAL/AUDI O/RADI O -
I NSTALLATI ON).
(9) Rei nstal l the speakers i nto the i nstrument
panel . (Refer to 8 - ELECTRI CAL/AUDI O/SPEAKER
- I NSTALLATI ON).
TJ INSTRUMENT PANEL 23 - 39
(10) Rei nstal l the grab handl e bezel onto the
i nstrument panel . (Refer to 23 - BODY/I NSTRU-
MENT PANEL/GRAB HANDLE BEZEL - I NSTAL-
LATI ON).
(11) Rei nstal l the accessory swi tch bezel onto the
i nstrument panel . (Refer to 23 - BODY/I NSTRU-
MENT PANEL/ACCESSORY SWI TCH BEZEL -
I NSTALLATI ON).
(12) Rei nstal l the i nstrument cl uster i nto the
i nstrument panel . (Refer to 8 - ELECTRI CAL/I N-
STRUMENT CLUSTER - I NSTALLATI ON).
(13) Reconnect the battery negati ve cabl e.
CENTER BEZEL
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the top cover from the i nstrument
panel . (Refer to 23 - BODY/I NSTRUMENT PANEL/
TOP COVER - REMOVAL).
(3) Remove the two screws that secure the top of
the center bezel to the top of the i nstrument panel
structural support. (Fi g. 3)
(4) Usi ng a tri m sti ck or another sui tabl e wi de
fl at-bl aded tool , gentl y pry the l ower edge of the cen-
ter bezel away from the i nstrument panel .
(5) Pul l the l ower edge of the center bezel away
from the i nstrument panel far enough to di sengage
the four snap cl i p retai ners that secure i t to the
receptacl es i n the i nstrument panel base tri m.
(6) Remove the center bezel from the i nstrument
panel .
INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Posi ti on the center bezel onto the i nstrument
panel .
(2) Al i gn the snap cl i ps on the center bezel wi th
the receptacl es i n the i nstrument panel base tri m.
(3) Usi ng hand pressure, press fi rml y on the cen-
ter bezel over each of the snap cl i p l ocati ons unti l
each of the snap cl i ps i s ful l y engaged i n i ts recepta-
cl e i n the i nstrument panel base tri m.
(4) I nstal l and ti ghten the two screws that secure
the top of the center bezel to the top of the i nstru-
ment panel structural support. Ti ghten the screws to
2 N·m (20 i n. l bs.).
(5) Rei nstal l the top cover onto the i nstrument
panel . (Refer to 23 - BODY/I NSTRUMENT PANEL/
TOP COVER - I NSTALLATI ON).
(6) Reconnect the battery negati ve cabl e.
Fig. 3 CENTER BEZEL
1 - BEZEL MAT
2 - TOP SCREWS (2)
3 - CENTER BEZEL
23 - 40 INSTRUMENT PANEL TJ
BASE TRIM (Continued)
CLUSTER BEZEL
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the steeri ng col umn openi ng cover
from the i nstrument panel . (Refer to 23 - BODY/I N-
STRUMENT PANEL/STEERI NG COLUMN OPEN-
I NG COVER - REMOVAL).
(3) Remove the top cover from the i nstrument
panel . (Refer to 23 - BODY/I NSTRUMENT PANEL/
TOP COVER - REMOVAL).
(4) Remove the two screws that secure the l ower
mounti ng tabs of the cl uster bezel to the i nstrument
panel (Fi g. 4).
(5) Remove the three screws that secure the upper
mounti ng fl ange of the cl uster bezel to the top of the
i nstrument panel (Fi g. 5).
(6) Remove the cl uster bezel from the i nstrument
panel .
INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Posi ti on the cl uster bezel onto the i nstrument
panel .
(2) I nstal l and ti ghten the three screws that secure
the upper mounti ng fl ange of the cl uster bezel to the
top of the i nstrument panel (Fi g. 5). Ti ghten the
screws to 2 N·m (20 i n. l bs.).
(3) I nstal l and ti ghten the two screws that secure
the l ower mounti ng tabs of the cl uster bezel to the
i nstrument panel (Fi g. 4). Ti ghten the screws to 2
N·m (20 i n. l bs.).
(4) Rei nstal l the top cover onto the i nstrument
panel . (Refer to 23 - BODY/I NSTRUMENT PANEL/
TOP COVER - I NSTALLATI ON).
(5) Rei nstal l the steeri ng col umn openi ng cover
onto the i nstrument panel . (Refer to 23 - BODY/I N-
STRUMENT PANEL/STEERI NG COLUMN OPEN-
I NG COVER - I NSTALLATI ON).
(6) Reconnect the battery negati ve cabl e.
Fig. 4 CLUSTER BEZEL LOWER SCREWS REMOVE/
INSTALL
1 - CLUSTER BEZEL
2 - SCREW (2)
Fig. 5 CLUSTER BEZEL UPPER SCREWS REMOVE/
INSTALL
1 - SCREW (3)
2 - CLUSTER BEZEL
TJ INSTRUMENT PANEL 23 - 41
GLOVE BOX
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Rel ease the gl ove box l atch and open the gl ove
box door.
(3) Whi l e supporti ng the gl ove box door wi th one
hand, grasp the check strap as cl ose to the gl ove box
door as possi bl e and sl i de the rol l ed end of the check
strap out of the sl ot i n the edge of the door (Fi g. 6).
(4) Lower the gl ove box door far enough to di sen-
gage the hi nge hook formati ons on the l ower edge of
the door from the hi nge pi ns on the l ower edge of the
i nstrument panel .
(5) Remove the gl ove box from the i nstrument
panel .
DISASSEMBLY
Some of the components of the gl ove box used i n
thi s vehi cl e are servi ced i ndi vi dual l y. The servi ced
components i ncl ude the gl ove box l atch and handl e
uni t, and the gl ove box l ock cyl i nder (Fi g. 7). Fol l ow-
i ng are the procedures for di sassembl i ng these com-
ponents from the gl ove box.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
GLOVE BOX LATCH AND HANDLE
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
Fig. 6 GLOVE BOX REMOVE/INSTALL
1 - GLOVE BOX DOOR
2 - CHECK STRAP
3 - SLOT
Fig. 7 GLOVE BOX COMPONENTS
1 - GLOVE BOX DOOR AND BIN
2 - SCREW
3 - CHECK STRAP
4 - LATCH AND HANDLE
5 - LOCK CYLINDER
23 - 42 INSTRUMENT PANEL TJ
(2) Remove the gl ove box from the i nstrument
panel . (Refer to 23 - BODY/I NSTRUMENT PANEL/
GLOVE BOX - REMOVAL).
(3) Remove the four screws that secure the gl ove
box l atch and handl e to the gl ove box door from the
i nsi de of the gl ove box.
(4) Remove the l atch and handl e from the i nsi de of
the gl ove box door.
GLOVE BOX LOCK CYLINDER
(1) Remove the gl ove box l atch and handl e uni t
from the gl ove box. Refer to GLOVE BOX LATCH
AND HANDLE.
(2) I nsert the key i nto the gl ove box l ock cyl i nder.
(3) I nsert a smal l screwdri ver i nto the retai ni ng
tumbl er rel ease sl ot and depress the retai ni ng tum-
bl er (Fi g. 8).
(4) Usi ng a gentl e twi sti ng and pul l i ng acti on wi th
the key, pul l the l ock cyl i nder out of the gl ove box
l atch and handl e uni t.
ASSEMBLY
Some of the components of the gl ove box used i n
thi s vehi cl e are servi ced i ndi vi dual l y. The servi ced
components i ncl ude the gl ove box l atch and handl e
uni t, and the gl ove box l ock cyl i nder (Fi g. 7). Fol l ow-
i ng are the procedures for assembl i ng these compo-
nents onto the gl ove box.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
GLOVE BOX LATCH AND HANDLE
(1) Posi ti on the l atch and handl e onto the i nsi de of
the gl ove box door.
(2) I nstal l and ti ghten the four screws that secure
the gl ove box l atch and handl e to the gl ove box door
from the i nsi de of the gl ove box. Ti ghten the screws
to 2 N·m (20 i n. l bs.).
(3) Rei nstal l the gl ove box onto the i nstrument
panel . (Refer to 23 - BODY/I NSTRUMENT PANEL/
GLOVE BOX - I NSTALLATI ON).
(4) Reconnect the battery negati ve cabl e.
GLOVE BOX LOCK CYLINDER
(1) I nsert the key i nto the gl ove box l ock cyl i nder.
(2) Usi ng a gentl e twi sti ng and pushi ng acti on on
the key, push the l ock cyl i nder i nto the gl ove box
l atch and handl e uni t.
(3) Rei nstal l the gl ove box l atch and handl e onto
the gl ove box. Refer to GLOVE BOX LATCH AND
HANDLE.
INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Posi ti on the gl ove box to the i nstrument panel .
(2) Engage the hi nge hook formati ons on the l ower
edge of the gl ove box door wi th the hi nge pi ns on the
l ower edge of the i nstrument panel .
(3) Ti l t the upper edge of the gl ove box door up
toward the i nstrument panel far enough to engage
the check strap wi th the door (Fi g. 6).
Fig. 8 GLOVE BOX LOCK CYLINDER REMOVE/
INSTALL
1 - GLOVE BOX LATCH
2 - RELEASE SLOT
3 - SMALL SCREWDRIVER
TJ INSTRUMENT PANEL 23 - 43
GLOVE BOX (Continued)
(4) Whi l e supporti ng the gl ove box door wi th one
hand, grasp the check strap as cl ose to the gl ove box
door as possi bl e and sl i de the rol l ed end of the check
strap i nto the sl ot i n the edge of the door.
(5) Cl ose and l atch the gl ove box door.
(6) Reconnect the battery negati ve cabl e.
GLOVE BOX CHECK STRAP
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the gl ove box from the i nstrument
panel . (Refer to 23 - BODY/I NSTRUMENT PANEL/
GLOVE BOX - REMOVAL).
(3) Remove the screw that secures the gl ove box
check strap to the i nstrument panel on the upper
gl ove box openi ng rei nforcement (Fi g. 9).
(4) Remove the check strap from the upper gl ove
box openi ng rei nforcement.
INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Posi ti on the check strap to the upper gl ove box
openi ng rei nforcement (Fi g. 9).
(2) I nstal l and ti ghten the screw that secures the
gl ove box check strap to the upper gl ove box openi ng
rei nforcement. Ti ghten the screw to 2 N·m (20 i n.
l bs.).
(3) Rei nstal l the gl ove box onto the i nstrument
panel . (Refer to 23 - BODY/I NSTRUMENT PANEL/
GLOVE BOX - I NSTALLATI ON).
(4) Reconnect the battery negati ve cabl e.
GLOVE BOX LATCH STRIKER
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the gl ove box from the i nstrument
panel . (Refer to 23 - BODY/I NSTRUMENT PANEL/
GLOVE BOX - REMOVAL).
Fig. 9 GLOVE BOX CHECK STRAP
1 - GLOVE BOX DOOR AND BIN
2 - SCREW
3 - CHECK STRAP
4 - LATCH AND HANDLE
5 - LOCK CYLINDER
23 - 44 INSTRUMENT PANEL TJ
GLOVE BOX (Continued)
(3) Remove the two screws that secure the l atch
stri ker to the upper gl ove box openi ng rei nforcement
(Fi g. 10).
(4) Remove the l atch stri ker from the upper gl ove
box openi ng rei nforcement.
INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Posi ti on the l atch stri ker onto the upper gl ove
box openi ng rei nforcement (Fi g. 10).
(2) I nstal l and ti ghten the two screws that secure
the l atch stri ker to the upper gl ove box openi ng rei n-
forcement. Ti ghten the screws to 2 N·m (20 i n. l bs.).
(3) Rei nstal l the gl ove box onto the i nstrument
panel . (Refer to 23 - BODY/I NSTRUMENT PANEL/
GLOVE BOX - I NSTALLATI ON).
(4) Reconnect the battery negati ve cabl e.
GRAB HANDLE
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the gl ove box from the i nstrument
panel . (Refer to 23 - BODY/I NSTRUMENT PANEL/
GLOVE BOX - REMOVAL).
(3) Reach through and above the gl ove box openi ng
to access and remove the two nuts that secure the
stud on each end of the grab handl e to the i nstru-
ment panel structural support (Fi g. 11). Di scard the
used grab handl e mounti ng nuts.
(4) Remove the grab handl e from the face of the
i nstrument panel .
INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
Fig. 10 GLOVE BOX LATCH STRIKER REMOVE/
INSTALL
1 - SCREW (2)
2 - LATCH STRIKER
Fig. 11 GRAB HANDLE REMOVE/INSTALL
1 - NUT (2)
2 - GLOVE BOX OPENING
3 - PASSENGER AIRBAG
TJ INSTRUMENT PANEL 23 - 45
GLOVE BOX LATCH STRIKER (Continued)
(1) Posi ti on the grab handl e onto the face of the
i nstrument panel .
NOTE: Always use new fasteners to install the grab
handle. The removed grab handle fasteners should
be discarded.
(2) Reach through and above the gl ove box openi ng
to i nstal l and ti ghten two new nuts to secure the
stud on each end of the grab handl e to the i nstru-
ment panel structural support (Fi g. 11). Ti ghten the
nuts to 6 N·m (50 i n. l bs.).
(3) Rei nstal l the gl ove box i nto the i nstrument
panel . (Refer to 23 - BODY/I NSTRUMENT PANEL/
GLOVE BOX - I NSTALLATI ON).
(4) Reconnect the battery negati ve cabl e.
GRAB HANDLE BEZEL
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the grab handl e from the i nstrument
panel . (Refer to 23 - BODY/I NSTRUMENT PANEL/
GRAB HANDLE - REMOVAL).
(3) Remove the gl ove box l atch stri ker from the
i nstrument panel . (Refer to 23 - BODY/I NSTRU-
MENT PANEL/GLOVE BOX LATCH STRI KER -
REMOVAL).
(4) Remove the two screws that secure the grab
handl e bezel to the upper gl ove box openi ng rei n-
forcement (Fi g. 12).
(5) Remove the grab handl e bezel from the i nstru-
ment panel .
INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Posi ti on the grab handl e bezel onto the i nstru-
ment panel (Fi g. 12).
(2) I nstal l and ti ghten the two screws that secure
the grab handl e bezel to the upper gl ove box openi ng
rei nforcement. Ti ghten the screws to 2 N·m (20 i n.
l bs.).
(3) Rei nstal l the gl ove box l atch stri ker onto the
gl ove box openi ng upper rei nforcement (Refer to 23 -
BODY/I NSTRUMENT PANEL/GLOVE BOX LATCH
STRI KER - I NSTALLATI ON).
(4) Rei nstal l the grab handl e onto the i nstrument
panel (Refer to 23 - BODY/I NSTRUMENT PANEL/
GRAB HANDLE - I NSTALLATI ON).
(5) Reconnect the battery negati ve cabl e.
Fig. 12 GRAB HANDLE BEZEL REMOVE/INSTALL
1 - GRAB HANDLE BEZEL
2 - SCREW (2)
3 - GRAB HANDLE
4 - LATCH STRIKER
23 - 46 INSTRUMENT PANEL TJ
GRAB HANDLE (Continued)
INSTRUMENT PANEL
ASSEMBLY
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
NOTE: Before starting this procedure, be certain to
turn the steering wheel until the front wheels are in
the straight-ahead position.
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the steeri ng col umn openi ng cover
from the i nstrument panel . (Refer to 23 - BODY/I N-
STRUMENT PANEL/STEERI NG COLUMN OPEN-
I NG COVER - REMOVAL).
(3) Remove the steeri ng col umn from the vehi cl e,
but do not remove the dri ver ai rbag, the steeri ng
wheel , or the swi tches from the steeri ng col umn. Be
certai n that the steeri ng wheel i s l ocked and secured
from rotati on to prevent the l oss of cl ockspri ng cen-
teri ng. (Refer to 19 - STEERI NG/COLUMN -
REMOVAL).
(4) From beneath the dri ver si de end of the i nstru-
ment panel , perform the fol l owi ng:
(a) Di sconnect the i nstrument panel wi re har-
ness connectors from the 100-way cross body wi re
harness connector near the l eft cowl si de i nner
panel .
(b) Di sconnect the dri ver si de wi ndow demi ster
hose at the heater-A/C housi ng demi ster/defroster
duct.
(5) Remove the gl ove box from the i nstrument
panel (Refer to 23 - BODY/I NSTRUMENT PANEL/
GLOVE BOX - REMOVAL).
(6) Reach through the i nstrument panel gl ove box
openi ng to perform the fol l owi ng:
(a) Di sconnect the heater-A/C control vacuum
harness connector from the heater-A/C housi ng
vacuum harness connector.
(b) Di sconnect the i nstrument panel wi re har-
ness connector from the heater-A/C housi ng wi re
harness connector.
(c) Di sconnect the cross body wi re harness con-
nector from the passenger ai rbag pi gtai l wi re con-
nector.
(d) Di sconnect the passenger si de wi ndow demi s-
ter hose at the heater-A/C housi ng demi ster/de-
froster duct.
(e) Di sconnect the two hal ves of the radi o
antenna coaxi al cabl e connector.
(f) Remove the two nuts that secure the passen-
ger ai rbag l ower bracket to the studs on the dash
panel (Fi g. 13).
(7) Remove the top cover from the i nstrument
panel . (Refer to 23 - BODY/I NSTRUMENT PANEL/
TOP COVER - REMOVAL).
(8) Remove the three screws that secure each end
of the i nstrument panel structural support to the
cowl si de i nner panel s at the front of each door open-
i ng (Fi g. 14).
(9) Remove the four nuts that secure the top of the
i nstrument panel structural support to the studs on
the top of the dash panel .
(10) Wi th the ai d of an assi stant, l i ft the i nstru-
ment panel off of the dash panel studs and remove i t
from the vehi cl e.
Fig. 13 PASSENGER AIRBAG LOWER BRACKET
NUTS REMOVE/INSTALL
1 - GRAB HANDLE
2 - NUT (2)
3 - GLOVE BOX OPENING
4 - PASSENGER AIRBAG LOWER BRACKET
TJ INSTRUMENT PANEL 23 - 47
INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Wi th the ai d of an assi stant, posi ti on the
i nstrument panel i nto the vehi cl e and onto the dash
panel studs (Fi g. 14).
(2) I nstal l and ti ghten the four nuts that secure
the top of the i nstrument panel structural support to
the studs on the top of the dash panel . Ti ghten the
nuts to 12 N·m (105 i n. l bs.).
(3) I nstal l and ti ghten the three screws that secure
each end of the i nstrument panel structural support
to the cowl si de i nner panel s at the front of each door
openi ng. Ti ghten the screws to 12 N·m (105 i n. l bs.).
(4) Rei nstal l the top cover onto the i nstrument
panel . (Refer to 23 - BODY/I NSTRUMENT PANEL/
TOP COVER - I NSTALLATI ON).
(5) Reach through the i nstrument panel gl ove box
openi ng to perform the fol l owi ng:
(a) I nstal l and ti ghten the two nuts that secure
the l ower passenger ai rbag bracket to the studs on
the dash panel (Fi g. 13). Ti ghten the nuts to 28
N·m (21 ft. l bs.).
(b) Reconnect the two hal ves of the radi o
antenna coaxi al cabl e connector.
(c) Reconnect the passenger si de wi ndow demi s-
ter hose to the heater-A/C housi ng demi ster/de-
froster duct.
(d) Reconnect the cross body wi re harness con-
nector to the passenger ai rbag pi gtai l wi re connec-
tor.
(e) Reconnect the i nstrument panel wi re harness
connector to the heater-A/C housi ng wi re harness
connector.
(f) Reconnect the heater-A/C control vacuum
harness connector to the heater-A/C housi ng vac-
uum harness connector.
(6) Rei nstal l the gl ove box onto the i nstrument
panel . (Refer to 23 - BODY/I NSTRUMENT PANEL/
GLOVE BOX - I NSTALLATI ON).
(7) From beneath the dri ver si de of the i nstrument
panel , perform the fol l owi ng:
(a) Reconnect the dri ver si de wi ndow demi ster
hose to the heater-A/C housi ng demi ster/defroster
duct.
(b) Reconnect the i nstrument panel wi re harness
connectors to the 100-way cross body wi re harness
connector near the l eft cowl si de i nner panel .
(8) Rei nstal l the steeri ng col umn i nto the vehi cl e.
Be certai n that the steeri ng wheel i s l ocked and
secured from rotati on to prevent the l oss of cl ock-
spri ng centeri ng. (Refer to 19 - STEERI NG/COL-
UMN - I NSTALLATI ON).
(9) Rei nstal l the steeri ng col umn openi ng cover
onto the i nstrument panel . (Refer to 23 - BODY/I N-
STRUMENT PANEL/STEERI NG COLUMN OPEN-
I NG COVER - I NSTALLATI ON).
(10) Reconnect the battery negati ve cabl e.
Fig. 14 INSTRUMENT PANEL REMOVE/INSTALL
1 - STUD (4)
2 - NUT (4)
3 - SCREW (6)
23 - 48 INSTRUMENT PANEL TJ
INSTRUMENT PANEL ASSEMBLY (Continued)
STEERING COLUMN OPENING
COVER
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) I f the vehi cl e i s so equi pped, move the ti l t
steeri ng col umn to the ful l y rai sed posi ti on.
(3) Remove the two screws that secure the steeri ng
col umn openi ng cover to the i nstrument panel struc-
tural support (Fi g. 15).
(4) Usi ng a tri m sti ck or another sui tabl e wi de
fl at-bl aded tool , gentl y pry the top of the steeri ng col -
umn openi ng cover away from the i nstrument panel
on each si de of the steeri ng col umn far enough to di s-
engage the two snap cl i p retai ners from thei r recep-
tacl es i n the i nstrument panel base tri m.
(5) I f the vehi cl e i s so equi pped, rol l the top of the
steeri ng col umn openi ng cover downward far enough
to access and di sconnect the wi re harness connector
for the headl amp l evel i ng swi tch from the swi tch con-
nector receptacl e.
(6) Pul l the top of the steeri ng col umn openi ng
cover rearward far enough to di sengage the hi nge
hook formati ons on the l ower edge of the cover from
the hi nge pi ns on the l ower edge of the i nstrument
panel .
(7) Remove the steeri ng col umn openi ng cover
from the i nstrument panel .
INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Posi ti on the steeri ng col umn openi ng cover to
the i nstrument panel .
(2) Engage the hi nge hook formati ons on the l ower
edge of the steeri ng col umn openi ng cover wi th the
hi nge pi ns on the l ower edge of the i nstrument panel
(Fi g. 15).
(3) I f the vehi cl e i s so equi pped, rol l the top of the
steeri ng col umn openi ng cover upward far enough to
reconnect the wi re harness connector for the head-
l amp l evel i ng swi tch to the swi tch connector recepta-
cl e.
(4) Ti l t the upper edge of the steeri ng col umn
openi ng cover up and al i gn the two snap cl i p retai n-
ers on the cover wi th thei r receptacl es i n the i nstru-
ment panel base tri m.
(5) Usi ng hand pressure, press fi rml y on the steer-
i ng col umn openi ng cover over each of the snap cl i p
l ocati ons unti l each of the snap cl i ps i s ful l y engaged
i n i ts receptacl e i n the i nstrument panel base tri m.
Fig. 15 STEERING COLUMN OPENING COVER
REMOVE/INSTALL
1 - WIRE HARNESS CONNECTOR
2 - STEERING COLUMN OPENING COVER
3 - HEADLAMP LEVELING SWITCH
4 - SCREW (2)
TJ INSTRUMENT PANEL 23 - 49
(6) I nstal l and ti ghten the two screws that secure
the steeri ng col umn openi ng cover to the i nstrument
panel structural support. Ti ghten the screws to 2
N·m (20 i n. l bs.).
(7) Reconnect the battery negati ve cabl e.
TOP COVER
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Usi ng a tri m sti ck or another sui tabl e wi de
fl at-bl aded tool , gentl y pry the i nstrument panel top
cover up and away from the i nstrument panel far
enough to di sengage the fi ve snap cl i p retai ners from
thei r receptacl es i n the i nstrument panel structural
support (Fi g. 16).
(3) Remove the top cover from the i nstrument
panel .
INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Posi ti on the top cover onto the i nstrument
panel (Fi g. 16).
(2) Al i gn the snap cl i ps on the top cover wi th the
snap cl i p receptacl es i n the i nstrument panel struc-
tural support.
(3) Usi ng hand pressure, press fi rml y downward
on the top cover over each of the snap cl i p l ocati ons
unti l each of the snap cl i ps i s ful l y seated i n i ts
receptacl e i n the i nstrument panel structural sup-
port.
(4) Reconnect the battery negati ve cabl e.
Fig. 16 TOP COVER REMOVE/INSTALL
1 - TOP COVER
23 - 50 INSTRUMENT PANEL TJ
STEERING COLUMN OPENING COVER (Continued)
INTERIOR
TABLE OF CONTENTS
page page
ADD-A-TRUNK
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 51
FRONT CARPET
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 52
CENTER CARPET
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 52
CARGO AREA CARPET
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 52
WHEELHOUSE CARPET
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 52
REAR VIEW MIRROR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 53
REAR VIEW MIRROR SUPPORT BRACKET
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 53
SUNVISOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 54
SHIFT BEZEL - AUTOMATIC TRANSMISSION
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 54
SHIFT BOOT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 55
CENTER CONSOLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 55
CENTER CONSOLE CUP HOLDER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 56
CONSOLE LOCK CYLINDER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 57
SPORT BAR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 57
A-PILLAR TRIM
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 58
REAR HEADER TRIM
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 58
WINDSHIELD HEADER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 59
SPORT BAR - SPEAKER POD
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 60
ADD-A-TRUNK
REMOVAL
(1) Rel ease l atches under trunk panel and l i ft
panel up.
(2) Remove bol ts attachi ng trunk to i nner body
panel (Fi g. 1).
(3) Separate trunk from vehi cl e.
INSTALLATION
(1) Posi ti on the trunk i n the cargo space.
(2) I nstal l the bol ts.
Fig. 1 ADD-A-TRUNK
1 - SCREW
2 - ADD-A-TRUNK PANEL
TJ INTERIOR 23 - 51
FRONT CARPET
REMOVAL
(1) I f necessary, remove the center consol e. (Refer
to 23 - BODY/I NTERI OR/CENTER CONSOLE -
REMOVAL)
(2) Remove the retai ners attachi ng the carpet to
the dash panel (Fi g. 2).
(3) Di sengage the snaps under front seats.
(4) Remove carpet from the vehi cl e
INSTALLATION
(1) Posi ti on the carpet i n the vehi cl e
(2) Engage the snaps around under front seats.
(3) I nstal l the retai ners attachi ng the carpet to the
dash panel .
(4) I f previ ousl y removed, i nstal l the center con-
sol e. (Refer to 23 - BODY/I NTERI OR/CENTER CON-
SOLE - I NSTALLATI ON)
CENTER CARPET
REMOVAL
(1) Di sengage the snaps under front seats.
(2) Remove the carpet.
INSTALLATION
(1) Posi ti on the carpet i n the vehi cl e.
(2) Engage the snaps under front seats.
CARGO AREA CARPET
REMOVAL
(1) Posi ti on the rear seat i n the fol d and tumbl ed
posi ti on.
(2) Pul l the carpet from under the rear seat.
(3) Remove the Add-A-Trunk, i f equi pped. (Refer to
23 - BODY/I NTERI OR/ADD-A-TRUNK - REMOVAL)
(4) Route the rear seat bel t buckl es through the
cargo area carpet.
(5) Separate the carpet from the vehi cl e (Fi g. 3).
INSTALLATION
(1) Posi ti on the carpet i n the vehi cl e.
(2) Route the rear seat bel t buckl es through the
cargo area carpet.
(3) I nstal l the Add-A-Trunk, i f equi pped. (Refer to
23 - BODY/I NTERI OR/ADD-A-TRUNK - I NSTALLA-
TI ON)
(4) Return the rear seat to the ful l rearward posi -
ti on.
WHEELHOUSE CARPET
REMOVAL
(1) Posi ti on the rear seat i n the ful l forward posi -
ti on.
(2) Remove the Add-A-trunk, i f equi pped. (Refer to
23 - BODY/I NTERI OR/ADD-A-TRUNK - REMOVAL)
(3) Grasp wheel house carpet and remove from
vehi cl e (Fi g. 3).
INSTALLATION
(1) Posi ti on wheel house carpet i n vehi cl e and
adjust as necessary.
(2) I nstal l the Add-A-trunk, i f equi pped. (Refer to
23 - BODY/I NTERI OR/ADD-A-TRUNK - I NSTALLA-
TI ON)
(3) Return the rear seat to the ful l rearward posi -
ti on.
Fig. 2 FRONT CARPET
1 - DASH PANEL
2 - CARPET
3 - PUSH ON RETAINER
23 - 52 INTERIOR TJ
REAR VIEW MIRROR
REMOVAL
(1) Di sconnect the el ectri cal connector, i f equi pped.
(Fi g. 4)
(2) Loosen the mi rror set screw.
(3) Sl i de the mi rror up and off the support button
(bracket).
INSTALLATION
(1) Sl i de the mi rror onto the support button
(bracket).
CAUTION: Do not over-tighten the setscrew
because glass chipping and/or breakage could
result.
(2) Ti ghten the mi rror set screw to 1 N·m (9 i n.
l bs.).
(3) Connect the el ectri cal connector, i f equi pped.
REAR VIEW MIRROR SUPPORT
BRACKET
INSTALLATION
(1) Mark the posi ti on for the mi rror bracket on the
outsi de of the wi ndshi el d gl ass wi th a wax penci l .
(2) Cl ean the bracket contact area on the gl ass.
Use a mi l d powdered cl eanser on a cl oth saturated
wi th i sopropyl (rubbi ng) al cohol . Fi nal l y, cl ean the
gl ass wi th a paper towel dampened wi th al cohol .
(3) Sand the surface on the support bracket wi th
fi ne gri t-sandpaper. Wi pe the bracket surface cl ean
wi th a paper towel .
(4) Appl y accel erator to the surface on the bracket
accordi ng to the fol l owi ng i nstructi ons:
• Crush the vi al to saturate the fel t appl i cator.
• Remove the paper sl eeve.
• Appl y accel erator to the contact surface on the
bracket.
• Al l ow the accel erator to dry for fi ve mi nutes.
• Do not touch the bracket contact surface after
the accel erator has been appl i ed.
Fig. 3 VEHICLE CARPET
1 - WHEEL HOUSE CARPET
2 - CARGO AREA CARPET
3 - CENTER FLOOR CARPET
4 - FRONT FLOOR CARPET
5 - SNAP
TJ INTERIOR 23 - 53
WHEELHOUSE CARPET (Continued)
(5) Appl y adhesi ve accel erator to the bracket con-
tact surface on the wi ndshi el d gl ass. Al l ow the accel -
erator to dry for one mi nute. Do not touch the gl ass
contact surface after the accel erator has been
appl i ed.
(6) I nstal l the bracket accordi ng to the fol l owi ng
i nstructi ons:
• Appl y one drop of adhesi ve at the center of the
bracket contact-surface on the wi ndshi el d gl ass.
• Appl y an even coat of adhesi ve to the contact
surface on the bracket.
• Al i gn the bracket wi th the marked posi ti on on
the wi ndshi el d gl ass.
• Press and hol d the bracket i n pl ace for at l east
one mi nute.
NOTE: Verify that the mirror support bracket is cor-
rectly aligned, because the adhesive will cure rap-
idly.
(7) Al l ow the adhesi ve to cure for 8-10 mi nutes.
Remove any excess adhesi ve wi th an al cohol -damp-
ened cl oth.
(8) Al l ow the adhesi ve to cure for an addi ti onal
8-10 mi nutes before i nstal l i ng the mi rror.
SUNVISOR
REMOVAL
(1) Remove the screws that attach the sunvi sor arm
support brackets to the wi ndshi el d frame (Fi g. 5).
(2) Remove the sunvi sor from the wi ndshi el d
frame.
INSTALLATION
(1) Posi ti on the sunvi sor on the wi ndshi el d frame
and al i gn the arm support bracket hol es wi th the
frame.
(2) I nstal l the screws that attach the sunvi sor arm
support brackets to the frame. Ti ghten the screws
securel y.
SHIFT BEZEL - AUTOMATIC
TRANSMISSION
REMOVAL
(1) Pul l shi ft l ever handl e off of shi ft l ever (Fi g. 6).
(2) Usi ng a tri m sti ck C-4755 or equi val ent,
remove the shi ft bezel .
(3) Twi st and remove the bezel l i ght.
INSTALLATION
(1) Connect the shi ft bezel l i ght by twi sti ng i nto
socket on the bezel .
(2) Posi ti on the shi ft bezel over the shi ft l ever and
i nstal l onto the consol e.
Fig. 4 REAR VIEW MIRROR
1 - SUPPORT BRACKET
2 - MIRROR ASSEMBLY
3 - ELECTRICAL CONNECTOR
Fig. 5 SUNVISOR
1 - SCREWS (2)
2 - WINDSHIELD FRAME
3 - VISOR
23 - 54 INTERIOR TJ
REAR VIEW MIRROR SUPPORT BRACKET (Continued)
(3) Al i gn the shi fter handl e keyways and push
handl e onto the shi fter unti l ful l y seated.
SHIFT BOOT
REMOVAL
(1) Usi ng a tri m sti ck C-4755 or equi val ent, pry
the shi ft boot from the bezel .
(2) Usi ng a smal l fl at bl ade, pry the shi ft pattern
i nsert from the shi ft knob.
(3) Remove the nut attachi ng the shi ft knob to the
shi ft l ever (Fi g. 7).
(4) Remove the knob and sl i de the shi ft boot from
the shi ft l ever.
INSTALLATION
(1) Sl i de the shi ft boot over the shi ft l ever.
(2) Snap the shi ft boot i nto pl ace i n the center con-
sol e.
(3) Posi ti on the shi ft knob on the l ever, i nstal l the
nut and ti ghten to 34 N·m (25 ft. l bs.).
(4) Posi ti on the shi ft pattern i nsert on the knob
and press i nto pl ace.
CENTER CONSOLE
REMOVAL
(1) Remove the cup hol der, i f equi pped. (Refer to
23 - BODY/I NTERI OR/CENTER CONSOLE CUP-
HOLDER ASSEMBLY - REMOVAL)
(2) On ful l consol e model s remove the tri m di sc
from the bottom of the cup hol der (Fi g. 10).
(3) Remove the automati c transmi ssi on shi ft bezel ,
i f equi pped. (Refer to 23 - BODY/I NTERI OR/SHI FT
BEZEL - REMOVAL)
(4) Usi ng a tri m sti ck C-4755 or equi val ent,
remove the ai r bag deacti vati on swi tch and di scon-
nect the el ectri cal connector, i f equi pped.
(5) Remove the bol t(s) attachi ng the consol e to the
fl oor pan (Fi g. 8) and (Fi g. 9).
(6) Shi ft transfer case to four l ow posi ti on.
(7) Shi ft transmi ssi on to L (2nd gear for manual
transmi ssi on) and remove the consol e assembl y.
INSTALLATION
(1) Connect the el ectri cal connector and i nstal l
consol e tower assembl y over the park brake l ever, i f
equi pped.
(2) I nstal l the tower bol ts.
(3) I nstal l the mi ni consol e assembl y over the
transmi ssi on and transfer case shi fters.
(4) I nstal l the consol e bol ts.
(5) Connect the ai r bag deacti vati on swi tch el ectri -
cal connector and i nstal l the swi tch, i f equi pped.
(6) Connect the ai r bag deacti vati on swi tch el ectri -
cal connector and i nstal l the swi tch, i f equi pped.
Fig. 6 SHIFT BEZEL
1 - COIN TRAY
2 - TRANSMISSION SHIFT LEVER HANDLE
3 - SHIFT BEZEL
4 - ASH RECEIVER (IF EQUIPPED)
5 - CUP HOLDER MAT
6 - SHIFT BEZEL LIGHT/SOCKET
Fig. 7 SHIFT BOOT
1 - BOOT SUPPORT TUBE
2 - SHIFT BOOT
3 - SHIFT KNOB
4 - SHIFT PATTERN CAP
5 - NUT
TJ INTERIOR 23 - 55
SHIFT BEZEL - AUTOMATIC TRANSMISSION (Continued)
(7) I nstal l the auto transmi ssi on shi ft bezel , i f
equi pped. (Refer to 23 - BODY/I NTERI OR/SHI FT
BEZEL - I NSTALLATI ON)
(8) I nstal l the manual transmi ssi on shi ft boot, i f
equi pped. (Refer to 23 - BODY/I NTERI OR/SHI FT
BOOT - I NSTALLATI ON)
(9) I nstal l the cup hol der and tri m di sc, i f
equi pped. (Refer to 23 - BODY/I NTERI OR/CENTER
CONSOLE CUPHOLDER ASSEMBLY - I NSTALLA-
TI ON)
CENTER CONSOLE CUP
HOLDER
REMOVAL
(1) Usi ng a tri m sti ck C-4755 or equi val ent,
remove the cup hol der i nsert. (Fi g. 10) and (Fi g. 8)
(2) On mi ni consol e equi pped model s remove the
bol t and remove the cup hol der. (Fi g. 8)
INSTALLATION
(1) On mi ni consol e equi pped model s i nstal l the
cup hol der and i nstal l the bol t.
(2) Ti ghten the bol t to 4 N·m (35 i n l bs.).
(3) I nstal l the cup hol der i nsert.
Fig. 8 MINI CONSOLE
1 - MINI CONSOLE
2 - BOLTS
3 - CUPHOLDER
Fig. 9 FULL CONSOLE
1 - FRONT CONSOLE
2 - BOLTS
3 - REAR TOWER
4 - BOLTS (2)
5 - ELECTRICAL CONNECTOR
Fig. 10 FULL CONSOLE CUP HOLDER
1 - FULL CONSOLE CUP HOLDER
2 - TRIM PIECE
3 - CONSOLE TOWER
23 - 56 INTERIOR TJ
CENTER CONSOLE (Continued)
CONSOLE LOCK CYLINDER
REMOVAL
(1) Open the consol e cover.
(2) Remove the screw that attaches the retai ner to
the l ock and then remove the retai ner from the l ock
(Fi g. 11).
(3) Remove the l ock cyl i nder from the consol e
cover.
INSTALLATION
(1) I nsert the assembl ed l ock i n the consol e cover
hol e and posi ti on the retai ner on the l ock and i nstal l
the screw.
SPORT BAR
REMOVAL
(1) Remove hard top and/or soft top. (Refer to 23 -
BODY/REMOVEABLE TOP/HARD TOP -
REMOVAL) or (Refer to 23 - BODY/REMOVEABLE
TOP/SOFT TOP - REMOVAL).
(2) Remove the door openi ng frames. (Refer to 23 -
BODY/I NTERI OR/DOOR OPENI NG FRAME -
REMOVAL)
(3) Remove the sunvi sors. (Refer to 23 - BODY/I N-
TERI OR/SUN VI SOR - REMOVAL)
(4) Remove the a-pi l l ar weatherstri ps.
(5) Remove the speaker pods. (Refer to 23 - BODY/
I NTERI OR/SPORT BAR - SPEAKER POD -
REMOVAL)
(6) Di sengage center support bar cover zi pper.
(7) Remove the bol ts attachi ng the sport bars to
the center support bar (Fi g. 12).
(8) Remove the bol ts attachi ng the si de support
bars to the wi ndshi el d frame.
(9) Remove the bol ts attachi ng the si de support
bars to the sport bars.
(10) Separate the si de support bars from the vehi -
cl e.
(11) Pul l back the center secti on of the carpet and
remove the bol ts attachi ng the sport bar to the cargo
fl oor panel .
(12) Remove the bol t attachi ng the sport bar to the
brackets behi nd the door stri kers.
(13) Lower the rear seat and l i ft rear seat to the
ful l forward posi ti on.
(14) Pul l back wheel house carpet and remove bol ts
attachi ng the sport bars to the wheel house.
(15) Remove the bol ts attachi ng the seatbel t
anchors to the wheel house.
(16) Careful l y l i ft the sport bar upward and
remove i t from the vehi cl e.
(17) I f necessary, remove the pads and covers from
the sport bar.
INSTALLATION
(1) I f necessary, transfer al l attached components.
(2) Cl ean the base pl ate contact surface areas on
the fl oor and wheel house panel s.
(3) Appl y epoxy chromate pri mer to the attachi ng
hol e edges for protecti on agai nst corrosi on.
(4) Posi ti on the sport bar base pl ates on the fl oor
and wheel house panel s wi th the hol es al i gned.
NOTE: To prevent water seepage, apply 3M Drip-
Chek Sealant (or an equivalent product) to the
underside of the sport bar base flanges and all the
bolt heads before installation.
(5) Posi ti on the center support bar i nto the sport
bars correctl y wi th the l arge hori zontal sl ots faci ng
rearward and hol e/sl ot faci ng downward.
(6) I nstal l the bol ts attachi ng the seatbel t anchors
to the wheel house.
(7) I nstal l the bol ts attachi ng the sport bars to the
wheel house and i nstal l the wheel house carpet.
Ti ghten the bol ts to 40 N·m (30 ft. l bs.).
(8) Return seat back to upri ght posi ti on.
(9) I nstal l the bol ts attachi ng the sport bar to the
cargo fl oor panel and i nstal l the center carpet.
Ti ghten the bol ts to 40 N·m (30 ft. l bs.).
(10) I nstal l the bol ts attachi ng the sport bar to the
brackets behi nd the door stri kers and ti ghten to 68
N·m (50 ft. l bs.).
(11) Posi ti on si de supports at the wi ndshi el d and
i nstal l the bol ts attachi ng the si de support bars to
the wi ndshi el d frame. Ti ghten the bol ts to 32 N·m
(24 ft. l bs.).
(12) I nstal l the bol ts attachi ng the si de support
bars to the sport bars and ti ghten to 20 N·m (15 ft.
l bs.).
Fig. 11 CONSOLE LOCK CYLINDER
1 - ATTACHING SCREW
2 - LOCK
3 - LOCK CYLINDER
4 - RETAINER
TJ INTERIOR 23 - 57
(13) I nstal l the bol ts attachi ng the center support
bar to the sport bar and ti ghten to 68 N·m (50 ft.
l bs.).
(14) Engage center support bar cover zi pper.
(15) I nstal l the speaker pods. (Refer to 23 - BODY/
I NTERI OR/SPORT BAR - SPEAKER POD - I NSTAL-
LATI ON)
(16) I nstal l the a-pi l l ar weatherstri ps.
(17) I nstal l the sun vi sors(Refer to 23 - BODY/I N-
TERI OR/SUN VI SOR - I NSTALLATI ON)
(18) I nstal l the door openi ng frames. (Refer to 23 -
BODY/I NTERI OR/DOOR OPENI NG FRAME -
I NSTALLATI ON)
(19) I nstal l hard top and/or soft top. (Refer to 23 -
BODY/REMOVEABLE TOP/HARD TOP - I NSTAL-
LATI ON) or (Refer to 23 - BODY/REMOVEABLE
TOP/SOFT TOP - I NSTALLATI ON).
A-PILLAR TRIM
REMOVAL
(1) Remove the a-pi l l ar tri m screws. (Fi g. 13)
(2) Starti ng at the bottom, pul l off the tri m and
remove.
INSTALLATION
(1) I nstal l the tri m over the sports bar and posi -
ti on i nto the top.
(2) Press the bottom i nto pl ace and i nstal l the
screws.
REAR HEADER TRIM
REMOVAL
(1) Di sconnect the rear wi ndow defogger el ectri cal
connectors, i f equi pped.
(2) Remove the wi per motor cover and di sconnect
the wi per motor el ectri cal connector and washer
hose. (Fi g. 14)
(3) Usi ng a tri m sti ck C-4755 or equi val ent, sepa-
rate the header tri m and retai ner cl i ps from the top.
(Fi g. 15)
(4) Pul l the wi re harnesses and washer hose
through the tri m panel and remove.
INSTALLATION
(1) Route the wi re harnesses and washer hose
through the tri m panel .
Fig. 12 SPORT BAR
1 - SIDE SUPPORT BAR
2 - CENTER SUPPORT BAR
3 - COVER
4 - COVER
5 - SPORT BAR
6 - COVER
7 - BRACKET
8 - COVER
23 - 58 INTERIOR TJ
SPORT BAR (Continued)
(2) I nstal l the header tri m and seat the retai ni ng
cl i ps ful l y.
(3) Connect the wi per motor el ectri cal and the
washer hose connecti on.
(4) Connect the rear wi ndow defogger el ectri cal
connectors, i f equi pped.
WINDSHIELD HEADER
REMOVAL
(1) Posi ti on both sun vi sors out.
(2) Usi ng a tri m sti ck C-4755 or equi val ent, sepa-
rate the retai ni ng cl i ps and remove the tri m from
behi nd the a-pi l l ar tri m panel s. (Fi g. 16)
INSTALLATION
(1) I nstal l the wi ndshi el d header tri m and posi ti on
the end tabs behi nd the a-pi l l ar tri m.
(2) Seat the retai ni ng cl i ps ful l y.
Fig. 13 A-PILLAR TRIM
1 - WINDSHIELD FRAME
2 - A-PILLAR TRIM
3 - SCREWS (3)
Fig. 14 REAR WIPER MOTOR TRIM COVER
REMOVE/INSTALL
1 - SCREW (3)
2 - TRIM COVER
3 - ELECTRICAL & WASHER HOSE CONNECTIONS
4 - WIPER MOTOR
5 - LIFTGATE GLASS
Fig. 15 REAR HEADER TRIM
1 - REAR HEADER TRIM
2 - WIRE OPENINGS (2)
Fig. 16 WINDSHIELD HEADER MOLDING
1 - WINDSHIELD HEADER TRIM
2 - WINDSHIELD FRAME
3 - SPRING CLIPS (4)
TJ INTERIOR 23 - 59
REAR HEADER TRIM (Continued)
SPORT BAR - SPEAKER POD
REMOVAL
(1) On vehi cl es equi pped wi th a soft top, unzi p the
si de panel next to the pod.
(2) On vehi cl es equi pped wi th a hard top, uncl i p
the wi ndshi el d cl amps.
(3) Remove the bol ts on si de of the top next to the
pod and l oosen the opposi te si de bol ts. (Refer to 23 -
BODY/REMOVEABLE TOP/HARD TOP -
REMOVAL)
(4) Li ft up the si de of the top to gai n access to the
pod bol ts and support wi th a bl ock of wood or si mi l ar.
(5) Remove the two bol ts securi ng the pod to the
sport bar.
(6) Separate the pod gui de pi n from the sport bar
and di sconnect the el ectri cal connector.
INSTALLATION
(1) Connect the pod el ectri cal connector and i nstal l
the pod onto the gui de pi n.
(2) I nstal l the bol ts and ti ghten to 68 N·m (50 ft.
l bs.).
(3) On vehi cl es equi pped wi th a hard top, i nstal l
the hard top. (Refer to 23 - BODY/REMOVABLE
TOP/HARD TOP - I NSTALLATI ON)
(4) On vehi cl es equi pped wi th a soft top, zi p up the
si de panel .
23 - 60 INTERIOR TJ
PAINT
TABLE OF CONTENTS
page page
PAINT
SPECIFICATIONS - PAINT CODES . . . . . . . . . . 61
PAINT CODE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 61
BASECOAT/CLEARCOAT FINISH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 62
PAINT TOUCH-UP
STANDARD PROCEDURE - PAINT TOUCH-UP . 62
FINESSE SANDING, BUFFING & POLISHING
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 62
PAINT
SPECIFICATIONS - PAINT CODES
NOTE: Because of late model changes to the avail-
able paint colors (Refer to VEHICLE DATA/VEHICLE
INFORMATION/VEHICLE CERTIFICATION LABEL -
DESCRIPTION) or (Refer to VEHICLE DATA/VEHI-
CLE INFORMATION/BODY CODE PLATE - DESCRIP-
TION) for the correct paint codes for each vehicle.
(Refer to 23 - BODY/PAINT/PAINT CODE - DESCRIP-
TION)
EXTERIOR COLORS
EXTERIOR COLOR DAIMLERCHRYSLER
CODE
Sienna Pearlcoat WU7
Flame Red Clearcoat PR4
Solar Yellow Clearcoat VYH
Light Khaki Metallic
Clearcoat
AJC
Electric Lime Green
Pearlcoat
BGL
Shale Green Metallic
Clearcoat
XGR
Moss Green Pearlcoat RJN
Patriot Blue Pearlcoat WBT
Bright Silver Metallic
Clearcoat
WSB
Black Clearcoat DX8
Stone White SW1
INTERIOR COLORS
INTERIOR COLOR DAIMLERCHRYSLER
CODE
Dark Slate Gray DV
Khaki J3
EXTERIOR HARD AND SOFT TOP COLORS
EXTERIOR HARD TOP
COLORS
DAIMLERCHRYSLER
CODE
Black SX9
Dark Khaki ZJ8
Dark Green AJ7
PAINT CODE
DESCRIPTION
Exteri or vehi cl e body col ors are i denti fi ed on the
Vehi cl e Certi fi cati on Label (Refer to VEHI CLE
DATA/VEHI CLE I NFORMATI ON/VEHI CLE CERTI -
FI CATI ON LABEL - DESCRI PTI ON) or the Body
Code Pl ate (Refer to VEHI CLE DATA/VEHI CLE
I NFORMATI ON/BODY CODE PLATE - DESCRI P-
TI ON). The fi rst di gi t of the pai nt code l i sted on the
vehi cl e i ndi cates the sequence of appl i cati on, i .e.: P =
pri mary coat, Q = secondary coat. The col or names
provi ded i n the Pai nt and Tri m Code Descri pti on
chart are the col or names used on most repai r prod-
uct contai ners. (Refer to 23 - BODY/PAI NT - SPECI -
FI CATI ONS)
TJ PAINT 23 - 61
BASECOAT/CLEARCOAT
FINISH
DESCRIPTION
On most vehi cl es a two-stage pai nt appl i cati on
(basecoat/cl earcoat) i s used. Col or that i s appl i ed to
pri mer i s cal l ed basecoat. The cl earcoat protects the
basecoat from ul travi ol et l i ght and provi des a dura-
bl e hi gh-gl oss fi ni sh.
PAINT TOUCH-UP
STANDARD PROCEDURE - PAINT TOUCH-UP
When a pai nted metal surface has been scratched
or chi pped, i t shoul d be touched-up as soon as possi -
bl e to avoi d corrosi on. For best resul ts, use Mopar௡
Scratch Fi l l er/Pri mer, Touch-Up Pai nts and Cl ear
Topcoat. Refer to I ntroducti on group of thi s manual
for Body Code Pl ate i nformati on.
WARNING: USE AN OSHA APPROVED RESPIRATOR
AND SAFETY GLASSES WHEN SPRAYING PAINT
OR SOLVENTS IN A CONFINED AREA. PERSONAL
INJURY CAN RESULT.
(1) Scrape l oose pai nt and corrosi on from i nsi de
scratch or chi p.
(2) Cl ean affected area wi th Mopar௡ Tar/Road Oi l
Remover, and al l ow to dry.
(3) Fi l l the i nsi de of the scratch or chi p wi th a coat
of fi l l er/pri mer. Do not overl ap pri mer onto good sur-
face fi ni sh. The appl i cator brush shoul d be wet
enough to puddl e-fi l l the scratch or chi p wi thout run-
ni ng. Do not stroke brush appl i cator on body surface.
Al l ow the fi l l er/pri mer to dry hard.
(4) Cover the fi l l er/pri mer wi th col or touch-up
pai nt. Do not overl ap touch-up col or onto the ori gi nal
col or coat around the scratch or chi p. Butt the new
col or to the ori gi nal col or, i f possi bl e. Do not stroke
appl i cator brush on body surface. Al l ow touch-up
pai nt to dry hard.
(5) On vehi cl es wi thout cl ear coat, the touch-up
col or can be l i ghtl y fi nesse sanded (1500 gri t) and
pol i shed wi th rubbi ng compound.
(6) On vehi cl es wi th cl earcoat, appl y cl ear topcoat
to touch-up pai nt wi th the same techni que as
descri bed i n Step 4. Al l ow cl ear topcoat to dry hard.
I f desi red, Step 5 can be performed on cl ear topcoat.
WARNING: AVOID PROLONGED SKIN CONTACT
WITH PETROLEUM OR ALCOHOL – BASED CLEAN-
ING SOLVENTS. PERSONAL INJURY CAN RESULT.
AVOID PROLONGED SKIN CONTACT WITH PETRO-
LEUM OR ALCOHOL – BASED CLEANING SOL-
VENTS. PERSONAL INJURY CAN RESULT.
FINESSE SANDING, BUFFING
& POLISHING
DESCRIPTION
CAUTION: Do not remove more than .5 mils of
clearcoat finish, if equipped. Basecoat paint must
retain clearcoat for durability.
Use a Paint Thickness Gauge #PR-ETG-2X or equiv-
alent to determine film thickness before and after
the repair.
Mi nor aci d etchi ng, orange peel , or smudgi ng i n
cl earcoat or si ngl e-stage fi ni shes can be reduced wi th
l i ght fi nesse sandi ng, hand buffi ng, and pol i shi ng. If
the finish has been finesse sanded in the past,
it cannot be repeated. Finesse sanding opera-
tion should be performed by a trained automo-
tive paint technician.
23 - 62 PAINT TJ
REMOVEABLE TOP
TABLE OF CONTENTS
page page
REMOVEABLE TOP
STANDARD PROCEDURE
HARD TOP REPAIR . . . . . . . . . . . . . . . . . . . . 63
HARD TOP REPAIR . . . . . . . . . . . . . . . . . . . . 63
HARD TOP FRACTURE REPAIR . . . . . . . . . . 64
HARD TOP SAG REPAIR . . . . . . . . . . . . . . . . 64
HARD TOP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 64
SOFT TOP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 66
SOFT TOP FABRIC
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 67
DOOR OPENING FRAME
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 67
HARD/SOFT TOP LATCH
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 67
REMOVEABLE TOP
STANDARD PROCEDURE
HARD TOP REPAIR
NOTE: The hard top is manufactured from a sheet
molded compound (SMC).
SMC is constructed using short fiberglass strands
usually less than 5.08 cm (2 inches) long. Sheet
stock of glass impregnated resin matting is placed
into the mold and pressed under heat to flow mate-
rial throughout the mold. Tooling is shear edge
designed to mold to net (i.e. no trimming at periph-
ery required).
SMC is repairable in accordance with established
procedures described within this manual. (Refer to
23 - BODY - STANDARD PROCEDURE - PLASTIC
BODY PANEL REPAIR)
Hard Top Locators
There are two hard top l ocator devi ces posi ti oned
approxi matel y 150 mm (6 i n.) from the most forward
attachment hol es. I f the l ocator devi ce i s mi ssi ng or
damaged i t must be repl aced, as i t wi l l assi st i n pl ac-
i ng the hard top back i nto the correct posi ti on for top
re-attachment.
I f the l ocator devi ce i s mi ssi ng just make sure that
the attachment hol es are cl ear and si mpl y i nsert the
new l ocator (part i s ori entated by hol e si ze and
i nserts from the bottom of the rai l before the hard
top i s re-attached to the vehi cl e).
I f the l ocator devi ce i s damaged, cut off the l ocki ng
tabs, remove and repl ace as descri bed above.
HARD TOP REPAIR
I f i t has been determi ned that the hard top can be
repai red. The fol l owi ng requi red materi al s and proce-
dures are to be used.
(1) Use a gri nder to remove the pai nt and outl i ne
the damaged area. Use a grade 150 gri t di sc for pai nt
removal .
(2) Gri nd the outl i ned surface area agai n wi th a
240 gri t di sc to prevent coarse scratches from appear-
i ng i n the fi nal fi ni sh.
(3) I f cracks extend from the hol e, i t wi l l be neces-
sary to stop-dri l l the crack(s) wi th a 3-mm (1/8-i n)
di ameter dri l l bi t. Thi s wi l l prevent the crack from
spreadi ng and al l ow repai r materi al to be effecti ve.
(4) Posi ti on a fi bergl ass mat or cl oth on the repai r
surface area. Cut the mat 2.5 cm (1 i n.) l arger than
repai r area but smal l er than the outl i ne area. Make
the outl i ne area l arger i f requi red.
(5) Cl ean the outl i ned area.
(6) Pl ace the fi bergl ass cl oth on al umi num foi l .
(7) Pour the fi bergl ass resi n i nto a cl ean contai ner.
(8) Mi x the appropri ate amount of hardener and
resi n. Fol l ow the manufacturers i nstructi ons.
(9) Appl y the hardener/resi n mi xture to both si des
of the fi bergl ass cl oth.
(10) Pl ace the fi bergl ass cl oth over the repai r area.
Next, pl ace the al umi num foi l over the cl oth usi ng a
pl asti c spreader to smooth-out the cl oth and resi n.
Use fi rm pressure to remove ai r bubbl es and to
smooth-out the cl oth. Remove the al umi num foi l .
(11) Al l ow the resi n to cure.
(12) Smooth-out the surface area to the contour of
the hard top wi th a 150-gri t di sc.
(13) Appl y pl asti c fi l l er to compl ete the repai r. Fi n-
i sh smoothi ng the surface area wi th 240-320 gri t
paper.
TJ REMOVEABLE TOP 23 - 63
(14) Repeat the previ ous steps on the i nsi de area
of the hard top.
(15) Featheredge the repai red surface area.
(16) Pri me the repai red surface area wi th PPG௡
Epoxy Pri mer, or an equi val ent product.
(17) Appl y surface pri mer to the surface area.
(18) Pri me the surface area for the col or coat.
(19) Appl y col or coat to the repai red surface area.
HARD TOP FRACTURE REPAIR
I f i t has been determi ned that the hard top can be
repai red. The fol l owi ng requi red materi al s and proce-
dures are to be used.
(1) Use a gri nder to remove the pai nt and outl i ne
the damaged area. Use a grade 150 gri t di sc for pai nt
removal .
(2) Gri nd the outl i ned surface area agai n wi th a
240 gri t di sc to prevent coarse scratches from appear-
i ng i n the fi nal fi ni sh.
(3) I f cracks extend from the damaged area, i t wi l l
be necessary to stop dri l l the cracks wi th a 3-mm
(1/8-i n) di ameter dri l l bi t. Thi s wi l l prevent the crack
and/or fracture from spreadi ng and al l ow repai r
materi al to be effecti ve.
(4) Bevel the edges of the crack/fracture on both
si des wi th a rotary fi l e.
NOTE: The edges should be beveled on the inside
and outside of the top to ensure sufficient surface
area for good bonding.
(5) Compl ete the repai rs wi th fi bergl ass cl oth and
resi n as descri bed i n the hard top hol e repai r proce-
dure. (Refer to 23 - BODY/REMOVABLE TOP -
STANDARD PROCEDURE)
HARD TOP SAG REPAIR
I nspect the roof/hard top assembl y for the presence
of sag, or i f the customer compl ai ns of water accumu-
l ati on on the roof. Perform the fol l owi ng procedure to
repai r.
(1) Di sengage l atches at wi ndshi el d frame (Fi g. 1).
NOTE: The two forward bolts/nuts are not captured.
Do not lose the nuts when removing.
(2) Remove the si x bol ts that attach the hard top
to the body (Fi g. 2).
(3) Depress tab on rear wi per motor connector and
pul l downward to di sengage (Fi g. 3).
(4) Make two marks on the i nsi de of the hard top
6 cm (2.5 i n.) on both si des of the center roof ri b,
di rectl y above the sport bar.
(5) Move the hard top back about 10 cm (4 i n.) to
expose the i nner ri b secti on.
(6) Cl ean the roof area wi th i sopropyl al cohol .
(7) I nstal l the foam repai r bl ocks by removi ng the
protecti ve backi ng tape from the adhesi ve si de. The
foam bl ocks must be centered above the sport bar
pad.
(8) Move the hard top assembl y back i nto posi ti on
and centered at the wi ndshi el d frame.
(9) I nspect the hard top seal s for damage and
repl ace, i f necessary.
(10) I nspect the wi ndshi el d header seal and make
sure i t i s cl ean, undamaged, and free of debri s.
(11) Careful l y posi ti on the hard top assembl y on
the vehi cl e maki ng sure that the l atches are not
pi nched between the wi ndshi el d frame and top.
CAUTION: Do not over tighten the top bolts. Over
tightening can cause cracking of the hardtop
assembly.
(12) Loosel y i nstal l the si x bol ts. Ensure that the
top i s centered on the vehi cl e and l ocators are i n
pl ace i n the body si de sl ots and ti ghten the bol ts to
17 N·m (150 i n. l bs.).
(13) Connect the wi re wi per motor harness connec-
tor.
(14) Connect the rear washer fl ui d hose.
(15) Engage the l atches at wi ndshi el d frame and
snap the cl amps home.
HARD TOP
REMOVAL
(1) Di sengage l atches at wi ndshi el d frame (Fi g. 1).
NOTE: The two forward bolts/nuts are not captured.
Do not lose the nuts when removing.
(2) Remove the si x bol ts that attach the hard top
to the body (Fi g. 2).
(3) Depress tab on rear wi per motor connector and
pul l downward to di sengage (Fi g. 3).
(4) Di sconnect the rear washer fl ui d hose. Cap the
hose to prevent washer fl ui d l eakage (Fi g. 4).
CAUTION: Protect the lower edges of the top from
potential damage, cracks, paint chips, gouges and
scratches that are not covered under warranty.
(5) Careful l y remove the hard top assembl y from
the vehi cl e.
INSTALLATION
(1) I nspect the hard top seal s for damage and
repl ace, i f necessary.
(2) I nspect the wi ndshi el d header seal and make
sure i t i s cl ean, undamaged, and free of debri s.
23 - 64 REMOVEABLE TOP TJ
REMOVEABLE TOP (Continued)
(3) Careful l y posi ti on the hard top assembl y on the
vehi cl e maki ng sure that the l atches are not pi nched
between the wi ndshi el d frame and top.
CAUTION: Do not over tighten the top bolts. Over
tightening can cause cracking of the hardtop
assembly.
(4) Loosel y i nstal l the si x bol ts. Ensure that the
top i s centered on the vehi cl e and ti ghten the bol ts to
17 N·m (150 i n. l bs.).
(5) Connect the wi re wi per motor harness connec-
tor.
(6) Connect the rear washer fl ui d hose.
(7) Engage the l atches at wi ndshi el d frame and
snap the cl amps home.
SOFT TOP
REMOVAL
(1) Di sengage the retai ners attachi ng the rear wi n-
dow to the body.
(2) Remove rear wi ndow, unzi ppi ng from ri ght to
l eft.
(3) Di sengage J-straps at soft top rear corners
(Fi g. 5).
(4) Unzi p quarter wi ndows, di sengage J-strap and
remove quarter wi ndows.
(5) Starti ng at the rear of the upper door openi ng
frame and worki ng forward, di sengage dri p rai l
retai ners attachi ng the soft top to the door openi ng
frame.
(6) Unl atch top at wi ndshi el d frame.
(7) Lower the top to the rearward posi ti on.
(8) Remove the screws attachi ng the roof bows to
the pi vot bracket (Fi g. 6).
Fig. 1 HARD TOP LATCH
1 - LATCH
2 - HARD TOP
3 - WINDSHIELD FRAME
Fig. 2 HARD TOP REMOVAL
1 - HARD TOP
2 - HOLD DOWN BOLT
3 - BODY RAIL
Fig. 3 REAR WIPER WIRE HARNESS CONNECTOR
1 - WIPER MOTOR CONNECTOR
Fig. 4 REAR WASHER FLUID TUBE
1 - WASHER HOSE CAP
2 - REAR WASHER SUPPLY HOSE - BODY HALF
TJ REMOVEABLE TOP 23 - 65
HARD TOP (Continued)
(9) Li ft up bows at pi vot bracket to di sengage from
pi vot bracket.
(10) Remove the top (Fi g. 7).
INSTALLATION
(1) Posi ti on the top on the vehi cl e.
(2) I nstal l the screws attachi ng the roof bows to
the pi vot bracket. (The front bow i s attached to the
pi vot bracket on the upper outward l ocati on).
(3) Rai se the top.
(4) Posi ti on l atch i n wi ndshi el d frame.
Fig. 6 ROOF BOW REMOVAL
1 - SPORT BAR
2 - REAR ROOF BOW
3 - SIDE ROOF BOW
Fig. 5 SOFT TOP J-STRAPS
1 - SOFT TOP CORNER J-STRAP
2 - QUARTER PANEL
Fig. 7 SOFT TOP
1 - HALF DOOR WINDOW
2 - DOOR OPENING FRAME
3 - QUARTER WINDOW
4 - SOFT TOP
5 - ROOF BOW
6 - LATCH REINFORCEMENT
23 - 66 REMOVEABLE TOP TJ
SOFT TOP (Continued)
(5) I nstal l the quarter wi ndows.
(6) Worki ng from front to rear, engage the J-straps
attachi ng the quarter wi ndow to the body.
(7) I nstal l rear wi ndow.
(8) Engage dri p rai l retai ners above door openi ng
frame.
(9) Worki ng from front to rear, engage J-straps at
soft top rear corners.
(10) Engage the retai ners attachi ng the rear wi n-
dow to the body.
(11) Cl ose l atch at wi ndshi el d frame.
SOFT TOP FABRIC
REMOVAL
(1) Di sengage the snaps attachi ng the soft top fab-
ri c to the rear roof bow.
(2) Di sengage the hook and l oop fastener attachi ng
soft top fabri c to the center roof bow.
(3) Lower the soft top.
(4) Remove the screws attachi ng the soft top fabri c
to the front roof bow and fol d back fabri c.
(5) Separate the soft top fabri c from the frame.
INSTALLATION
(1) Posi ti on the soft top fabri c on the frame.
(2) I nstal l the screws attachi ng the soft top fabri c
to the front roof bow.
(3) Engage the hook and l oop fastener attachi ng
soft top fabri c to the center roof bow.
(4) Engage the snaps attachi ng the soft top fabri c
to the rear roof bow.
(5) Rai se and secure the soft top.
DOOR OPENING FRAME
REMOVAL
Vehi cl es equi pped wi th a soft top requi re a door
openi ng frame to compl ete the seal for the soft top
door assembl y.
(1) Lower the top to the rearward posi ti on.
(2) Turn the knobs l ocated on top of the door open-
i ng frame counter cl ockwi se and remove compl etel y
(Fi g. 8).
(3) Pul l door openi ng frame outward and up. Sep-
arate from vehi cl e.
INSTALLATION
Vehi cl es equi pped wi th a soft top requi re a door
openi ng frame to compl ete the seal for the soft top
door assembl y.
(1) I nstal l the al i gnment pi n at the base of the
door openi ng frame i nto the hol e at the top of the
quarter panel .
(2) Posi ti on the door openi ng frame on the si de
support bar and i nstal l the knobs.
(3) Rai se and secure the top.
HARD/SOFT TOP LATCH
REMOVAL
(1) Unl atch the top (Fi g. 9).
(2) Usi ng a grease penci l or equi val ent, mark the
posi ti on of the l atch on the top.
(3) Remove the screws attachi ng the l atch to the
top.
INSTALLATION
(1) Posi ti on the l atch on the top and i nstal l the
screws.
Fig. 8 DOOR OPENING FRAME
1 - DOOR OPENING FRAME
2 - KNOBS
Fig. 9 HARD/SOFT TOP LATCH
1 - LATCH
2 - HARD TOP
3 - WINDSHIELD FRAME
TJ REMOVEABLE TOP 23 - 67
SOFT TOP (Continued)
SEATS
TABLE OF CONTENTS
page page
FRONT SEAT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 68
FRONT SEAT BACK
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 69
FRONT SEAT BACK COVER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 70
FRONT SEAT CUSHION COVER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 70
FRONT SEAT BACK RECLINER/COVER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 70
FRONT SEAT BACK RECLINER CABLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 71
FRONT SEAT FOLDING RELEASE CABLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 72
FRONT SEAT BACK DUMP CABLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 72
FRONT SEAT TRACK ADJUSTER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 72
REAR SEAT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 73
REAR SEAT BACK
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 74
REAR SEAT BACK HINGE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 74
REAR SEAT BACK COVER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 74
REAR SEAT CUSHION COVER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 75
REAR SEAT RELEASE CABLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 76
REAR SEAT STRIKERS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 76
FRONT SEAT
REMOVAL
(1) Di sengage seat bel t el ectri cal connector (Fi g. 1).
(2) Remove the bol ts attachi ng the seat adjuster to
the fl oor panel (Fi g. 2).
(3) Remove the seat from the vehi cl e.
INSTALLATION
(1) Posi ti on the seat i n the vehi cl e.
(2) I nstal l the bol ts attachi ng the rear of seat
frame to the fl oor panel . Ti ghten outboard bol t to 33
N·m (25 ft. l bs.). Ti ghten i nboard bol t to 74 N·m (55
ft. l bs.).
(3) I nstal l the bol ts attachi ng the front of seat
frame to the fl oor panel and ti ghten bol ts to 33 N·m
(25 ft. l bs.).
(4) Engage seat bel t el ectri cal connector.
Fig. 1 SEAT BELT ELECTRICAL
1 - FRONT SEAT
2 - SEAT BELT ELECTRICAL CONNECTOR
23 - 68 SEATS TJ
FRONT SEAT BACK
REMOVAL
(1) Remove seat. (Refer to 23 - BODY/SEATS/
FRONT SEAT - REMOVAL)
(2) Di sengage the j-straps at the l ower edge of the
seat back and posi ti on the seat back cover asi de.
(3) Usi ng a smal l fl at bl aded tool , rel ease the
hi nge cover retai ni ng tab and remove. (Fi g. 3)
(4) Di sconnect the recl i ner cabl es. (Fi g. 4)
(5) Remove the upper recl i ner bol ts and remove
the seat back
INSTALLATION
(1) Posi ti on the seatback on the seat cushi on.
(2) Passenger seat and dri ver dumpi ng seat:
(a) Engage seat dump cabl e to cl i p on recl i ner.
(3) I nstal l the bol ts attachi ng the recl i ner to the
seat cushi on frame.
(4) Engage the seat cushi on corner cover j-retai n-
ers.
(5) Engage the retai ners attachi ng the cushi on
cover to the outboard seat cushi on frame.
(6) I nstal l seat. (Refer to 23 - BODY/SEATS/
FRONT SEAT - I NSTALLATI ON)
FRONT SEAT BACK COVER
REMOVAL
(1) Remove the seat. (Refer to 23 - BODY/SEATS/
SEAT - REMOVAL)
(2) Di sconnect the j-straps at the bottom of the
seat back.
(3) Remove the bottom hog ri ngs.
(4) Remove the upper hog ri ngs.
(5) Remove the support rods from the seat back.
(6) Usi ng a tri m sti ck C-4755 or equi val ent,
remove and di scard the seat rel ease handl e knob.
(Fi g. 5)
Fig. 2 BUCKET SEAT REMOVAL
1 - BUCKLE
2 - SEAT
3 - TURNING LOOP
4 - COVER
5 - ADJUSTER
6 - RETRACTOR
7 - MOUNTING BRACKET
Fig. 3 SEAT BACK HINGE COVER
1 - SEAT BACK COVER
2 - RECLINER COVER RETAINING TAB
3 - SEAT CUSHION FRAME
4 - RECLINER COVER
Fig. 4 SEAT BACK HINGE
1 - DUMP CABLE CONNECTIONS
2 - SEAT BACK BOLTS (4)
3 - SEAT BACK RECLINER
TJ SEATS 23 - 69
FRONT SEAT (Continued)
(7) Remove the screw and remove the rel ease han-
dl e bezel .
(8) Remove the seat cover and cushi on.
INSTALLATION
(1) Posi ti on cover and cushi on on seatback.
(2) I nstal l the rel ease handl e bezel and i nstal l the
screw.
(3) I nstal l a new rel ease handl e knob.
(4) I nstal l the support rods.
(5) I nstal l the upper hog ri ngs.
(6) I nstal l the bottom hog ri ngs.
(7) Connect the j-straps at the bottom of the seat
back.
(8) I nstal l seat back. (Refer to 23 - BODY/SEATS/
FRONT SEAT BACK - I NSTALLATI ON)
FRONT SEAT CUSHION COVER
REMOVAL
(1) Remove seat back. (Refer to 23 - BODY/SEATS/
FRONT SEAT BACK - REMOVAL)
(2) Di sengage i nboard j-strap.
(3) Di sengage front j-strap.
(4) Di sengage rear j-strap
(5) Rol l cover up to access hog ri ngs.
(6) Di sengage i nboard and outboard hog ri ngs.
(7) Separate cover from cushi on.
INSTALLATION
(1) Posi ti on cover on cushi on and al i gn seams.
(2) Engage i nboard and outboard hog ri ngs.
(3) Rol l cover over cushi on edges.
(4) Engage i nboard j-strap.
(5) Engage front j-strap.
(6) Engage rear j-strap
(7) I nstal l seat back. (Refer to 23 - BODY/SEATS/
FRONT SEAT BACK - I NSTALLATI ON)
FRONT SEAT BACK RECLINER/
COVER
REMOVAL
(1) Remove the seat. (Refer to 23 - BODY/SEATS/
FRONT SEAT - REMOVAL)
(2) Di sconnect the j-straps at the l ower edge of the
seat back and posi ti on asi de.
(3) Di sconnect the rear j-straps of the cushi on and
posi ti on asi de.
(4) Usi ng a smal l fl at bl aded tool , rel ease the
recl i ner cover retai ni ng tab and remove. (Fi g. 3)
(5) Di sconnect the seat back dump cabl es. (Fi g. 4)
(6) Remove the two seat back bol ts.
(7) Remove the two seat cushi on frame bol ts.
(8) Di sconnect the recl i ner cabl e.
(9) For the i nboard recl i ner, di sconnect the forward
fol di ng cabl e assembl y, i f equi pped.
INSTALLATION
(1) Connect the forward fol di ng cabl e assembl y, i f
equi pped.
(2) Connect the recl i ner cabl e.
(3) I nstal l the two seat cushi on frame bol ts.
(4) I nstal l the two seat back bol ts.
(5) Connect the seat back dump cabl es.
(6) I nstal l the recl i ner cover.
(7) Connect the rear j-straps of the cushi on.
(8) Connect the j-straps at the l ower edge of the
seat back.
(9) I nstal l the seat. (Refer to 23 - BODY/SEATS/
SEAT - I NSTALLATI ON)
FRONT SEAT BACK RECLINER
CABLE
REMOVAL
(1) Remove seat cushi on cover. (Refer to 23 -
BODY/SEATS/SEAT CUSHI ON COVER -
REMOVAL)
(2) Di sengage cabl e from recl i ner rel ease handl e.
(Fi g. 6) and (Fi g. 7)
(3) Route cabl e through seat cushi on pad.
(4) Di sengage cabl e from mounti ng bracket.
Fig. 5 FORWARD FOLDING SEAT RELEASE
HANDLE
1 - SEAT BACK
2 - BEZEL SCREW
3 - RELEASE HANDLE BEZEL
4 - RELEASE HANDLE KNOB
23 - 70 SEATS TJ
FRONT SEAT BACK COVER (Continued)
INSTALLATION
(1) Engage cabl e to mounti ng bracket.
(2) Route cabl e through seat cushi on pad.
(3) Engage cabl e to recl i ner rel ease.
(4) I nstal l seat back cover. (Refer to 23 - BODY/
SEATS/FRONT SEAT BACK COVER - I NSTALLA-
TI ON)
FRONT SEAT FOLDING
RELEASE CABLE
REMOVAL
(1) Remove the seat. (Refer to 23 - BODY/SEATS/
SEAT - REMOVAL)
(2) Di sconnect the rel ease cabl e fol di ng end. (Fi g. 8)
(3) Remove the i nboard recl i ner. (Refer to 23 -
BODY/SEATS/SEAT BACK RECLI NER - REMOVAL)
(4) Di sconnect the rel ease cabl e assembl y at the
i nboard recl i ner, from the support bracket. (Fi g. 9)
(5) Di sconnect the cabl e assembl y at the sl i der and
remove. (Fi g. 10)
Fig. 6 RECLINER HANDLE/CABLE
1 - RECLINER HANDLE
2 - RECLINER CABLE END
3 - RECLINER CABLE
4 - RECLINER HANDLE BOLT
Fig. 7 RECLINER CABLE END
1 - RECLINER CABLE
2 - RECLINER CABLE END
Fig. 8 RELEASE CABLE/FOLDING END
1 - CABLE END CLIP
2 - CABLE HOUSING
3 - CABLE ASSEMBLY
Fig. 9 RELEASE CABLE/RECLINER END
1 - CABLE ASSEMBLY
2 - CABLE HOUSING
3 - SEAT CUSHION FRAME
4 - CABLE SUPPORT BRACKET
TJ SEATS 23 - 71
FRONT SEAT BACK RECLINER CABLE (Continued)
INSTALLATION
(1) Connect the cabl e assembl y at the sl i der.
(2) Connect the i nboard rel ease cabl e assembl y to
the support bracket at the recl i ner.
(3) I nstal l the i nboard recl i ner. (Refer to 23 -
BODY/SEATS/SEAT BACK RECLI NER - I NSTAL-
LATI ON)
(4) Connect the fol di ng end of the rel ease cabl e
assembl y.
(5) I nstal l the seat. (Refer to 23 - BODY/SEATS/
SEAT - I NSTALLATI ON)
FRONT SEAT BACK DUMP
CABLE
REMOVAL
(1) Remove the seat back cover. (Refer to 23 -
BODY/SEATS/FRONT SEAT BACK COVER -
REMOVAL)
(2) Di sconnect the dump cabl es from the recl i ners.
(Fi g. 4)
(3) Remove the two dump handl e assembl y screws
and remove the rel ease cabl e assembl y.
INSTALLATION
(1) I nstal l the dump handl e assembl y and i nstal l
the two screws.
(2) Connect the dump cabl es at the recl i ners.
(3) I nstal l the seat back cover. (Refer to 23 -
BODY/SEATS/SEAT BACK COVER - I NSTALLA-
TI ON)
FRONT SEAT TRACK
ADJ USTER
REMOVAL
(1) Remove the seat. (Refer to 23 - BODY/SEATS/
SEAT - REMOVAL)
(2) Posi ti on asi de the seat back cover. (Refer to 23
- BODY/SEATS/SEAT BACK COVER - REMOVAL)
(3) Remove the recl i ner covers. (Refer to 23 -
BODY/SEATS/SEAT BACK RECLI NER - REMOVAL)
(4) Posi ti on asi de the seat cushi on cover. (Refer to
23 - BODY/SEATS/SEAT CUSHI ON COVER -
REMOVAL)
(5) Di sconnect the recl i ner cabl e ends. (Fi g. 11)
and (Fi g. 12)
(6) Remove the seat cushi on to hi nge bol ts. (Fi g.
11) and (Fi g. 12)
(7) Di sconnect the fol di ng rel ease cabl e from the
seat back recl i ner, i f equi pped. (Fi g. 11)
(8) Remove the seat back assembl y.
(9) Remove the two bol ts on ei ther si de of the seat
cushi on and remove the seat track assembl y. (Fi g. 13)
INSTALLATION
(1) I nstal l the seat track assembl y and i nstal l the
two front bol ts.
(2) I nstal l the seat back assembl y.
(3) Connect the fol di ng rel ease cabl e assembl y end
to the seat back recl i ner.
(4) I nstal l the seat back assembl y bol ts.
(5) Ti ghten the seat track bol ts to 50 N·m (37 ft.
l bs.)
(6) Connect the recl i ner cabl es.
Fig. 10 RELEASE CABLE/SLIDER END
1 - CABLE HOUSING
2 - CABLE END
3 - SLIDER
4 - SEAT CUSHION FRAME
Fig. 11 INBOARD SEAT CUSHION AND HINGE
1 - RECLINER CABLE
2 - SEAT CUSHION FRAME BOLTS
3 - SEAT CUSHION FRAME
4 - FOLDING RELEASE CABLE ASSEMBLY END
23 - 72 SEATS TJ
FRONT SEAT FOLDING RELEASE CABLE (Continued)
(7) I nstal l the seat cushi on cover. (Refer to 23 -
BODY/SEATS/SEAT CUSHI ON COVER - I NSTAL-
LATI ON)
(8) I nstal l the recl i ner covers. (Refer to 23 - BODY/
SEATS/SEAT BACK RECLI NER - I NSTALLATI ON)
(9) I nstal l the seat back cover. (Refer to 23 -
BODY/SEATS/SEAT BACK COVER - I NSTALLA-
TI ON)
(10) I nstal l the seat. (Refer to 23 - BODY/SEATS/
SEAT - I NSTALLATI ON)
REAR SEAT
REMOVAL
(1) Remove the add-a-trunk, i f equi pped. (Refer to
23 - BODY/I NTERI OR/ADD-A-TRUNK - REMOVAL)
(2) Usi ng the l atch handl e, fol d the seat back down
and ti p the seat assembl y forward. (Fi g. 14)
(3) Squeeze the rel ease bar and di sengage the
front l atches. (Fi g. 15)
(4) Remove the seat through tai l gate openi ng.
INSTALLATION
(1) Posi ti on the seat on the rear fl oor panel and
engage the seat frame rel ease l atch wi th the front
stri kers.
Fig. 12 SEAT CUSHION AND HINGE
1 - SEAT CUSHION FRAME BOLTS
2 - RECLINER CABLE END
3 - RECLINER HANDLE
Fig. 13 FRONT SEAT CUSHION BOLTS
1 - SEAT TRACK
2 - SEAT CUSHION FRAME BOLT
3 - SEAT CUSHION
Fig. 14 REAR SEAT BACK
1 - REAR SEAT BACK
2 - RELEASE HANDLE
Fig. 15 REAR SEAT RELEASE LATCH ROD
1 - RELEASE LATCH ROD
2 - REAR SEAT CUSHION
3 - REAR SEAT LATCH ASSEMBLY
4 - REAR SEAT LATCH STRIKER (4)
TJ SEATS 23 - 73
FRONT SEAT TRACK ADJ USTER (Continued)
(2) Rol l seat back and engage the rear l atches wi th
the rear stri kers.
(3) Return the seat back to the up posi ti on.
(4) I nstal l the add-a-trunk, i f equi pped. (Refer to
23 - BODY/I NTERI OR/ADD-A-TRUNK - I NSTALLA-
TI ON)
REAR SEAT BACK
REMOVAL
(1) Remove rear seat. (Refer to 23 - BODY/SEATS/
REAR SEAT - REMOVAL)
(2) Remove the bol ts attachi ng the seat back
assembl y to the seat cushi on and remove the seat
back. (Fi g. 16)
INSTALLATION
(1) Posi ti on the seat back on the seat cushi on and
i nstal l the bol ts.
(2) Ti ghten the bol ts to 50 N·m (37 ft. l bs.).
(3) I nstal l rear seat. (Refer to 23 - BODY/SEATS/
REAR SEAT - I NSTALLATI ON)
REAR SEAT BACK HINGE
REMOVAL
(1) Remove the seat. (Refer to 23 - BODY/SEATS/
REAR SEAT - REMOVAL)
(2) Remove the l ower hi nge bol ts. (Fi g. 16)
(3) Di sconnect the l ower j-straps of the seat back
and posi ti on asi de the seat back cover.
(4) Di sconnect the rel ease cabl e. (Fi g. 17)
(5) Remove the bol ts and remove the hi nge.
INSTALLATION
(1) I nstal l the hi nge and i nstal l the bol ts.
(2) Ti ghten the bol ts to 50 N·m (37 ft. l bs.).
(3) Connect the rel ease cabl e.
(4) Connect the l ower j-straps of the seat back.
(5) I nstal l the l ower hi nge bol ts and ti ghten to 50
N·m (37 ft. l bs.).
(6) I nstal l the seat. (Refer to 23 - BODY/SEATS/
REAR SEAT - I NSTALLATI ON)
REAR SEAT BACK COVER
REMOVAL
(1) Remove the seat. (Refer to 23 - BODY/SEATS/
SEAT - REMOVAL)
(2) Remove the screws and remove the seat back
rel ease handl e bezel . (Fi g. 18)
(3) Rel ease the j-cl i ps at the bottom of the seat
back and remove the seat cover.
(4) Remove the hog ri ngs and remove the seat
cushi on. (Fi g. 19)
INSTALLATION
(1) Posi ti on the cushi on onto the seat back frame
and i nstal l new hog ri ng fasteners.
(2) I nstal l the cover over the seat back frame and
cushi on.
Fig. 16 REAR SEAT BACK HINGE
1 - SEAT CUSHION BOLTS
2 - SEAT BACK HINGE
3 - SEAT CUSHION
Fig. 17 REAR SEAT BACK HINGE
1 - RELEASE CABLE GUIDE
2 - BOLTS
3 - SEAT BACK HINGE
4 - RELEASE CABLE CONNECTION
5 - SEAT BACK FRAME
23 - 74 SEATS TJ
REAR SEAT (Continued)
(3) Connect the bottom j-cl i ps.
(4) I nstal l the rel ease handl e bezel and i nstal l the
screws.
(5) I nstal l the rear seat back. (Refer to 23 - BODY/
SEATS/REAR SEAT BACK - I NSTALLATI ON)
REAR SEAT CUSHION COVER
REMOVAL
(1) Remove the rear seat back. (Refer to 23 -
BODY/SEATS/REAR SEAT BACK - REMOVAL)
(2) Un-zi p the cover. (Fi g. 20)
(3) Rel ease the J-cl i ps. (Fi g. 21)
(4) Rol l the cover from seat cushi on and separate
from the seat cushi on frame.
(5) Remove the hogri ngs from the foam to cover.
INSTALLATION
(1) Posi ti on the cover on the cushi on, i nstal l new
hogri ngs to foam, and rol l cover downward over the
corners.
(2) Connect the J-cl i ps to the seat cushi on frame.
Fig. 18 RELEASE HANDLE
1 - RELEASE HANDLE
2 - BEZEL
3 - SCREWS (2)
Fig. 19 SEAT BACK CUSHION
1 - SEAT BACK FRAME
2 - SEAT BACK RELEASE HANDLE
3 - HOG RINGS (4)
Fig. 20 SEAT CUSHION COVER
1 - SEAT CUSHION
2 - COVER ZIPPER
Fig. 21 SEAT CUSHION
1 - SEAT CUSHION FRAME
2 - J-STRAPS
TJ SEATS 23 - 75
REAR SEAT BACK COVER (Continued)
(3) Cl ose the cover zi pper and tuck the zi pper ends
i nto the cover.
(4) I nstal l the rear seat back. (Refer to 23 - BODY/
SEATS/REAR SEAT BACK - I NSTALLATI ON)
REAR SEAT RELEASE CABLE
REMOVAL
(1) Remove the seat. (Refer to 23 - BODY/SEATS/
REAR SEAT - REMOVAL)
(2) Remove the screws and remove the seat back
rel ease handl e bezel . (Fi g. 18)
(3) Rel ease the j-cl i ps at the bottom of the seat
back and remove the seat cover.
(4) Di sconnect the cabl es at the seat back hi nges.
(Fi g. 17)
(5) Posi ti on the seat back cushi on asi de and
remove the screws. (Fi g. 22)
(6) Remove the seat back rel ease cabl e assembl y.
INSTALLATION
(1) I nstal l the seat back rel ease cabl e assembl y
and i nstal l the screws.
(2) Connect the cabl es at the seat back hi nges.
(3) I nstal l the seat cover and engage the j-cl i ps at
the bottom of the seat back.
(4) I nstal l the handl e bezel and i nstal l the screws.
(5) I nstal l the seat. (Refer to 23 - BODY/SEATS/
REAR SEAT - I NSTALLATI ON)
REAR SEAT STRIKERS
REMOVAL
Rear Strikers
(1) Rel ease the seat back and fol d seat assembl y
forward.
(2) Remove the bol ts and remove the stri ker. (Fi g.
23)
Front Strikers
(1) Remove the seat. (Refer to 23 - BODY/SEATS/
REAR SEAT - REMOVAL)
(2) Remove the bol ts and remove the stri ker. (Fi g.
23)
INSTALLATION
Front Strikers
(1) I nstal l the stri ker and i nstal l the bol ts.
(2) Ti ghten the bol ts to 61 N·m (45 ft. l bs.).
(3) I nstal l the seat. (Refer to 23 - BODY/SEATS/
REAR SEAT - I NSTALLATI ON)
Rear Strikers
(1) I nstal l the stri ker and i nstal l the bol ts.
(2) Ti ghten the bol ts to 61 N·m (45 ft. l bs.).
(3) Return the seat to the down posi ti on.
Fig. 22 RELEASE CABLE ASSEMBLY
1 - SEAT BACK FRAME
2 - RELEASE CABLE ASSEMBLY HANDLE
3 - SCREWS
Fig. 23 REAR SEAT STRIKERS
1 - FRONT STRIKER
2 - BOLTS (2 PER STRIKER)
3 - REAR STRIKER
23 - 76 SEATS TJ
REAR SEAT CUSHION COVER (Continued)
STATIONARY GLASS
TABLE OF CONTENTS
page page
STATIONARY GLASS
DESCRIPTION
WINDSHIELD SAFETY PRECAUTIONS . . . . . 77
QUARTER GLASS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 78
WINDSHIELD
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 79
WINDSHIELD HINGE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 80
WINDSHIELD FRAME
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 81
STATIONARY GLASS
DESCRIPTION
WINDSHIELD SAFETY PRECAUTIONS
DESCRIPTION
WARNING: DO NOT OPERATE THE VEHICLE
WITHIN 24 HOURS OF WINDSHIELD INSTALLATION.
IT TAKES AT LEAST 24 HOURS FOR URETHANE
ADHESIVE TO CURE. IF IT IS NOT CURED, THE
WINDSHIELD MAY NOT PERFORM PROPERLY IN
AN ACCIDENT.
• URETHANE ADHESIVES ARE APPLIED AS A
SYSTEM. USE GLASS CLEANER, GLASS PREP
SOLVENT, GLASS PRIMER, PVC (VINYL) PRIMER
AND PINCH WELD (FENCE) PRIMER PROVIDED BY
THE ADHESIVE MANUFACTURER. IF NOT, STRUC-
TURAL INTEGRITY COULD BE COMPROMISED.
• DAIMLERCHRYSLER DOES NOT RECOMMEND
GLASS ADHESIVE BY BRAND. TECHNICIANS
SHOULD REVIEW PRODUCT LABELS AND TECHNI-
CAL DATA SHEETS, AND USE ONLY ADHESIVES
THAT THEIR MANUFACTURES WARRANT WILL
RESTORE A VEHICLE TO THE REQUIREMENTS OF
FMVSS 212. TECHNICIANS SHOULD ALSO INSURE
THAT PRIMERS AND CLEANERS ARE COMPATIBLE
WITH THE PARTICULAR ADHESIVE USED.
• BE SURE TO REFER TO THE URETHANE MAN-
UFACTURER’S DIRECTIONS FOR CURING TIME
SPECIFICATIONS, AND DO NOT USE ADHESIVE
AFTER ITS EXPIRATION DATE.
• VAPORS THAT ARE EMITTED FROM THE URE-
THANE ADHESIVE OR PRIMER COULD CAUSE
PERSONAL INJURY. USE THEM IN A WELL-VENTI-
LATED AREA.
• SKIN CONTACT WITH URETHANE ADHESIVE
SHOULD BE AVOIDED. PERSONAL INJURY MAY
RESULT.
• ALWAYS WEAR EYE AND HAND PROTECTION
WHEN WORKING WITH GLASS.
CAUTION: Protect all painted and trimmed surfaces
from coming in contact with urethane or primers.
Be careful not to damage painted surfaces when
removing moldings or cutting urethane around
windshield.
OPERATION
The wi ndshi el d i s attached to the wi ndow frame
wi th urethane adhesi ve. The urethane adhesi ve i s
appl i ed col d and seal s the surface area between the
wi ndow openi ng and the gl ass. The pri mer adheres
the urethane adhesi ve to the wi ndshi el d.
I t i s di ffi cul t to sal vage a wi ndshi el d duri ng the
removal operati on. The wi ndshi el d i s part of the
structural support for the roof. The urethane bondi ng
used to secure the wi ndshi el d to the fence i s di ffi cul t
to cut or cl ean from any surface. I f the mol di ngs are
set i n urethane, i t woul d al so be unl i kel y they coul d
be sal vaged. Before removi ng the wi ndshi el d, check
the avai l abi l i ty of the wi ndshi el d and mol di ngs from
the parts suppl i er.
QUARTER GLASS
REMOVAL
(1) Cover surface areas wi th protecti ve coveri ng to
avoi d pai nt damage and extra cl ean-up ti me.
(2) Usi ng a razor kni fe, sl i de the bl ade between
the quarter gl ass and the i nboard edge of the reveal
mol di ng.
(3) Cut around the i nteri or peri meter of the reveal
mol di ng and sever the cap of the reveal mol di ng.
TJ STATIONARY GLASS 23 - 77
(4) Usi ng a col d kni fe, cut the urethane around the
peri meter of the quarter gl ass.
(5) Remove the quarter gl ass from the openi ng
(Fi g. 1).
INSTALLATION
(1) Tri m the urethane from the quarter gl ass open-
i ng fence. Leave a 3 mm (0.1 i n.) l evel base of ure-
thane on the quarter gl ass openi ng fence.
(2) Pl ace repl acement quarter gl ass i nto quarter
gl ass openi ng and posi ti on gl ass i n the center of the
openi ng agai nst fence.
(3) Veri fy the gl ass l ays evenl y agai nst the fence at
the si des, top and bottom of the repl acement quarter
gl ass. Next, make al i gnment marks on gl ass and top
wi th a grease penci l .
(4) Remove repl acement quarter gl ass from open-
i ng.
(5) Posi ti on the quarter gl ass i nsi de up on a sui t-
abl e work surface.
WARNING: DO NOT USE SOLVENT BASED GLASS
CLEANER TO CLEAN QUARTER GLASS BEFORE
APPLYING GLASS PREP AND PRIMER. POOR
ADHESION CAN RESULT.
(6) Cl ean i nsi de of quarter gl ass wi th ammoni a
based gl ass cl eaner and l i nt-free cl oth.
(7) Cl ean the outer edge of the wi ndow gl ass wi th
naphtha or a si mi l ar product.
(8) Appl y mol di ng to peri meter of quarter gl ass.
The butt wel d of the mol di ng shoul d be centered at
the bottom edge of the quarter gl ass.
(9) Appl y Gl ass Prep adhesi on promoter 25 mm (1
i n.) wi de around peri meter of the quarter gl ass and
wi pe wi th cl ean/dry l i nt-free cl oth unti l no streaks
are vi si bl e.
(10) Appl y Gl ass Pri mer 25 mm (1 i n.) wi de
around peri meter of quarter gl ass. Al l ow at l east
three mi nutes dryi ng ti me.
(11) Appl y Pi nchwel d pri mer 15 mm (0.75 i n.) wi de
around the quarter gl ass fence. Al l ow at l east three
mi nutes dryi ng ti me.
(12) Appl y a 10 mm (0.4 i n.) di ameter bead of ure-
thane to the center of the quarter gl ass fence surface
area.
CAUTION: Be prepared to install the quarter glass
immediately after applying the adhesive. The adhe-
sive begins to cure within 10-15 minutes.
(13) Al i gn the quarter gl ass wi th the grease penci l
marks and posi ti on quarter gl ass on fence.
(14) Push the quarter gl ass i nward unti l the
reveal mol di ng i s seated on the hardtop. Use care to
avoi d excessi ve squeeze-out of adhesi ve.
(15) Open wi ndows and l i ftgate to prevent pres-
sure bui l d-up whi l e the urethane i s curi ng.
(16) Appl y 150 mm (6 i n.) l engths of 50 mm (2 i n.)
maski ng tape spaced 250 mm (10 i n.) apart to hol d
quarter gl ass i n pl ace unti l urethane cures.
(17) After urethane has cured, remove tape stri ps
and water test quarter gl ass to veri fy repai r.
WINDSHIELD
REMOVAL
The wi ndshi el d i s posi ti oned i n the reveal mol di ng
and i s bonded to the wi ndshi el d frame wi th urethane
adhesi ve. The wi ndshi el d i nteri or tri m mol di ng i s
posi ti oned onto the i nner wi ndshi el d frame pi nch-
wel d.
(1) Cover body surface areas wi th protecti ve cover-
i ng to avoi d pai nt damage and extra cl ean-up ti me.
(2) Remove the wi ndshi el d wi per arms. (Refer to 8
- ELECTRI CAL/WI PERS/WASHERS/WI PER ARMS -
REMOVAL)
(3) Remove the rear vi ew mi rror. (Refer to 23 -
BODY/I NTERI OR/REAR VI EW MI RROR -
REMOVAL)
(4) Usi ng a razor kni fe, sl i de the bl ade between
the wi ndshi el d gl ass and the i nboard edge of the
reveal mol di ng.
(5) Cut around the i nteri or peri meter of the reveal
mol di ng and sever the cap of the reveal mol di ng.
(6) Usi ng a col d kni fe, cut the urethane around the
peri meter of the wi ndshi el d.
(7) Remove the wi ndshi el d gl ass from the frame
(Fi g. 2).
Fig. 1 HARD TOP QUARTER GLASS
1 - HARD TOP
2 - QUARTER GLASS REVEAL MOLDING
3 - QUARTER GLASS
23 - 78 STATIONARY GLASS TJ
QUARTER GLASS (Continued)
INSTALLATION
(1) Tri m the urethane from the pi nchwel d fl anges.
Leave a 3 mm (0.1 i n.) l evel base of urethane on the
pi nchwel d fl anges.
(2) Pl ace repl acement wi ndshi el d i nto wi ndshi el d
openi ng and posi ti on gl ass i n the center of the open-
i ng agai nst pi nchwel d fl ange.
(3) Veri fy the gl ass l ays evenl y agai nst the pi nch
wel d fence at the si des, top and bottom of the
repl acement wi ndshi el d. I f not, the pi nchwel d fl ange
must be formed to the shape of the new gl ass. Next,
make al i gnment marks on gl ass and body wi th a
grease penci l .
(4) Remove repl acement wi ndshi el d from wi nd-
shi el d openi ng.
(5) Posi ti on the wi ndshi el d i nsi de up on a sui tabl e
work surface wi th two padded, wood 10 cm by 10 cm
by 50 cm (4 i n. by 4 i n. by 20 i n.) bl ocks, pl aced par-
al l el 75 cm (2.5 ft.) apart (Fi g. 3).
WARNING: DO NOT USE SOLVENT BASED GLASS
CLEANER TO CLEAN WINDSHIELD BEFORE
APPLYING GLASS PREP AND PRIMER. POOR
ADHESION CAN RESULT.
(6) Cl ean i nsi de of wi ndshi el d wi th ammoni a based
gl ass cl eaner and l i nt-free cl oth.
(7) Appl y mol di ng to peri meter of wi ndshi el d. The
butt wel d of the mol di ng shoul d be centered at the
bottom edge of the wi ndshi el d.
(8) Appl y Gl ass Prep adhesi on promoter 25 mm (1
i n.) wi de around peri meter of wi ndshi el d and wi pe
wi th cl ean/dry l i nt-free cl oth unti l no streaks are vi s-
i bl e.
(9) Appl y Gl ass Pri mer 25 mm (1 i n.) wi de around
peri meter of wi ndshi el d. Al l ow at l east three mi nutes
dryi ng ti me.
(10) Appl y Pi nchwel d pri mer 15 mm (.75 i n.) wi de
around the wi ndshi el d fence. Al l ow at l east three
mi nutes dryi ng ti me.
(11) Appl y a urethane bead (Fi g. 4) on the pi nch-
wel d fl ange surface area 6 mm (.25 i n.) from the out-
board edge.
CAUTION: Be prepared to install the windshield
glass immediately after applying the adhesive. The
adhesive begins to cure within 10-15 minutes.
(12) Al i gn the wi ndshi el d wi th the grease penci l
marks and posi ti on wi ndshi el d on pi nchwel d fl anges.
(13) Push the wi ndshi el d gl ass i nward unti l the
reveal mol di ng i s seated on the wi ndshi el d frame.
Use care to avoi d excessi ve squeeze-out of adhesi ve.
(14) Open wi ndows and l i ftgate to prevent pres-
sure bui l d-up whi l e the urethane i s curi ng.
(15) Starti ng i n each corner, appl y 150 mm (6 i n.)
l engths of 50 mm (2 i n.) maski ng tape spaced 250
mm (10 i n.) apart to hol d wi ndshi el d i n pl ace unti l
urethane cures.
(16) I nstal l the rear vi ew mi rror support bracket.
(Refer to 23 - BODY/I NTERI OR/REAR VI EW MI R-
ROR SUPPORT BRACKET - I NSTALLATI ON)
(17) I nstal l the rear vi ew mi rror. (Refer to 23 -
BODY/I NTERI OR/REAR VI EW MI RROR - I NSTAL-
LATI ON)
(18) I nstal l the wi per arms. (Refer to 8 - ELEC-
TRI CAL/WI PERS/WASHERS/WI PER ARMS -
I NSTALLATI ON)
(19) After urethane has cured, remove tape stri ps
and water test wi ndshi el d to veri fy repai r.
Fig. 2 WINDSHIELD
1 - WINDSHIELD
2 - INNER TRIM MOLDING
3 - WINDSHIELD FRAME
4 - WINDSHIELD MOLDING
Fig. 3 WORK SURFACE SET UP AND MOLDING
INSTALLATION
1 - WINDSHIELD AND MOLDINGS
2 - BLOCKS
TJ STATIONARY GLASS 23 - 79
WINDSHIELD (Continued)
WINDSHIELD HINGE
REMOVAL
NOTE: If both hinges are to be replaced, the wind-
shield must be tilted to the full forward position.
(Refer to 23 - BODY/STATIONARY GLASS/WIND-
SHIELD - REMOVAL)
(1) Remove door. (Refer to 23 - BODY/DOOR -
FRONT/DOOR - REMOVAL)
(2) Remove the bol ts attachi ng the hi nge to the
cowl (Fi g. 5).
(3) Remove the bol ts attachi ng the hi nge to the
wi ndshi el d frame.
(4) Separate the hi nge from the vehi cl e.
INSTALLATION
(1) Pai nt as requi red.
(2) Cl ean the contact surface of the hi nge and cowl
wi th i sopropyl al cohol or equi val ent.
(3) Appl y a 4 mm bead of Mopar௡ Vi nyl Acryl i c
Seal ant or equi val ent around the peri meter of the
hi nge contact surface. The bead shoul d be 10 mm
i nboard of the edge.
(4) Posi ti on the hi nge on the vehi cl e.
(5) I nstal l the bol ts attachi ng the hi nge to the
wi ndshi el d frame.
(6) I nstal l the bol ts attachi ng the hi nge to the
cowl .
(7) Ensure that the seal ant provi des compl ete cov-
erage. Wi pe away excess seal ant.
(8) I nstal l door. (Refer to 23 - BODY/DOOR -
FRONT/DOOR - I NSTALLATI ON)
WINDSHIELD FRAME
REMOVAL
(1) Unl atch top.
(2) Remove the bol ts attachi ng the sport bar to the
wi ndshi el d frame.
(3) Remove the wi ndshi el d wi per arms. (Refer to 8
- ELECTRI CAL/WI PERS/WASHERS/WI PER ARMS -
REMOVAL)
(4) Remove the torx screw cl osest to the hi nge
pi vot poi nt and ti l t the wi ndshi el d forward.
(5) Remove the torx screws attachi ng the wi nd-
shi el d hi nge to the wi ndshi el d frame (Fi g. 6).
(6) Separate the wi ndshi el d frame from the vehi -
cl e.
Fig. 4 URETHANE BEAD
1 - WINDSHIELD
2 - MOLDING
3 - URETHANE BEAD
Fig. 5 WINDSHIELD HINGE
1 - COWL
2 - WINDSHIELD
3 - WINDSHIELD HINGE
Fig. 6 WINDSHIELD FRAME
1 - WINDSHIELD HOLD DOWN LOOP
2 - WINDSHIELD HINGE
23 - 80 STATIONARY GLASS TJ
WINDSHIELD (Continued)
INSTALLATION
NOTE: Inspect windshield to cowl seal for damage
and confirm correct position.
(1) Posi ti on the wi ndshi el d frame on the vehi cl e.
(2) I nstal l the torx screws attachi ng the wi nd-
shi el d hi nge to the wi ndshi el d frame.
(3) Ti l t the wi ndshi el d rearward.
(4) I nstal l the torx screw cl osest to the hi nge pi vot
poi nt and l ock the wi ndshi el d i n the upri ght posi ti on.
(5) I nstal l the wi ndshi el d wi per arms. (Refer to 8 -
ELECTRI CAL/WI PERS/WASHERS/WI PER ARMS -
I NSTALLATI ON)
(6) I nstal l the bol ts attachi ng the sport bar to the
wi ndshi el d frame.
(7) Latch top.
TJ STATIONARY GLASS 23 - 81
WINDSHIELD FRAME (Continued)
WEATHERSTRIP/SEALS
TABLE OF CONTENTS
page page
HOOD TO COWL WEATHERSTRIP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 82
FULL DOOR INNER BELT WEATHERSTRIP
DESCRIPTION - FULL DOOR INNER BELT
WEATHERSTRIP . . . . . . . . . . . . . . . . . . . . . . 82
FULL DOOR OUTER BELT SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 83
FULL DOOR WEATHERSTRIP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 83
HALF DOOR WEATHERSTRIP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 83
TAILGATE WEATHERSTRIP AND CHANNEL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 84
WINDSHIELD FRAME WEATHERSTRIP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 84
HOOD TO COWL
WEATHERSTRIP
REMOVAL
(1) Careful l y separate the weatherstri p from the
cowl fl ange (Fi g. 1).
INSTALLATION
(1) Posi ti on the weatherstri p on the cowl fl ange
and press i t i nto pl ace.
FULL DOOR INNER BELT
WEATHERSTRIP
DESCRIPTION - FULL DOOR INNER BELT
WEATHERSTRIP
The i nner bel t weatherstri p i s attached to the door
tri m panel and i s not servi ceabl e. I f the i nner bel t
weatherstri p needs to be repl aced, repl ace the door
tri m panel .
FULL DOOR OUTER BELT
SEAL
REMOVAL
(1) Remove the door sai l panel .
(2) Di sengage the cl i ps attachi ng the outer bel t
seal to the door (Fi g. 2).
(3) Separate the seal from the door.
Fig. 1 HOOD TO COWL WEATHERSTRIP
1 - COWL
2 - COWL FLANGE
3 - COWL PLENUM DRAIN
4 - HOOD TO COWL WEATHERSTRIP
23 - 82 WEATHERSTRIP/SEALS TJ
INSTALLATION
(1) Posi ti on the seal on the door.
(2) Engage the cl i ps attachi ng the outer bel t seal
to the door.
(3) I nstal l the door sai l panel .
FULL DOOR WEATHERSTRIP
REMOVAL
NOTE: The upper portion of the weatherstrip is
seated into a channel around the window opening
frame. The lower portion of the weatherstrip is
attached to the door with push-in fasteners.
(1) Peel the weatherstri p from the channel .
(2) Remove the push-i n fasteners attachi ng the
weatherstri p to the door (Fi g. 3).
INSTALLATION
(1) Posi ti on the l ower part of the weatherstri p and
seat the push-i n fasteners ful l y.
(2) I nstal l the weatherstri p i n the upper weather-
stri p channel seat ful l y.
HALF DOOR WEATHERSTRIP
REMOVAL
NOTE: The weatherstrip is attached to the door with
push-in fasteners.
(1) Remove tri m panel . (Refer to 23 - BODY/HALF
DOOR/TRI M PANEL - REMOVAL)
(2) Remove wi ndow retai ni ng sl eeve.
(3) Remove the push-i n fasteners attachi ng the
weatherstri p to the door. (Fi g. 4)
INSTALLATION
NOTE: The weatherstrip is attached to the door with
push-in fasteners.
(1) Posi ti on the weatherstri p onto the door and
seat the push-i n fasteners ful l y.
(2) I nstal l wi ndow retai ni ng sl eeve.
Fig. 2 FULL DOOR OUTER BELT SEAL
1 - OUTER BELTLINE WEATHERSTRIP
2 - OUTSIDE DOOR HANDLE
3 - CLIPS
Fig. 3 FULL DOOR WEATHERSTRIP
1 - FULL DOOR
2 - WEATHERSTRIP
3 - WATERDAM
4 - OUTER DOOR BELT SEAL
TJ WEATHERSTRIP/SEALS 23 - 83
FULL DOOR OUTER BELT SEAL (Continued)
(3) I nstal l tri m panel . (Refer to 23 - BODY/HALF
DOOR/TRI M PANEL - I NSTALLATI ON)
TAILGATE WEATHERSTRIP
AND CHANNEL
REMOVAL
(1) Open the tai l gate.
(2) Remove the push-i n fasteners attachi ng the
weatherstri p to the top corners of the tai l gate (Fi g. 5).
(3) Peel the weatherstri p from the upper tai l gate
corners.
(4) Sl i de the weatherstri p out of the tai l gate channel .
(5) I f the weatherstri p channel requi res repl ace-
ment, peel the weatherstri p channel from the tai l gate.
INSTALLATION
(1) I f the weatherstri p channel i s bei ng repl aced;
(a) Cl ean the channel contact surface on the tai l -
gate wi th i sopropyl al cohol , or equi val ent.
(b) Peel the paper backi ng from the weatherstri p
channel .
(c) I nstal l the push pi n fasteners attachi ng the
weatherstri p to the tai l gate.
(d) Posi ti on weatherstri p channel to the tai l gate
and press i nto pl ace.
(e) Use hand pressure or a rol l er to wet out the
tape adhesi ve hol di ng the weatherstri p channel to
the tai l gate.
(2) I nstal l the push pi n fasteners attachi ng the
weatherstri p to the tai l gate.
(3) Sl i de the weatherstri p i nto the weatherstri p
channel .
WINDSHIELD FRAME
WEATHERSTRIP
REMOVAL
UPPER (Header)
(1) Di sconnect the top from the wi ndshi el d frame.
(2) Di sengage the push-i n fasteners attachi ng the
weatherstri p to the wi ndshi el d frame.
(3) Peel the weatherstri p from the frame.
LOWER
NOTE: The lower windshield frame weatherstrip can
be removed with the frame tilted forward to the full
horizontal position.
(1) Remove the wi per arms. (Refer to 8 - ELEC-
TRI CAL/WI PERS/WASHERS/WI PER ARMS -
REMOVAL)
(2) Di sconnect the top from the wi ndshi el d frame.
(3) Remove the cowl gri l l e. (Refer to 23 - BODY/
EXTERI OR/COWL GRI LLE AND SCREEN -
REMOVAL)
(4) Remove the torx screws on each si de of the
wi ndshi el d frame al l owi ng the wi ndshi el d frame to
ti l t to the ful l hori zontal posi ti on.
(5) Di sengage the outboard push-i n fasteners at
the top of cowl on each hi nge pi l l ar (Fi g. 6).
(6) Remove the weatherstri p from the cowl .
INSTALLATION
UPPER (Header)
(1) Cl ean the seal contact surface on the wi nd-
shi el d frame wi th i sopropyl al cohol or equi val ent.
Fig. 4 HALF DOOR WEATHERSTRIP
1 - HALF DOOR
2 - WEATHERSTRIP
Fig. 5 TAILGATE WEATHERSTRIP
1 - TAILGATE
2 - WEATHERSTRIP
23 - 84 WEATHERSTRIP/SEALS TJ
HALF DOOR WEATHERSTRIP (Continued)
NOTE: Ensure that the contact surface is dry and
free from any residue, poor adhesion will result.
(2) Posi ti on the weatherstri p on the wi ndshi el d
frame, al i gn the push-i n fasteners and press i t i nto
pl ace (Fi g. 6).
(3) Remove adhesi ve backi ng from the bottom of
the weatherstri p.
(4) Usi ng forceful hand pressure, seat the adhesi ve
on the contact surface.
NOTE: If tape surface becomes contaminated, it will
not adhere to the windshield frame.
(5) Connect the top to the wi ndshi el d frame.
LOWER
(1) Posi ti on the weatherstri p on the cowl .
(2) Al i gn the outer push-i n fasteners and press
them i nto pl ace.
(3) Ti l t the wi ndshi el d frame rearward to the ful l
verti cal posi ti on.
NOTE: Ensure weatherstrip outer detail mates with
the a-pillar trim. Outer detail must be flush with trim
surface for proper sealing performance.
(4) I nstal l the torx screws on each si de of the
wi ndshi el d securi ng the wi ndshi el d frame.
(5) Connect the top to the wi ndshi el d frame.
(6) I nstal l cowl gri l l e. (Refer to 23 - BODY/EXTE-
RI OR/COWL GRI LLE AND SCREEN - I NSTALLA-
TI ON)
(7) I nstal l the wi per arms. (Refer to 8 - ELECTRI -
CAL/WI PERS/WASHERS/WI PER ARMS - I NSTAL-
LATI ON)
Fig. 6 WINDSHIELD FRAME WEATHERSTRIP
1 - WINDSHIELD FRAME
2 - UPPER HEADER WEATHERSTRIP
3 - PUSH-IN FASTENER
4 - WINDSHIELD TO COWL WEATHERSTRIP
5 - COWL
6 - VIEW OF ARROW Y
7 - PUSH-IN FASTENERS (2 per end)
TJ WEATHERSTRIP/SEALS 23 - 85
WINDSHIELD FRAME WEATHERSTRIP (Continued)
BODY STRUCTURE
TABLE OF CONTENTS
page page
GAP AND FLUSH
SPECIFICATIONS - GAP AND FLUSH . . . . . . . . 86
OPENING DIMENSIONS
SPECIFICATIONS
BODY OPENING DIMENSIONS . . . . . . . . . . . 89
SEALER LOCATIONS
SPECIFICATIONS
SEALER LOCATIONS . . . . . . . . . . . . . . . . . . 94
STRUCTURAL ADHESIVE LOCATIONS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . 111
WELD LOCATIONS
SPECIFICATIONS
WELD LOCATIONS . . . . . . . . . . . . . . . . . . . 120
GAP AND FLUSH
SPECIFICATIONS - GAP AND FLUSH
INDEX
DESCRIPTION FIGURE
FRONT/SIDE DIMENSIONS 1
REAR/SIDE DIMENSIONS 2
23 - 86 BODY STRUCTURE TJ
Fig. 1 FRONT/SIDE DIMENSIONS
TJ BODY STRUCTURE 23 - 87
GAP AND FLUSH (Continued)
Fig. 2 REAR/SIDE DIMENSIONS
23 - 88 BODY STRUCTURE TJ
GAP AND FLUSH (Continued)
OPENING DIMENSIONS
SPECIFICATIONS
BODY OPENING DIMENSIONS
INDEX
DESCRIPTION FIGURE
WINDSHIELD OPENING 3
DOOR OPENING 4
QUARTER WINDOW OPENING 5
ENGINE COMPARTMENT 6
TAILGATE AND LIFTGATE OPENING 7
• A & B. Center of radi us at bottom to center of
radi us top.
Fig. 3 WINDSHIELD OPENING
TJ BODY STRUCTURE 23 - 89
• A. Center of radi us at bottom front to center of
radi us at top rear.
• B. Center of door l ower rear corner to center of
top of wi ndshi el d frame.
• C. Center of door l ower rear corner to top of
cowl .
• D. Center of door hi nge mount to center of door
stri ker mount.
Fig. 4 DOOR OPENING
23 - 90 BODY STRUCTURE TJ
OPENING DIMENSIONS (Continued)
Fig. 5 QUARTER WINDOW OPENING
TJ BODY STRUCTURE 23 - 91
OPENING DIMENSIONS (Continued)
Fig. 6 ENGINE COMPARTMENT
23 - 92 BODY STRUCTURE TJ
OPENING DIMENSIONS (Continued)
• A. Center of l i ftgate openi ng to fl oor.
• B. Center of radi us upper corner to center of
body and fl oor corner.
• C. Li ftgate openi ng di stance.
• D. Tai l gate openi ng di stance.
Fig. 7 TAILGATE AND LIFTGATE OPENING
TJ BODY STRUCTURE 23 - 93
OPENING DIMENSIONS (Continued)
SEALER LOCATIONS
SPECIFICATIONS
SEALER LOCATIONS
DESCRIPTION FIGURE
APPLICATION METHODS 8
COWL AND PLENUM 9
COWL TOP END AND PLENUM 10
COWL AND WINDSHIELD OUTER PANEL 11
INNER WHEELHOUSE 12
REAR FLOOR RISER AND OUTER BODY SEAMS 13
REAR CORNER PANEL 14
HALF DOOR 15
FULL DOOR 16
DASH COWL AND PLENUM 17
DASH, COWL AND PLENUM 18
DASH, COWL AND PLENUM 19
DASH, COWL AND PLENUM 20
DASH, COWL AND PLENUM SUPPORTS AND REINFORCEMENTS 21
DASH, COWL AND PLENUM SUPPORTS AND REINFORCEMENTS 22
FRONT FLOOR, STRAINER, REINFORCEMENT AND COWL SIDE LOWER 23
BODY SIDE APERTURE 24
WHEELHOUSE 25
COWL AND PLENUM 26
REAR FLOOR AND OUTER BODY SEAMS 27
23 - 94 BODY STRUCTURE TJ
Fig. 8 APPLICATION METHODS
TJ BODY STRUCTURE 23 - 95
SEALER LOCATIONS (Continued)
Fig. 9 COWL AND PLENUM
23 - 96 BODY STRUCTURE TJ
SEALER LOCATIONS (Continued)
Fig. 10 COWL TOP END AND PLENUM
TJ BODY STRUCTURE 23 - 97
SEALER LOCATIONS (Continued)
Fig. 11 COWL AND WINDSHIELD OUTER PANEL
Fig. 12 INNER WHEELHOUSE
23 - 98 BODY STRUCTURE TJ
SEALER LOCATIONS (Continued)
Fig. 13 REAR FLOOR RISER AND OUTER BODY SEAMS
Fig. 14 REAR CORNER PANEL
TJ BODY STRUCTURE 23 - 99
SEALER LOCATIONS (Continued)
Fig. 15 HALF DOOR
Fig. 16 FULL DOOR
23 - 100 BODY STRUCTURE TJ
SEALER LOCATIONS (Continued)
Fig. 17 DASH COWL AND PLENUM
TJ BODY STRUCTURE 23 - 101
SEALER LOCATIONS (Continued)
Fig. 18 DASH, COWL AND PLENUM
23 - 102 BODY STRUCTURE TJ
SEALER LOCATIONS (Continued)
Fig. 19 DASH, COWL AND PLENUM
TJ BODY STRUCTURE 23 - 103
SEALER LOCATIONS (Continued)
Fig. 20 DASH, COWL AND PLENUM
23 - 104 BODY STRUCTURE TJ
SEALER LOCATIONS (Continued)
Fig. 21 DASH, COWL AND PLENUM SUPPORTS AND REINFORCEMENTS
TJ BODY STRUCTURE 23 - 105
SEALER LOCATIONS (Continued)
Fig. 22 DASH, COWL AND PLENUM SUPPORTS AND REINFORCEMENTS
23 - 106 BODY STRUCTURE TJ
SEALER LOCATIONS (Continued)
Fig. 23 FRONT FLOOR, STRAINER, REINFORCEMENT AND COWL SIDE LOWER
TJ BODY STRUCTURE 23 - 107
SEALER LOCATIONS (Continued)
Fig. 24 BODY SIDE APERTURE
23 - 108 BODY STRUCTURE TJ
SEALER LOCATIONS (Continued)
Fig. 25 WHEELHOUSE
Fig. 26 COWL AND PLENUM
TJ BODY STRUCTURE 23 - 109
SEALER LOCATIONS (Continued)
Fig. 27 REAR FLOOR AND OUTER BODY SEAMS
23 - 110 BODY STRUCTURE TJ
SEALER LOCATIONS (Continued)
STRUCTURAL ADHESIVE
LOCATIONS
SPECIFICATIONS
INDEX
DESCRIPTION FIGURE
BODY SIDE APERTURE 28
WHEELHOUSE 29
DOOR OUTER PANELS 30
REAR FLOOR PAN 31
HOOD ASSEMBLY 32
TAIL GATE 33
BODY SIDE/WHEELHOUSE LONG WHEEL BASE (LWB) 34
REAR FLOOR LWB 35
UNDERBODY LWB 36
BODY SIDE COMPLETE LWB 37
BODY COMPLETE LWB 38
TJ BODY STRUCTURE 23 - 111
Fig. 28 BODY SIDE APERTURE
23 - 112 BODY STRUCTURE TJ
STRUCTURAL ADHESIVE LOCATIONS (Continued)
Fig. 29 WHEELHOUSE
Fig. 30 DOOR OUTER PANELS
TJ BODY STRUCTURE 23 - 113
STRUCTURAL ADHESIVE LOCATIONS (Continued)
Fig. 31 REAR FLOOR PAN
Fig. 32 HOOD ASSEMBLY
23 - 114 BODY STRUCTURE TJ
STRUCTURAL ADHESIVE LOCATIONS (Continued)
Fig. 33 TAIL GATE
TJ BODY STRUCTURE 23 - 115
STRUCTURAL ADHESIVE LOCATIONS (Continued)
Fig. 34 BODY SIDE/WHEELHOUSE LONG WHEEL BASE (LWB)
23 - 116 BODY STRUCTURE TJ
STRUCTURAL ADHESIVE LOCATIONS (Continued)
Fig. 35 REAR FLOOR LWB
Fig. 36 UNDERBODY LWB
TJ BODY STRUCTURE 23 - 117
STRUCTURAL ADHESIVE LOCATIONS (Continued)
Fig. 37 BODY SIDE COMPLETE LWB
23 - 118 BODY STRUCTURE TJ
STRUCTURAL ADHESIVE LOCATIONS (Continued)
Fig. 38 BODY COMPLETE LWB
TJ BODY STRUCTURE 23 - 119
STRUCTURAL ADHESIVE LOCATIONS (Continued)
WELD LOCATIONS
SPECIFICATIONS
WELD LOCATIONS
DESCRIPTION FIGURE
CROSSMEMBERS/STRAINERS 39
FRONT FLOOR PAN (1 OF 3) 40
FRONT FLOOR PAN (2 OF 3) 41
FRONT FLOOR PAN (3 OF 3) 42
REAR FLOOR PAN (1 OF 2) 43
REAR FLOOR PAN (2 OF 2) 44
DASH PANEL - LEFT HAND DRIVE 45
COWL ASSEMBLY - LEFT HAND DRIVE (1 OF 3) 46
COWL ASSEMBLY - LEFT HAND DRIVE (2 OF 3) 47
COWL ASSEMBLY - LEFT HAND DRIVE (3 OF 3) 48
DASH COWL ASSEMBLY - LEFT HAND DRIVE 49
WINDSHIELD FRAME 50
DASH PANEL - RIGHT HAND DRIVE 51
COWL ASSEMBLY - RIGHT HAND DRIVE (1 OF 3) 52
COWL ASSEMBLY - RIGHT HAND DRIVE (2 OF 3) 53
COWL ASSEMBLY - RIGHT HAND DRIVE (3 OF 3) 54
DASH COWL ASSEMBLY - RIGHT HAND DRIVE 55
BODY SIDE ASSEMBLY 56
WHEELHOUSE ASSEMBLY 57
SPORT BAR ASSEMBLY (ROLL BAR) 58
HALF DOOR ASSEMBLY 59
FULL DOOR ASSEMBLY (1 OF 2) 60
FULL DOOR ASSEMBLY (2 OF 2) 61
FRONT FENDER ASSEMBLY 62
HOOD ASSEMBLY 63
TAILGATE ASSEMBLY 64
RADIATOR GUARD ASSEMBLY 65
DASH, COWL AND FLOOR ASSEMBLY - LEFT HAND DRIVE 66
DASH, COWL AND FLOOR ASSEMBLY - RIGHT HAND DRIVE 67
FRONT AND REAR FLOOR PAN 68
BODY SIDE (1 OF 2) 69
BODY SIDE (2 OF 2) 70
BODY COMPLETE (1 OF 4) 71
BODY COMPLETE (2 OF 4) 72
BODY COMPLETE (3 OF 4) 73
BODY COMPLETE (4 OF 4) 74
BODY COMPLETE LONG WHEEL BASE (LWB) (1 OF 3) 75
23 - 120 BODY STRUCTURE TJ
DESCRIPTION FIGURE
BODY COMPLETE LWB (2 OF 3) 76
BODY COMPLETE LWB (3 OF 3 77
REAR FLOOR LWB (1 OF 3) 78
REAR FLOOR LWB (2 OF 3) 79
REAR FLOOR LWB (3 OF 3) 80
UNDERBODY COMPLETE LWB (1 OF 3) 81
UNDERBODY COMPLETE LWB (2 OF 3) 82
UNDERBODY COMPLETE LWB (3 OF 3) 83
BODY SIDE COMPLETE LWB (1 OF 2) 84
BODY SIDE COMPLETE LWB (2 OF 2) 85
BODY COMPLETE LWB (1 OF 4) 86
BODY COMPLETE LWB (2 OF 4) 87
BODY COMPLETE LWB (3 OF 4) 88
BODY COMPLETE LWB (4 OF 4) 89
TJ BODY STRUCTURE 23 - 121
WELD LOCATIONS (Continued)
Fig. 39 CROSSMEMBERS/STRAINERS
23 - 122 BODY STRUCTURE TJ
WELD LOCATIONS (Continued)
F
i
g
.
4
0
F
R
O
N
T
F
L
O
O
R
P
A
N
(
1
O
F
3
)
TJ BODY STRUCTURE 23 - 123
WELD LOCATIONS (Continued)
F
i
g
.
4
1
F
R
O
N
T
F
L
O
O
R
P
A
N
(
2
O
F
3
)
23 - 124 BODY STRUCTURE TJ
WELD LOCATIONS (Continued)
Fig. 42 FRONT FLOOR PAN (3 OF 3)
TJ BODY STRUCTURE 23 - 125
WELD LOCATIONS (Continued)
Fig. 43 REAR FLOOR PAN (1 OF 2)
23 - 126 BODY STRUCTURE TJ
WELD LOCATIONS (Continued)
Fig. 44 REAR FLOOR PAN (2 OF 2)
TJ BODY STRUCTURE 23 - 127
WELD LOCATIONS (Continued)
Fig. 45 DASH PANEL - LEFT HAND DRIVE
23 - 128 BODY STRUCTURE TJ
WELD LOCATIONS (Continued)
F
i
g
.
4
6
C
O
W
L
A
S
S
E
M
B
L
Y
-
L
E
F
T
H
A
N
D
D
R
I
V
E
(
1
O
F
3
)
TJ BODY STRUCTURE 23 - 129
WELD LOCATIONS (Continued)
Fig. 47 COWL ASSEMBLY - LEFT HAND DRIVE (2 OF 3)
23 - 130 BODY STRUCTURE TJ
WELD LOCATIONS (Continued)
Fig. 48 COWL ASSEMBLY - LEFT HAND DRIVE (3 OF 3)
TJ BODY STRUCTURE 23 - 131
WELD LOCATIONS (Continued)
Fig. 49 DASH COWL ASSEMBLY - LEFT HAND DRIVE
23 - 132 BODY STRUCTURE TJ
WELD LOCATIONS (Continued)
Fig. 50 WINDSHIELD FRAME
TJ BODY STRUCTURE 23 - 133
WELD LOCATIONS (Continued)
Fig. 51 DASH PANEL - RIGHT HAND DRIVE
23 - 134 BODY STRUCTURE TJ
WELD LOCATIONS (Continued)
F
i
g
.
5
2
C
O
W
L
A
S
S
E
M
B
L
Y
-
R
I
G
H
T
H
A
N
D
D
R
I
V
E
(
1
O
F
3
)
TJ BODY STRUCTURE 23 - 135
WELD LOCATIONS (Continued)
Fig. 53 COWL ASSEMBLY - RIGHT HAND DRIVE (2 OF 3)
23 - 136 BODY STRUCTURE TJ
WELD LOCATIONS (Continued)
Fig. 54 COWL ASSEMBLY - RIGHT HAND DRIVE (3 OF 3)
TJ BODY STRUCTURE 23 - 137
WELD LOCATIONS (Continued)
Fig. 55 DASH COWL ASSEMBLY - RIGHT HAND DRIVE
23 - 138 BODY STRUCTURE TJ
WELD LOCATIONS (Continued)
Fig. 56 BODY SIDE ASSEMBLY
TJ BODY STRUCTURE 23 - 139
WELD LOCATIONS (Continued)
Fig. 57 WHEELHOUSE ASSEMBLY
23 - 140 BODY STRUCTURE TJ
WELD LOCATIONS (Continued)
Fig. 58 SPORT BAR ASSEMBLY
TJ BODY STRUCTURE 23 - 141
WELD LOCATIONS (Continued)
Fig. 59 HALF DOOR ASSEMBLY
23 - 142 BODY STRUCTURE TJ
WELD LOCATIONS (Continued)
Fig. 60 FULL DOOR ASSEMBLY (1 OF 2)
TJ BODY STRUCTURE 23 - 143
WELD LOCATIONS (Continued)
Fig. 61 FULL DOOR ASSEMBLY (2 OF 2)
23 - 144 BODY STRUCTURE TJ
WELD LOCATIONS (Continued)
Fig. 62 FRONT FENDER ASSEMBLY
TJ BODY STRUCTURE 23 - 145
WELD LOCATIONS (Continued)
Fig. 63 HOOD ASSEMBLY
23 - 146 BODY STRUCTURE TJ
WELD LOCATIONS (Continued)
Fig. 64 TAILGATE ASSEMBLY
TJ BODY STRUCTURE 23 - 147
WELD LOCATIONS (Continued)
Fig. 65 RADIATOR GUARD ASSEMBLY
23 - 148 BODY STRUCTURE TJ
WELD LOCATIONS (Continued)
F
i
g
.
6
6
D
A
S
H
,
C
O
W
L
A
N
D
F
L
O
O
R
A
S
S
E
M
B
L
Y
-
L
E
F
T
H
A
N
D
D
R
I
V
E
TJ BODY STRUCTURE 23 - 149
WELD LOCATIONS (Continued)
F
i
g
.
6
7
D
A
S
H
,
C
O
W
L
A
N
D
F
L
O
O
R
A
S
S
E
M
B
L
Y
-
R
I
G
H
T
H
A
N
D
D
R
I
V
E
23 - 150 BODY STRUCTURE TJ
WELD LOCATIONS (Continued)
Fig. 68 FRONT AND REAR FLOOR PAN
TJ BODY STRUCTURE 23 - 151
WELD LOCATIONS (Continued)
Fig. 69 BODY SIDE (1 OF 2)
23 - 152 BODY STRUCTURE TJ
WELD LOCATIONS (Continued)
Fig. 70 BODY SIDE (2 OF 2)
TJ BODY STRUCTURE 23 - 153
WELD LOCATIONS (Continued)
F
i
g
.
7
1
B
O
D
Y
C
O
M
P
L
E
T
E
(
1
O
F
4
)
23 - 154 BODY STRUCTURE TJ
WELD LOCATIONS (Continued)
F
i
g
.
7
2
B
O
D
Y
C
O
M
P
L
E
T
E
(
2
O
F
4
)
TJ BODY STRUCTURE 23 - 155
WELD LOCATIONS (Continued)
F
i
g
.
7
3
B
O
D
Y
C
O
M
P
L
E
T
E
(
3
O
F
4
)
23 - 156 BODY STRUCTURE TJ
WELD LOCATIONS (Continued)
Fig. 74 BODY COMPLETE (4 OF 4)
TJ BODY STRUCTURE 23 - 157
WELD LOCATIONS (Continued)
Fig. 75 BODY COMPLETE LONG WHEEL BASE (LWB) (1 OF 3)
23 - 158 BODY STRUCTURE TJ
WELD LOCATIONS (Continued)
Fig. 76 BODY COMPLETE LWB (2 OF 3)
TJ BODY STRUCTURE 23 - 159
WELD LOCATIONS (Continued)
Fig. 77 BODY COMPLETE LWB (3 OF 3)
23 - 160 BODY STRUCTURE TJ
WELD LOCATIONS (Continued)
Fig. 78 REAR FLOOR LWB (1 OF 3)
TJ BODY STRUCTURE 23 - 161
WELD LOCATIONS (Continued)
Fig. 79 REAR FLOOR LWB (2 OF 3)
23 - 162 BODY STRUCTURE TJ
WELD LOCATIONS (Continued)
Fig. 80 REAR FLOOR LWB (3 OF 3)
TJ BODY STRUCTURE 23 - 163
WELD LOCATIONS (Continued)
Fig. 81 UNDERBODY COMPLETE LWB (1 OF 3)
23 - 164 BODY STRUCTURE TJ
WELD LOCATIONS (Continued)
Fig. 82 UNDERBODY COMPLETE LWB (2 OF 3)
TJ BODY STRUCTURE 23 - 165
WELD LOCATIONS (Continued)
Fig. 83 UNDERBODY COMPLETE LWB (3 OF 3)
23 - 166 BODY STRUCTURE TJ
WELD LOCATIONS (Continued)
Fig. 84 BODY SIDE COMPLETE LWB (1 OF 2)
TJ BODY STRUCTURE 23 - 167
WELD LOCATIONS (Continued)
Fig. 85 BODY SIDE COMPLETE LWB (2 OF 2)
23 - 168 BODY STRUCTURE TJ
WELD LOCATIONS (Continued)
F
i
g
.
8
6
B
O
D
Y
C
O
M
P
L
E
T
E
L
W
B
(
1
O
F
4
)
TJ BODY STRUCTURE 23 - 169
WELD LOCATIONS (Continued)
Fig. 87 BODY COMPLETE LWB (2 OF 4)
Fig. 88 BODY COMPLETE LWB (3 OF 4)
23 - 170 BODY STRUCTURE TJ
WELD LOCATIONS (Continued)
Fig. 89 BODY COMPLETE LWB (4 OF 4)
TJ BODY STRUCTURE 23 - 171
WELD LOCATIONS (Continued)
HEATING & AIR CONDITIONING
TABLE OF CONTENTS
page page
HEATING & AIR CONDITIONING
DESCRIPTION
ENGINE COOLING SYSTEM
REQUIREMENTS. . . . . . . . . . . . . . . . . . . . . . . 1
HEATER AND AIR CONDITIONER . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DIAGNOSIS AND TESTING
A/C PERFORMANCE . . . . . . . . . . . . . . . . . . . . 3
HEATER PERFORMANCE . . . . . . . . . . . . . . . . 6
SPECIFICATIONS
HEATING AND A/C SYSTEM . . . . . . . . . . . . . . 7
CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
DISTRIBUTION . . . . . . . . . . . . . . . . . . . . . . . . . . 33
PLUMBING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
HEATING & AIR
CONDITIONING
DESCRIPTION
ENGINE COOLING SYSTEM REQUIREMENTS
To mai ntai n the performance l evel of the heati ng-ai r
condi ti oni ng system, the engi ne cool i ng system must
be properl y mai ntai ned. The use of a bug screen i s not
recommended. Any obstructi ons i n front of the radi ator
or condenser wi l l reduce the performance of the ai r
condi ti oni ng and engi ne cool i ng systems.
The engi ne cool i ng system i ncl udes the radi ator,
thermostat, radi ator hoses and the engi ne cool ant
pump. Refer to Cool i ng for more i nformati on before
openi ng or attempti ng any servi ce to the engi ne cool -
i ng system.
HEATER AND AIR CONDITIONER
A manual l y control l ed si ngl e zone type heati ng-ai r
condi ti oni ng system or a manual l y control l ed heater-
onl y system i s avai l abl e on thi s model (dependi ng on
market).
Al l vehi cl es are equi pped wi th a common heater,
venti l ati on and ai r condi ti oni ng (HVAC) housi ng (Fi g.
1). The system combi nes ai r condi ti oni ng, heati ng
and venti l ati on capabi l i ti es i n a si ngl e uni t mounted
wi thi n the passenger compartment under the i nstru-
ment panel . The HVAC housi ng i ncl udes:
• Bl ower motor
• Bl ower motor resi stor bl ock
• Reci rcul ati on door and actuator (A/C system
onl y)
• Heater core
• Evaporator coi l (A/C system onl y)
• Bl end door and actuator (A/C system onl y)
• Defrost, fl oor and panel /demi st doors and actua-
tors
On heater-onl y systems, the evaporator coi l and
reci rcul ati ng ai r door are omi tted from the housi ng.
Based upon the system and mode sel ected, condi -
ti oned ai r can exi t the heater-onl y or heater-A/C sys-
tem housi ng through one or a combi nati on of the
three mai n housi ng outl ets: defrost, panel or fl oor.
The defrost outl et i s l ocated on the top of the hous-
i ng, the panel outl et i s l ocated on the face of the
housi ng and the fl oor outl et i s l ocated on the bottom
of the housi ng. Once the condi ti oned ai r exi ts the
uni t housi ng, i t i s further di rected through mol ded
pl asti c ducts to the vari ous outl ets i n the vehi cl e
i nteri or. These outl ets and thei r l ocati ons are as fol -
l ows:
• Defroster Outlet - A si ngl e l arge defroster out-
l et i s l ocated i n the center of the i nstrument panel
top cover, near the base of the wi ndshi el d.
• Side Window Demister Outlets - There are
two si de wi ndow demi ster outl ets, one i s l ocated at
each outboard end of the i nstrument panel top cover,
near the bel t l i ne at the A-pi l l ars.
Fig. 1 Common Blend-Air HVAC System - Typical
1 - HEATER CORE
2 - BLEND-AIR DOOR
3 - EVAPORATOR (A/C SYSTEM ONLY)
4 - RECIRCULATING AIR DOOR (A/C SYSTEM ONLY)
5 - FLOOR/PANEL DOOR
6 - FLOOR/DEFROST DOOR
TJ HEATING & AIR CONDITIONING 24 - 1
• Panel Outlets - There are four panel outl ets i n
the i nstrument panel , one l ocated near each outboard
end of the i nstrument panel faci ng the rear of the
vehi cl e and two l ocated near the top of the i nstru-
ment panel center bezel .
• Front Floor Outlets - There are two front fl oor
outl ets, one l ocated above each si de of the fl oor panel
center tunnel near the dash panel .
OPERATION
The heati ng and ai r condi ti oni ng systems pul l s
outsi de (ambi ent) ai r through the cowl openi ng at the
base of the wi ndshi el d, then i nto the pl enum cham-
ber above the heati ng, venti l ati on and ai r condi ti on-
i ng (HVAC) housi ng. On model s equi pped wi th ai r
condi ti oni ng, the ai r passes through the evaporator
coi l . Ai r fl ow can be di rected ei ther through or
around the heater core. Thi s i s done by adjusti ng the
bl end door wi th the temperature control knob on the
A/C-heater control panel l ocated the i nstrument
panel . The ai r fl ow can then be di rected from the
panel , fl oor and defrost outl ets i n vari ous combi na-
ti ons usi ng the mode control knob l ocated on the A/C-
heater control panel . Ai r fl ow vel oci ty can be
adjusted wi th the bl ower speed sel ector l ocated on
the A/C-heater control panel .
NOTE: It is important to keep the air intake opening
clear of debris. Leaf particles and other debris that is
small enough to pass through the cowl opening
screen can accumulate within the HVAC housing. The
closed, warm, damp and dark environment created
within the housing is ideal for the growth of certain
molds, mildews and other fungi. Any accumulation of
decaying plant matter provides an additional food
source for fungal spores, which enter the housing
with the fresh intake-air. Excess debris, as well as
objectionable odors created by decaying plant matter
and growing fungi can be discharged into the pas-
senger compartment during heater-A/C operation if
the air intake opening is not kept clear of debris.
Both the heater-onl y and heater-ai r condi ti oner
systems are bl end-ai r type systems. I n a bl end-ai r
system, a bl end door control s the amount of uncondi -
ti oned ai r (or cool ed ai r from the evaporator coi l on
model s wi th ai r condi ti oni ng) that i s al l owed to fl ow
through, or around, the heater core. The temperature
control knob determi nes the di scharge ai r tempera-
ture by actuati ng an el ectri c motor, whi ch operates
the bl end door. Thi s al l ows an al most i mmedi ate con-
trol of the output ai r temperature of the system.
On ai r condi ti oned vehi cl es, the outsi de ai r i ntake
can be shut off by sel ecti ng the Reci rcul ati on Mode
wi th the mode control knob. Thi s wi l l operate a vac-
uum actuated reci rcul ati ng ai r door that cl oses off
the outsi de fresh ai r i ntake and reci rcul ates the ai r
that i s al ready i nsi de the vehi cl e.
The ai r condi ti oni ng compressor can be engaged by
turni ng the mode control knob cl ockwi se from the Off
posi ti on. I t can al so be engaged by pl aci ng the mode
control i n the mi x to defrost posi ti ons. Thi s wi l l
remove heat and humi di ty from the ai r before i t i s
di rected through or around the heater core. The
mode control knob on the A/C-heater control panel i s
used to al so di rect the condi ti oned ai r to the sel ected
system outl ets. The mode control swi tch uses engi ne
vacuum to control the mode doors, whi ch are oper-
ated by vacuum actuators.
The defroster outl et recei ves ai rfl ow from the
HVAC housi ng through the mol ded pl asti c defroster
duct, whi ch i s snapped onto the housi ng defroster
outl et and secured by two mounti ng tabs to the dash
panel . The ai rfl ow from the defroster outl et i s
di rected by fi xed vanes i n the defroster outl et gri l l e
and cannot be adjusted. The defroster outl et gri l l e i s
i ntegral to the i nstrument panel top cover.
The si de wi ndow demi ster outl ets recei ve ai rfl ow
from the HVAC housi ng through the mol ded pl asti c
defroster duct and two mol ded pl asti c demi ster hoses.
The ai rfl ow from the si de wi ndow demi ster outl ets i s
di rected by fi xed vanes i n the demi ster outl et gri l l es
and cannot be adjusted. The si de wi ndow demi ster
outl et gri l l es are i ntegral to the i nstrument panel .
The demi sters di rect ai r from the HVAC housi ng
through the outl ets l ocated on the top corners of the
i nstrument panel . The demi sters operate when the
mode control knob i s posi ti oned i n the fl oor-defrost
and defrost-onl y setti ngs. Some ai r may be noti ceabl e
from the demi ster outl ets when the mode control i s
i n the bi -l evel to fl oor posi ti ons.
The panel outl ets recei ve ai rfl ow from the HVAC
housi ng through a mol ded pl asti c mai n panel duct,
center panel duct and two end panel ducts. The two
end panel ducts di rect ai rfl ow to the l eft and ri ght
i nstrument panel outl ets, whi l e the center panel duct
di rects ai rfl ow to the two center panel outl ets. Each
of these outl ets can be i ndi vi dual l y adjusted to di rect
the fl ow of ai r.
The fl oor outl ets recei ve ai rfl ow from the HVAC
housi ng through the fl oor di stri buti on duct. The front
fl oor outl ets are i ntegral to the mol ded pl asti c fl oor
di stri buti on duct, whi ch i s secured to the bottom of
the housi ng. The fl oor outl ets cannot be adjusted.
The avai l abl e ai r condi ti oner system i s desi gned for
the use of non-CFC, R-134a refri gerant. Thi s ai r con-
di ti oni ng system uses a fi xed ori fi ce tube i n the l i q-
ui d l i ne near the condenser outl et to meter
refri gerant fl ow to the evaporator coi l . To mai ntai n
mi ni mum evaporator temperature and prevent evap-
orator freezi ng, the compressor cl utch i s cycl ed on
and off by an A/C l ow pressure swi tch mounted on
the accumul ator.
24 - 2 HEATING & AIR CONDITIONING TJ
HEATING & AIR CONDITIONING (Continued)
DIAGNOSIS AND TESTING
A/C PERFORMANCE
The ai r condi ti oni ng system i s desi gned to remove
heat and humi di ty from the ai r enteri ng the passen-
ger compartment. The evaporator, l ocated i n the
heater-A/C uni t, i s cool ed to temperatures near the
freezi ng poi nt. As warm damp ai r passes over the
fi ns i n the evaporator, moi sture i n the ai r condenses
to water, dehumi di fyi ng the ai r. Condensati on on the
evaporator fi ns reduces the evaporators abi l i ty to
absorb heat. Duri ng peri ods of hi gh heat and humi d-
i ty, an ai r condi ti oni ng system wi l l be l ess effecti ve.
Wi th the i nstrument control set to Reci rcul ati on
mode, onl y ai r from the passenger compartment
passes through the evaporator. As the passenger com-
partment ai r dehumi di fi es, A/C performance l evel s
ri se.
Humi di ty has an i mportant beari ng on the temper-
ature of the ai r del i vered to the i nteri or of the vehi -
cl e. I t i s i mportant to understand the effect that
humi di ty has on the performance of the ai r condi ti on-
i ng system. When humi di ty i s hi gh, the evaporator
has to perform a doubl e duty. I t must l ower the ai r
temperature, and i t must l ower the temperature of
the moi sture i n the ai r that condenses on the evapo-
rator fi ns. Condensi ng the moi sture i n the ai r trans-
fers heat energy i nto the evaporator fi ns and tubi ng.
Thi s reduces the amount of heat the evaporator can
absorb from the ai r. Hi gh humi di ty greatl y reduces
the abi l i ty of the evaporator to l ower the temperature
of the ai r.
However, evaporator capaci ty used to reduce the
amount of moi sture i n the ai r i s not wasted. Wri ng-
i ng some of the moi sture out of the ai r enteri ng the
vehi cl e adds to the comfort of the passengers.
Al though, an owner may expect too much from thei r
ai r condi ti oni ng system on humi d days. A perfor-
mance test i s the best way to determi ne whether the
system i s performi ng up to standard. Thi s test al so
provi des val uabl e cl ues as to the possi bl e cause of
troubl e wi th the ai r condi ti oni ng system.
A/C PERFORMANCE TEST
Revi ew Safety Warni ngs and Cauti ons before per-
formi ng thi s procedure (Refer to 24 - HEATI NG &
AI R CONDI TI ONI NG/PLUMBI NG - WARNI NG) and
(Refer to 24 - HEATI NG & AI R CONDI TI ONI NG/
PLUMBI NG - CAUTI ON). Ai r temperature i n test
room and on vehi cl e must be 21° C (70° F) mi ni mum
for thi s test.
NOTE: When connecting the service equipment
coupling to the line fitting, verify that the valve of
the coupling is fully closed. This will reduce the
amount of effort required to make the connection.
(1) Connect a tachometer and a mani fol d gauge
set.
(2) Set the mode control to the Reci rcul ati on Mode
posi ti on, the temperature control to the ful l cool posi -
ti on and the bl ower to the hi ghest speed posi ti on.
(3) Start the engi ne and hol d at 1,000 rpm wi th
the A/C compressor cl utch engaged.
(4) The engi ne shoul d be warmed up to operati ng
temperature wi th the doors cl osed and wi ndows
open.
(5) I nsert a thermometer i n the dri ver’s si de center
panel A/C-heater outl et and operate the engi ne for
fi ve mi nutes.
(6) The compressor cl utch may cycl e, dependi ng
upon the ambi ent temperature and humi di ty. I f the
cl utch cycl es, unpl ug the A/C l ow pressure swi tch
wi re harness connector from the swi tch l ocated on
the accumul ator (Fi g. 2). Pl ace a jumper wi re across
the termi nal s of the A/C l ow pressure swi tch wi re
harness connector.
(7) Wi th the A/C compressor cl utch engaged, com-
pare the di scharge ai r temperature and the compres-
sor di scharge pressure.
(8) I f the di scharge ai r temperature fai l s to meet
the speci fi cati ons i n the A/C Performance Tempera-
ture chart, refer to the Pressure Di agnosi s Chart.
Fig. 2 A/C Low Pressure Switch - Typical
1 - A/C LOW PRESSURE SWITCH
2 - ACCUMULATOR
TJ HEATING & AIR CONDITIONING 24 - 3
HEATING & AIR CONDITIONING (Continued)
PERFORMANCE TEMPERATURE AND PRESSURE
Ambient Air
Temperature
21°C
(70°F)
27°C
(80°F)
32°C
(90°F)
38°C
(100°F)
43°C
(110°F)
Air Temperature at
Center Panel Outlet
-3 to 3°C
(27 to 38°F)
1 to 7°C
(33 to 44°F)
3 to 9°C
(37 to 48°F)
6 to 13°C
(43 to 55°F)
10 to 18°C
(50 to 64°F)
Evaporator Inlet
Pressure at Charge
Port
179 to 241 kPa
(26 to 35 psi)
221 to 283 kPa
(32 to 41 psi)
262 to 324
kPa
(38 to 47 psi)
303 to 365
kPa
(44 to 53 psi)
345 to 414 kPa
(50 to 60 psi)
Compressor
Discharge Pressure
1240 to 1655
kPa
(180 to 240
psi)
1380 to 1790
kPa
(200 to 260
psi)
1720 to 2070
kPa
(250 to 300
psi)
1860 to 2345
kPa
(270 to 340
psi)
2070 to 2690
kPa
(300 to 390 psi)
(9) Compare the compressor di scharge pressure to
the Performance Temperature and Pressure chart. I f
the compressor di scharge pressure i s hi gh, see the
Pressure Di agnosi s chart.
PRESSURE DIAGNOSIS
Condition Possible Causes Correction
Rapid compressor clutch
cycling (ten or more cycles
per minute).
1. Low refrigerant system
charge.
1. See Refrigerant System Leaks in this group.
Test the refrigerant system for leaks. Repair,
evacuate and charge the refrigerant system, if
required.
Equal pressures, but the
compressor clutch does not
engage.
1. No refrigerant in the
refrigerant system.
1. See Refrigerant System Leaks in this group.
Test the refrigerant system for leaks. Repair,
evacuate and charge the refrigerant system, if
required.
2. Faulty fuse. 2. Check the fuses in the Power Distribution
Center and the fuse block. Repair the shorted
circuit or component and replace the fuses, if
required. Refer to Group 8.
3. Faulty A/C compressor
clutch coil.
3. See A/C Compressor Clutch Coil in this group.
Test the compressor clutch coil and replace, if
required.
4. Faulty A/C compressor
clutch relay.
4. See A/C Compressor Clutch Relay in this
group. Test the compressor clutch relay and relay
circuits. Repair the circuits or replace the relay, if
required.
5. Improperly installed or
faulty A/C low pressure
switch.
5. See A/C Low Pressure Switch in this group.
Test the low pressure switch and tighten or
replace, if required.
6. Faulty A/C high pressure
switch.
6. See A/C High Pressure switch in this group.
Test the high pressure switch and replace, if
required.
7. Faulty Powertrain Control
Module (PCM).
7. Refer to the proper Diagnostic Procedures
manual for testing of the PCM. Test the PCM and
replace, if required.
24 - 4 HEATING & AIR CONDITIONING TJ
HEATING & AIR CONDITIONING (Continued)
Condition Possible Causes Correction
Normal pressures, but A/C
Performance Test air
temperatures at center panel
outlet are too high.
1. Excessive refrigerant oil in
system.
1. See Refrigerant Oil Level in this group.
Recover the refrigerant from the refrigerant
system and inspect the refrigerant oil content.
Restore the refrigerant oil to the proper level, if
required.
2. Blend-air door motor
improperly installed or faulty.
2. See Blend-Air Door Motor in this group.
Inspect the motor for proper operation and
replace, if required.
3. Blend-air door inoperative
or sealing improperly.
3. See Blend-Air Door in this group. Inspect the
blend-air door for proper operation and sealing
and correct, if required.
The low side pressure is
normal or slightly low, and the
high side pressure is too low.
1. Low refrigerant system
charge.
1. See Refrigerant System Leaks in this group.
Test the refrigerant system for leaks. Repair,
evacuate and charge the refrigerant system, if
required.
2. Refrigerant flow through
the accumulator is restricted.
2. See Accumulator in this group. Replace the
restricted accumulator, if required.
3. Refrigerant flow through
the evaporator coil is
restricted.
3. See A/C Evaporator Coil in this group.
Replace the restricted evaporator coil, if required.
4. Faulty compressor. 4. See A/C Compressor in this group. Replace
the compressor, if required.
The low side pressure is
normal or slightly high, and
the high side pressure is too
high.
1. Condenser air flow
restricted.
1. Check the A/C condenser for damaged fins,
foreign objects obstructing air flow through the
condenser fins, and missing or improperly
installed air seals. Clean, repair, or replace
components as required.
2. Inoperative radiator
cooling fan.
2. Test the radiator cooling fan and replace, if
required. Refer to Group 7.
3. Refrigerant system
overcharged.
3. See Refrigerant System Charge in this group.
Recover the refrigerant from the refrigerant
system. Charge the refrigerant system to the
proper level, if required.
4. Air in the refrigerant
system.
4. See Refrigerant System Leaks in this group.
Test the refrigerant system for leaks. Repair,
evacuate and charge the refrigerant system, if
required.
5. Engine overheating. 5. Test the engine cooling system and repair, if
required. Refer to Group 7.
The low side pressure is too
high, and the high side
pressure is too low.
1. Accessory drive belt
slipping.
1. Inspect the accessory drive belt condition and
tension. Tighten or replace the accessory drive
belt, if required. Refer to Group 7.
2. Faulty fixed orifice tube. 2. See A/C Fixed Orifice Tube in this group.
Replace the liquid line, if required.
3. Faulty A/C compressor. 3. See A/C Compressor in this group. Replace
the compressor, if required.
TJ HEATING & AIR CONDITIONING 24 - 5
HEATING & AIR CONDITIONING (Continued)
Condition Possible Causes Correction
The low side pressure is too
low, and the high side
pressure is too high.
1. Restricted refrigerant flow
through the refrigerant lines.
1. See Liquid Line and Suction and Discharge
Line in this group. Inspect the refrigerant lines for
kinks, tight bends or improper routing. Correct
the routing or replace the refrigerant line, if
required.
2. Restricted refrigerant flow
through the fixed orifice tube.
2. See A/C Fixed Orifice Tube in this group.
Replace the liquid line, if required.
3. Restricted refrigerant flow
through the A/C condenser.
3. See A/C Condenser in this group. Replace the
restricted condenser, if required.
HEATER PERFORMANCE
Revi ew Safety Warni ngs and Cauti ons before per-
formi ng thi s procedure (Refer to 24 - HEATI NG &
AI R CONDI TI ONI NG/PLUMBI NG - WARNI NG) and
(Refer to 24 - HEATI NG & AI R CONDI TI ONI NG/
PLUMBI NG - CAUTI ON).
Check the cool ant l evel , dri ve bel t tensi on, vacuum
l i ne connecti ons, radi ator ai r fl ow and fan operati on.
Start engi ne and al l ow to warm up to normal tem-
perature.
WARNING: DO NOT REMOVE RADIATOR CAP
WHEN ENGINE IS HOT, PERSONAL INJURY CAN
RESULT.
I f vehi cl e has been run recentl y, wai t 15 mi nutes
before removi ng cap. Pl ace a rag over the cap and
turn i t to the fi rst safety stop. Al l ow pressure to
escape through the overfl ow tube. When the system
stabi l i zes, remove the cap compl etel y.
MAXIMUM HEATER OUTPUT: TEST AND ACTION
Engi ne cool ant i s provi ded to the heater system by
two heater hoses. Wi th the engi ne i dl i ng at normal
operati ng temperature, set the temperature control
to maxi mum heat, the mode control to the fl oor posi -
ti on, and the bl ower i n the hi ghest speed posi ti on.
Usi ng a test thermometer, check the temperature of
the ai r bei ng di scharged from the fl oor outl ets. Com-
pare the test thermometer readi ng to the Tempera-
ture Reference Chart.
TEMPERATURE REFERENCE CHART
Ambient Air Temperature
15.5°C
(60°F)
21.1°C
(70°F)
26.6°C
(80°F)
32.2°C
(90°F)
Minimum Air Temperature at
Floor Outlet
62.2°C
(144°F)
63.8°C
(147°F)
65.5°C
(150°F)
67.2°C
(153°F)
Both of the heater hoses shoul d be HOT to the
touch (cool ant return hose shoul d be sl i ghtl y cool er
than the suppl y hose. I f the cool ant return hose i s
much cool er than the suppl y hose, l ocate and repai r
the engi ne cool ant fl ow obstructi on i n the heater sys-
tem. I f both heater hoses are cool to the touch,
i nspect the engi ne cool i ng system (Refer to 7 -
COOLI NG - DI AGNOSI S AND TESTI NG).
OBSTRUCTED COOLANT FLOW Possi bl e l oca-
ti ons or causes of obstructed cool ant fl ow are as fol -
l ows:
• Pi nched or ki nked heater hoses.
• I mproper heater hose routi ng.
• Pl ugged heater hoses or suppl y and return ports
at the cool i ng system connecti ons.
• Pl ugged heater core.
I f proper cool ant fl ow through the cool i ng system i s
veri fi ed, and heater outl et ai r temperature i s i nsuffi -
ci ent, a mechani cal probl em may exi st.
MECHANI CAL PROBLEMS Possi bl e causes of
i nsuffi ci ent heat due to mechani cal probl ems are as
fol l ows:
• Obstructed cowl ai r i ntake.
• Obstructed heater system outl ets.
• Bl end-ai r door not functi oni ng properl y.
TEMPERATURE CONTROL
I f the heater outl et ai r temperature cannot be
adjusted wi th the temperature control knob on the
A/C-heater control panel , the fol l owi ng coul d requi re
servi ce:
• Bl end-ai r door bi ndi ng.
• Faul ty bl end-ai r door motor.
• Faul ty A/C-heater control .
• Faul ty rel ated wi ri ng harness or connectors.
• I mproper engi ne cool ant temperature.
24 - 6 HEATING & AIR CONDITIONING TJ
HEATING & AIR CONDITIONING (Continued)
SPECIFICATIONS
HEATING AND A/C SYSTEM
REFRIGERANT SYSTEM CHARGE
The R-134a refri gerant system charge capaci ty for
thi s vehi cl e can be found on the underhood Speci fi ca-
ti on Label .
A/C SYSTEM
Item Description Notes
Compressor Denso 10PA17 ND-8 PAG Oil
Freeze–up
Control
Low pressure
clutch cycling
switch
Input to PCM,
accumulator
mounted -
cycles clutch off
below -1°C
(30°F), cycles
back on above
7.2°C (45°F)
Low psi Control Low pressure
clutch cycling
switch
Accumulator
mounted -
opens below
172 kPa (25
psi) - resets
above 276 kPa
(40 psi)
Item Description Notes
High psi Control High pressure
cut out switch
Discarge line
mounted -
opens at
discharge
pressure above
3100 - 3375
kPa (450 - 490
psi) - resets at
1860 - 2275
kPa (270 - 330
psi)
Compressor
Clutch Coil
Draw
2.0 - 3.7 amps
@ 12V ± 0.5V
@ 21°C (70°
F)
Compressor
Clutch Air Gap
0.35 - 0.65 mm
(0.014 - 0.026
in)
FASTENER TORQUE
Description N·m Ft. Lbs. In. Lbs.
A/C Compressor Shaft
Bolt
13 – 115
A/C Compressor Mounting
Bolts (4.0L)
45-65 35-50 –
A/C Compressor Rear
Brace Bolts (4.0L)
40-55 30-40 –
A/C Compressor Mounting
Bolts (2.4L)
28 21 –
A/C-heater Control Screws 2.2 – 20
Accumulator Retaining
Band Bolt
4.5 – 40
Blend Door Actuator
Screws
1.1 – 10
Blower Motor Switch
Screw
2.2 – 20
Blower Motor Resistor
Block Screws
2.2 – 20
Center Panel Duct Screws 2.2 – 20
TJ HEATING & AIR CONDITIONING 24 - 7
HEATING & AIR CONDITIONING (Continued)
Description N·m Ft. Lbs. In. Lbs.
Discharge Line to
Compressor
25.4 20 –
Discharge Line to
Condenser Nut
12 – 105
End Panel Duct Screws 2.2 – 20
Evaporator Tube Clamp
Screw
2.2 – 20
Floor Distribution Duct
Screws
2.2 – 20
HVAC Housing Screws 2.2 – 20
HVAC Housing Outboard
Screw
3.4 – 30
HVAC Housing Stud Nuts 6.2 – 55
Liquid Line to Condenser
Nut
12 – 105
Lower Condenser Bracket
Screws
2.2 – 20
Main Panel Duct Screws 2.2 – 20
Refrigerant Line Support
Bracket Bolt
28 21 –
Radiator Shroud Screws 8 – 72
Recirculation Housing
Screws
2.2 – 20
Suction Lines to
Accumulator Nut
2.2 – 20
Suction Line to
Compressor
25.4 20 –
Upper Condenser
Mounting Bracket Screws
2.2 – 20
Vacuum Reservoir Screw 2.2 – 20
24 - 8 HEATING & AIR CONDITIONING TJ
HEATING & AIR CONDITIONING (Continued)
CONTROLS
TABLE OF CONTENTS
page page
A/C COMPRESSOR CLUTCH/COIL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 10
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 10
DIAGNOSIS AND TESTING
A/C COMPRESSOR CLUTCH/COIL . . . . . . 10
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 13
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 13
A/C COMPRESSOR CLUTCH RELAY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 14
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 14
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 15
A/C HEATER CONTROL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 15
DIAGNOSIS AND TESTING
VACUUM CONTROL SYSTEM . . . . . . . . . . 16
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 20
A/C HIGH PRESSURE SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 21
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 21
DIAGNOSIS AND TESTING
A/C HIGH PRESSURE SWITCH . . . . . . . . . 21
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 21
A/C LOW PRESSURE SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 22
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 22
DIAGNOSIS AND TESTING
A/C LOW PRESSURE SWITCH . . . . . . . . . 22
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 22
BLEND DOOR ACTUATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 23
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 23
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 23
BLOWER MOTOR RELAY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 24
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 24
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 25
BLOWER MOTOR RESISTOR BLOCK
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 25
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 25
DIAGNOSIS AND TESTING
BLOWER MOTOR RESISTOR BLOCK . . . . 25
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 26
BLOWER MOTOR SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 26
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 26
DIAGNOSIS AND TESTING
BLOWER MOTOR SWITCH . . . . . . . . . . . . 26
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 27
MODE DOOR ACTUATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 27
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 29
RECIRCULATION DOOR ACTUATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 29
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 30
VACUUM CHECK VALVE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 31
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 31
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 31
VACUUM RESERVOIR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 32
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 32
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 32
TJ CONTROLS 24 - 9
A/C COMPRESSOR CLUTCH/
COIL
DESCRIPTION
The compressor cl utch assembl y consi sts of a sta-
ti onary el ectromagneti c coi l , a hub beari ng and pul -
l ey assembl y, and a cl utch pl ate (Fi g. 1). The
el ectromagneti c coi l uni t and the hub beari ng and
pul l ey assembl y are each retai ned on the nose of the
compressor front housi ng wi th snap ri ngs. The cl utch
pl ate i s keyed to the compressor shaft and secured
wi th a retai ner. These components provi de the means
to engage and di sengage the compressor from the
engi ne serpenti ne accessory dri ve bel t.
OPERATION
When the cl utch coi l i s energi zed, i t magneti cal l y
draws the cl utch i nto contact wi th the pul l ey and
dri ves the compressor shaft. When the coi l i s not
energi zed, the pul l ey freewheel s on the cl utch hub
beari ng, whi ch i s part of the pul l ey. The compressor
cl utch and coi l are the onl y servi ced parts on the
compressor.
A/C compressor cl utch engagement i s control l ed by
the fol l owi ng components:
• A/C-heater mode control swi tch
• A/C l ow pressure swi tch
• A/C hi gh pressure swi tch
• A/C compressor cl utch rel ay
• Powertrai n Control Modul e (PCM)
The PCM may del ay compressor cl utch engage-
ment for up to thi rty seconds.
DIAGNOSIS AND TESTING
A/C COMPRESSOR CLUTCH/COIL
For ci rcui t descri pti ons and di agrams, refer to the
appropri ate wi ri ng i nformati on. The wi ri ng i nforma-
ti on i ncl udes wi ri ng di agrams, proper wi re and con-
nector repai r procedures, further detai l s on wi re
harness routi ng and retenti on, as wel l as pi n-out and
l ocati on vi ews for the vari ous wi re harness connec-
tors, spl i ces and grounds. Begi n testi ng of a sus-
pected compressor cl utch coi l probl em by performi ng
the prel i mi nary checks.
PRELIMINARY CHECKS
(1) I f the compressor cl utch wi l l not engage, veri fy
the refri gerant charge l evel (Refer to 24 - HEATI NG
& AI R CONDI TI ONI NG/PLUMBI NG - STANDARD
PROCEDURE). I f the refri gerant charge l evel i s OK,
go to Step 2. I f the refri gerant charge l evel i s not OK,
adjust the refri gerant charge as requi red.
(2) I f the a/c compressor cl utch sti l l wi l l not
engage, di sconnect the headl amp and dash wi re har-
ness connector for the A/C pressure transducer and
check for battery current at the connector wi th the
engi ne runni ng and the heater-A/C control set to the
A/C mode. I f OK, go to TESTS. I f not OK, refer to
the Body Di agnosti c Procedures to perform further
di agnosi s.
Fig. 1 A/C Compressor Clutch - Typical
1 - CLUTCH PLATE
2 - SHAFT KEY
3 - PULLEY
4 - COIL
5 - CLUTCH SHIMS
6 - SNAP RING
7 - SNAP RING
24 - 10 CONTROLS TJ
TESTS
(1) Veri fy the battery state of charge (Refer to 8 -
ELECTRI CAL/BATTERY SYSTEM - DI AGNOSI S
AND TESTI NG).
(2) Connect an ammeter (0 to 10 ampere scal e
sel ected) i n seri es wi th the cl utch coi l feed termi nal .
Connect a vol tmeter (0 to 20 vol t scal e sel ected) to
measure vol tage across the battery and the cl utch
coi l .
(3) Wi th the A/C-heater control i n any A/C mode
and the bl ower at the l owest speed, start the engi ne
and al l ow i t to run at a normal i dl e speed.
(4) The compressor cl utch shoul d engage i mmedi -
atel y, and the cl utch coi l vol tage shoul d be wi thi n
two vol ts of the battery vol tage. I f the coi l vol tage i s
not wi thi n two vol ts of battery vol tage, test the
cl utch coi l feed ci rcui t for excessi ve vol tage drop. I f
the compressor cl utch does not engage, refer to Body
Di agnosti c Procedures to perform further di agnosi s.
The fol l owi ng components must be checked and
repai red as requi red before you can compl ete testi ng
of the cl utch coi l :
• Fuses i n the fuse bl ock and the Power Di stri bu-
ti on Center (PDC)
• A/C-heater mode control swi tch
• A/C Compressor cl utch rel ay
• A/C Hi gh pressure swi tch
• A/C Low pressure swi tch
• Powertrai n Control Modul e (PCM)
(5) Wi th the ambi ent temperature at 21° C (70° F),
the compressor cl utch coi l i s acceptabl e i f the current
draw i s 2.0 to 3.7 amperes at 11.5 to 12.5 vol ts at the
cl utch coi l . I f the vol tage i s more than 12.5 vol ts, add
el ectri cal l oads by turni ng on el ectri cal accessori es
unti l the vol tage reads bel ow 12.5 vol ts.
(a) I f the compressor cl utch coi l current readi ng
i s zero, the coi l i s open and must be repl aced.
(b) I f the compressor cl utch coi l current readi ng
i s four amperes or more, the coi l i s shorted and
must be repl aced.
REMOVAL
NOTE: The compressor clutch can be serviced in
the vehicle. The refrigerant system can remain fully-
charged during compressor clutch, pulley, or coil
replacement.
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the serpenti ne dri ve bel t (Refer to 7 -
COOLI NG/ACCESSORY DRI VE/DRI VE BELTS -
REMOVAL) and (Refer to 7 - COOLI NG/ACCES-
SORY DRI VE/DRI VE BELTS - REMOVAL).
(3) Remove the bol t that secures the compressor
cl utch to the compressor shaft (Fi g. 2). A band-type
oi l fi l ter wrench may be used to secure the cl utch
duri ng bol t removal .
Fig. 2 A/C Compressor Shaft Bolt
1 - COMPRESSOR CLUTCH PLATE
2 - COMPRESSOR SHAFT BOLT
TJ CONTROLS 24 - 11
A/C COMPRESSOR CLUTCH/COIL (Continued)
(4) Tap the cl utch pl ate wi th a pl asti c mal l et to
rel ease i t from the spl i nes on the compressor shaft.
Remove the cl utch pl ate and shi m(s) from the com-
pressor shaft (Fi g. 3).
NOTE: Use care not to lose any of the shim(s).
CAUTION: Do not use screwdrivers between the
clutch plate assembly and pulley to remove front
plate as this may damage the front plate assembly.
(5) Remove the external snap ri ng that secures the
compressor cl utch pul l ey to the nose of the compres-
sor front housi ng wi th snap ri ng pl i ers (Speci al Tool
C-4574) or equi val ent and sl i de the pul l ey assembl y
off of the compressor (Fi g. 4).
(6) Remove the screw and retai ner from the cl utch
coi l l ead wi re harness on the compressor front hous-
i ng.
(7) Remove the external snap ri ng that secures the
compressor cl utch coi l to the nose of the compressor
front housi ng wi th snap ri ng pl i ers and sl i de the coi l
assembl y off of the compressor (Fi g. 5).
Fig. 3 Clutch Plate and Shim(s)
1 - COMPRESSOR SHAFT
2 - CLUTCH PLATE
3 - CLUTCH PLATE SHIM
Fig. 4 Pulley Snap Ring
1 - SNAP RING
Fig. 5 Clutch Coil Snap Ring
1 - SNAP RING PLIERS
2 - CLUTCH COIL
3 - SNAP RING
4 - COMPRESSOR
24 - 12 CONTROLS TJ
A/C COMPRESSOR CLUTCH/COIL (Continued)
INSPECTION
NOTE: The compressor clutch can be serviced in
the vehicle. The refrigerant system can remain fully-
charged during compressor clutch, pulley, or coil
replacement.
Exami ne the fri cti on surfaces of the cl utch pul l ey
and the cl utch pl ate for wear. The pul l ey and pl ate
shoul d be repl aced i f there i s excessi ve wear or scor-
i ng.
I f the fri cti on surfaces are oi l y, i nspect the shaft
and nose area of the compressor for refri gerant oi l .
Remove the fel t wi ck from around the shaft i nsi de
the nose of the compressor front housi ng. I f the fel t
i s saturated wi th refri gerant oi l , the compressor
shaft seal i s l eaki ng and the compressor must be
repl aced.
Check the cl utch pul l ey beari ng for roughness or
excessi ve l eakage of grease. Repl ace the beari ng, i f
requi red.
INSTALLATION
(1) Al i gn the dowel pi n on the back of the cl utch
fi el d coi l wi th the hol e i n the compressor front hous-
i ng and press the fi el d coi l i nto pl ace over the nose of
the compressor.
(2) I nstal l the cl utch coi l l ead wi re harness retai n-
i ng cl i p on the compressor front housi ng and ti ghten
the retai ni ng screw.
(3) I nstal l the cl utch fi el d coi l and snap ri ng wi th
snap ri ng pl i ers (Speci al Tool C-4574). The bevel si de
of the snap ri ng must be faci ng outward. Al so, both
eyel ets of the snap ri ng must be to the ri ght or l eft of
the pi n on the compressor. Press i n on the snap ri ng
to be certai n that i t i s properl y seated i n the groove.
CAUTION: If the snap ring is not fully seated in the
groove it will vibrate out, resulting in a clutch fail-
ure and severe damage to the front housing of the
compressor.
(4) I nstal l the pul l ey assembl y onto the compres-
sor. I f necessary, pl ace a bl ock of wood on the fri cti on
surface and tap gentl y wi th a hammer (Fi g. 6).
CAUTION: Do not mar the pulley friction surface.
(5) I nstal l the pul l ey assembl y retai ni ng snap ri ng
(bevel si de outward) wi th snap ri ng pl i ers (Speci al
Tool C-4574). Press i n on the snap ri ng to be certai n
that i t i s properl y seated i n the groove.
(6) I f the ori gi nal cl utch pl ate assembl y and pul l ey
assembl y are to be reused, the ol d shi m(s) can be
used. I f not, pl ace a stack of shi m(s) equal to the ol d
shi m(s) on the shaft agai nst the shoul der.
(7) I nstal l the cl utch pl ate assembl y onto the
shaft.
NOTE: The shims may compress after tightening
the shaft bolt. Check the air gap in four or more
places to verify the air gap is still correct. Spin the
pulley before performing a final check of the air
gap.
Fig. 6 Pulley Assembly - Install
1 - PULLEY ASSEMBLY
2 - WOOD BLOCK
TJ CONTROLS 24 - 13
A/C COMPRESSOR CLUTCH/COIL (Continued)
(8) Wi th the cl utch pl ate assembl y ti ght agai nst
the shi m(s), measure the ai r gap between the cl utch
pl ate and the pul l ey face wi th feel er gauges. The ai r
gap shoul d be between 0.35 to 0.65 mm (0.014 to
0.026 i n.). I f the proper ai r gap i s not obtai ned, add
or subtract shi ms as needed unti l the desi red ai r gap
i s obtai ned.
(9) I nstal l the compressor shaft bol t. Ti ghten the
bol t to 13 N·m (115 i n. l bs.).
(10) I nstal l the serpenti ne dri ve bel t (Refer to 7 -
COOLI NG/ACCESSORY DRI VE/DRI VE BELTS -
I NSTALLATI ON) or (Refer to 7 - COOLI NG/ACCES-
SORY DRI VE/DRI VE BELTS - I NSTALLATI ON).
(11) Reconnect the battery negati ve cabl e.
CLUTCH BREAK-IN
After a new compressor cl utch has been i nstal l ed,
cycl e the compressor cl utch approxi matel y twenty
ti mes (fi ve seconds on, then fi ve seconds off). Duri ng
thi s procedure, set the A/C-heater control to the A/C
Reci rcul ati on Mode, the bl ower motor swi tch i n the
hi ghest speed posi ti on, and the engi ne speed at 1500
to 2000 rpm. Thi s procedure (burni shi ng) wi l l seat
the opposi ng fri cti on surfaces and provi de a hi gher
compressor cl utch torque capabi l i ty.
A/C COMPRESSOR CLUTCH
RELAY
DESCRIPTION
The A/C compressor cl utch rel ay (Fi g. 7) i s a I nter-
nati onal Standards Organi zati on (I SO) mi cro-rel ay.
Rel ays conformi ng to the I SO speci fi cati ons have
common physi cal di mensi ons, current capaci ti es, ter-
mi nal patterns, and termi nal functi ons. The I SO
mi cro-rel ay termi nal functi ons are the same as a con-
venti onal I SO rel ay. However, the I SO mi cro-rel ay
termi nal pattern (or footpri nt) i s di fferent, the cur-
rent capaci ty i s l ower, and the physi cal di mensi ons
are smal l er than those of the conventi onal I SO rel ay.
The A/C compressor cl utch rel ay i s l ocated i n the
Power Di stri buti on Center (PDC) i n the engi ne com-
partment. See the fuse and rel ay l ayout l abel affi xed
to the i nsi de surface of the PDC cover for A/C com-
pressor cl utch rel ay i denti fi cati on and l ocati on.
The bl ack, mol ded pl asti c case i s the most vi si bl e
component of the A/C compressor cl utch rel ay. Fi ve
mal e spade-type termi nal s extend from the bottom of
the base to connect the rel ay to the vehi cl e el ectri cal
system, and the I SO desi gnati on for each termi nal i s
mol ded i nto the base adjacent to each termi nal . The
I SO termi nal desi gnati ons are as fol l ows:
• 30 (Common Feed) - Thi s termi nal i s con-
nected to the movabl e contact poi nt of the rel ay.
• 85 (Coil Ground) - Thi s termi nal i s connected
to the ground feed si de of the rel ay control coi l .
• 86 (Coil Battery) - Thi s termi nal i s connected
to the battery feed si de of the rel ay control coi l .
• 87 (Normally Open) - Thi s termi nal i s con-
nected to the normal l y open fi xed contact poi nt of the
rel ay.
• 87A (Normally Closed) - Thi s termi nal i s con-
nected to the normal l y cl osed fi xed contact poi nt of
the rel ay.
The A/C compressor cl utch rel ay cannot be
adjusted or repai red. I f the rel ay i s damaged or
faul ty, i t must be repl aced.
OPERATION
The A/C compressor cl utch rel ay i s an el ectrome-
chani cal swi tch that uses a l ow current i nput from
the Powertrai n Control Modul e (PCM) to control the
hi gh current output to the Compressor cl utch el ectro-
magneti c coi l . The movabl e common feed contact
poi nt i s hel d agai nst the fi xed normal l y cl osed con-
tact poi nt by spri ng pressure. When the rel ay coi l i s
energi zed, an el ectromagneti c fi el d i s produced by the
coi l wi ndi ngs. Thi s el ectromagneti c fi el d draws the
movabl e rel ay contact poi nt away from the fi xed nor-
mal l y cl osed contact poi nt, and hol ds i t agai nst the
fi xed normal l y open contact poi nt. When the rel ay
coi l i s de-energi zed, spri ng pressure returns the mov-
abl e contact poi nt back agai nst the fi xed normal l y
cl osed contact poi nt. The resi stor or di ode i s con-
nected i n paral l el wi th the rel ay coi l i n the rel ay, and
hel ps to di ssi pate vol tage spi kes and el ectromagneti c
i nterference that can be generated as the el ectromag-
neti c fi el d of the rel ay coi l col l apses.
Fig. 7 A/C Compressor Clutch Relay
30 - COMMON FEED
85 - COIL GROUND
86 - COIL BATTERY
87 - NORMALLY OPEN
87A - NORMALLY CLOSED
24 - 14 CONTROLS TJ
A/C COMPRESSOR CLUTCH/COIL (Continued)
The A/C compressor cl utch rel ay termi nal s are con-
nected to the vehi cl e el ectri cal system through a
receptacl e i n the PDC. The i nputs and outputs of the
A/C compressor cl utch rel ay i ncl ude:
• The common feed termi nal (30) recei ves a bat-
tery current i nput from a fuse i n the PDC through a
fused B(+) ci rcui t at al l ti mes.
• The coi l ground termi nal (85) recei ves a ground
i nput from the PCM through the A/C compressor
cl utch rel ay control ci rcui t onl y when the PCM el ec-
troni cal l y pul l s the control ci rcui t to ground.
• The coi l battery termi nal (86) recei ves a battery
current i nput from a fuse i n the fuse bl ock modul e
through a fused i gni ti on swi tch output (run-start) ci r-
cui t onl y when the i gni ti on swi tch i s i n the On or
Start posi ti ons.
• The normal l y open termi nal (87) provi des a bat-
tery current output to the compressor cl utch coi l
through the A/C compressor cl utch rel ay output ci r-
cui t onl y when the A/C compressor cl utch rel ay coi l i s
energi zed.
• The normal l y cl osed termi nal (87A) i s not con-
nected to any ci rcui t i n thi s appl i cati on, but provi des
a battery current output onl y when the A/C compres-
sor cl utch rel ay coi l i s de-energi zed.
Refer to the appropri ate wi ri ng i nformati on for
di agnosi s and testi ng of the mi cro-rel ay and for com-
pl ete HVAC wi ri ng di agrams.
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the cover from the Power Di stri buti on
Center (PDC) (Fi g. 8).
(3) Refer to the fuse and rel ay l ayout l abel affi xed
to the undersi de of the PDC cover for A/C compressor
cl utch rel ay i denti fi cati on and l ocati on.
(4) Remove the A/C compressor cl utch rel ay from
the PDC.
INSTALLATION
(1) See the fuse and rel ay l ayout l abel affi xed to
the undersi de of the PDC cover for A/C compressor
cl utch rel ay l ocati on.
(2) Posi ti on the A/C compressor cl utch rel ay i n the
proper receptacl e i n the PDC.
(3) Al i gn the A/C compressor cl utch rel ay termi -
nal s wi th the termi nal cavi ti es i n the PDC recepta-
cl e.
(4) Push down fi rml y on the A/C compressor cl utch
rel ay unti l the termi nal s are ful l y seated i n the ter-
mi nal cavi ti es i n the PDC receptacl e.
(5) I nstal l the cover onto the PDC.
(6) Reconnect the battery negati ve cabl e.
A/C HEATER CONTROL
DESCRIPTION
Both the heater-onl y and heater-A/C systems use a
combi nati on of mechani cal , el ectri cal , and vacuum
control s. These control s provi de the vehi cl e operator
wi th a number of setti ng opti ons to hel p control the
cl i mate and comfort wi thi n the vehi cl e. Refer to the
owner’s manual i n the vehi cl e gl ove box for more
i nformati on on the suggested operati on and use of
these control s.
The heater-onl y or heater-A/C system control panel
i s l ocated at the center of the i nstrument panel . The
control panel contai ns rotary-type knobs. There i s a
bl ower motor speed control , mode control and tem-
perature control .
The bl ower motor and mode control swi tch, control
knobs and i l l umi nati on l amps are avai l abl e for ser-
vi ce repl acement.
Fig. 8 Power Distribution Center - LHD Shown, RHD
Typical
1 - BATTERY POSITIVE CABLE
2 - BATTERY NEGATIVE CABLE
3 - DASH PANEL
4 - INNER FENDER
5 - POWER DISTRIBUTION CENTER (PDC)
6 - NUT
TJ CONTROLS 24 - 15
A/C COMPRESSOR CLUTCH RELAY (Continued)
DIAGNOSIS AND TESTING
VACUUM CONTROL SYSTEM
Vacuum control i s used to operate the mode doors
i n the HVAC housi ng. Testi ng of the heater-A/C mode
control swi tch operati on wi l l determi ne i f the vacuum
and mechani cal control s are functi oni ng. However, i t
i s possi bl e that a vacuum control system that oper-
ates correctl y at engi ne i dl e (hi gh engi ne vacuum)
may not functi on properl y at hi gh engi ne speeds or
l oads (l ow engi ne vacuum). Thi s can be caused by
l eaks i n the vacuum system, or a faul ty vacuum
check val ve.
A vacuum system test wi l l hel p to i denti fy the
source of poor vacuum system performance or vac-
uum system l eaks. Before starti ng thi s test, stop the
engi ne and make certai n that the probl em i sn’t a di s-
connected vacuum suppl y tube at the engi ne i ntake
mani fol d vacuum tap or the vacuum reservoi r.
Use an adjustabl e vacuum test set (Speci al Tool
C-3707-B) and a sui tabl e vacuum pump to test the
heater-A/C vacuum control system. Wi th a fi nger
pl aced over the end of the vacuum test hose probe
(Fi g. 9), adjust the bl eed val ve on the test set gauge
to obtai n a vacuum of exactl y 27 kPa (8 i n. Hg.).
Rel ease and bl ock the end of the probe several ti mes
to veri fy that the vacuum readi ng returns to the
exact 27 kPa (8 i n. Hg.) setti ng. Otherwi se, a fal se
readi ng wi l l be obtai ned duri ng testi ng.
VACUUM CHECK VALVE
(1) Remove the vacuum check val ve. The val ve i s
l ocated i n the (bl ack) vacuum suppl y tube at the
i ntake mani fol d vacuum tap.
(2) Connect the test set vacuum suppl y hose to the
heater-A/C system (natural col or) si de of the val ve.
When connected to thi s si de of the check val ve, no
vacuum shoul d pass and the test set gauge shoul d
return to the 27 kPa (8 i n. Hg.) setti ng. I f OK, go to
Step 3. I f not OK, repl ace the faul ty val ve.
(3) Connect the test set vacuum suppl y hose to the
engi ne vacuum (bl ack col or) si de of the val ve. When
connected to thi s si de of the check val ve, vacuum
shoul d fl ow through the val ve wi thout restri cti on. I f
not OK, repl ace the faul ty val ve.
HEATER-A/C CONTROLS
(1) Connect the test set vacuum probe to the heat-
er-A/C vacuum suppl y (bl ack) tube i n the engi ne
compartment. Posi ti on the test set gauge so that i t
can be vi ewed from the passenger compartment.
(2) Pl ace the heater-A/C mode control swi tch knob
i n each mode posi ti on, one posi ti on at a ti me, and
pause after each sel ecti on. The test set gauge shoul d
return to the 27 kPa (8 i n. Hg.) setti ng shortl y after
each sel ecti on i s made. I f not OK, a component or
vacuum l i ne i n the vacuum ci rcui t of the sel ected
mode has a l eak. See the procedure i n Locati ng Vac-
uum Leaks.
CAUTION: Do not use lubricant on the switch ports
or in the holes in the plug, as lubricant will ruin the
vacuum valve in the switch. A drop of clean water
in the connector plug holes will help the connector
slide onto the switch ports.
Fig. 9 Adjust Vacuum Test Bleed Valve
1 - VACUUM PUMP TOOL C-4289
2 - VACUUM TEST SET C-3707
3 - BLEED VALVE
4 - PROBE
24 - 16 CONTROLS TJ
A/C HEATER CONTROL (Continued)
LOCATING VACUUM LEAKS
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Di sconnect the vacuum harness connector at
the back of the A/C-heater control .
(2) Connect the test set vacuum hose probe to each
port i n the vacuum harness connector, one port at a
ti me, and pause after each connecti on (Fi g. 10). The
test set gauge shoul d return to the 27 kPa (8 i n. Hg.)
setti ng shortl y after each connecti on i s made. I f OK,
repl ace the faul ty mode control swi tch. I f not OK, go
to Step 3.
(3) Determi ne the vacuum l i ne col or of the vacuum
ci rcui t that i s l eaki ng. To determi ne the vacuum l i ne
col ors, refer to the Vacuum Ci rcui t charts (Fi g. 11)
and (Fi g. 12).
(4) Di sconnect and pl ug the vacuum l i ne from the
component (fi tti ng, actuator, val ve, swi tch, or reser-
voi r) on the other end of the l eaki ng ci rcui t. I nstru-
ment panel di sassembl y or removal may be necessary
to gai n access to some components.
(5) Connect the test set hose or probe to the open
end of the l eaki ng ci rcui t. The test set gauge shoul d
return to the 27 kPa (8 i n. Hg.) setti ng shortl y after
each connecti on i s made. I f OK, repl ace the faul ty
di sconnected component. I f not OK, go to Step 6.
(6) To l ocate a l eak i n a vacuum l i ne, l eave one
end of the l i ne pl ugged and connect the test set hose
or probe to the other end. Run your fi ngers sl owl y
al ong the l i ne whi l e watchi ng the test set gauge. The
vacuum readi ng wi l l fl uctuate when your fi ngers con-
tact the source of the l eak. To repai r the vacuum
l i ne, cut out the l eaki ng secti on of the l i ne. Then,
i nsert the l oose ends of the l i ne i nto a sui tabl e l ength
of 3 mm (1/8 i n.) i nsi de di ameter rubber hose.
Fig. 10 Vacuum Circuit Test
TJ CONTROLS 24 - 17
A/C HEATER CONTROL (Continued)
Fig. 11 Vacuum Circuits - Heater Only
24 - 18 CONTROLS TJ
A/C HEATER CONTROL (Continued)
A - NOT USED
B - DEFROST ACTUATOR, FULL POSITION (YELLOW)
C - FLOOR ACTUATOR (BROWN)
D - DEFROST ACTUATOR, MID-POSITION (BLUE)
E - VACUUM SUPPLY, RESERVOIR (BLACK)
F - PANEL ACTUATOR (RED)
G - NOT USED
Fig. 12 Vacuum Circuits - Heater-A/C
A - NOT USED
B - DEFROST ACTUATOR (YELLOW)
C - FLOOR ACTUATOR (BROWN)
D - DEFROST ACTUATOR, MID-POSITION (BLUE)
E - VACUUM SUPPLY, RESERVOIR (BLACK)
F - PANEL ACTUATOR (RED)
G - RECIRCULATION ACTUATOR (GREEN)
TJ CONTROLS 24 - 19
A/C HEATER CONTROL (Continued)
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the gl ove box from the i nstrument
panel (Refer to 23 - BODY/I NSTRUMENT PANEL/
GLOVE BOX - REMOVAL).
(3) Remove the center bezel from the i nstrument
panel (Refer to 23 - BODY/I NSTRUMENT PANEL/
I NSTRUMENT PANEL CENTER BEZEL -
REMOVAL).
(4) Reach through the i nstrument panel gl ove box
openi ng to access and di sconnect the two hal ves of
the A/C-heater control vacuum harness connector
(Fi g. 13).
(5) Remove the two screws that secure the A/C-
heater control to the i nstrument panel .
(6) Pul l the A/C-heater control away from the
i nstrument panel to access the connecti ons on the
back of the control .
(7) Di sconnect the three wi re harness connectors
from the back of the A/C-heater control (Fi g. 14).
(8) Remove the A/C-heater control from the i nstru-
ment panel .
INSTALLATION
(1) Connect the three wi re harness connectors to
the A/C-heater control .
(2) Posi ti on the A/C-heater control onto the i nstru-
ment panel and i nstal l the retai ni ng screws. Ti ghten
the screws to 2.2 N·m (20 i n. l bs.).
(3) Reach through the i nstrument panel gl ove box
openi ng and reconnect the A/C-heater vacuum har-
ness connector.
(4) I nstal l the gl ove box (Refer to 23 - BODY/I N-
STRUMENT PANEL/GLOVE BOX - I NSTALLA-
TI ON).
(5) I nstal l the center bezel (Refer to 23 - BODY/
I NSTRUMENT PANEL/I NSTRUMENT PANEL
CENTER BEZEL - I NSTALLATI ON).
(6) Reconnect the battery negati ve cabl e.
Fig. 13 A/C-Heater Control - Typical
1 - BLOWER MOTOR CONTROL
2 - TEMPERATURE CONTROL
3 - MODE CONTROL
4 - VACUUM HARNESS CONNECTOR
5 - MOUNTING SCREW LOCATIONS
Fig. 14 A/C-Heater Control Connections - Typical
1 - A/C-HEATER CONTROL
2 - BLOWER MOTOR SWITCH
3 - BLOWER MOTOR SWITCH CONNECTOR
4 - TEMPERATURE/ILLUMINATION CONNECTOR
5 - MODE SWITCH CONNECTOR
6 - VACUUM HARNESS
7 - MODE SWITCH
24 - 20 CONTROLS TJ
A/C HEATER CONTROL (Continued)
A/C HIGH PRESSURE SWITCH
DESCRIPTION
The A/C hi gh pressure swi tch i s mounted on a fi t-
ti ng l ocated on the di scharge l i ne near the A/C com-
pressor. The A/C hi gh pressure swi tch turns off the
A/C compressor i f the refri gerant system pressure
exceeds 3100 - 3375 kPa (450 - 490 psi ). The A/C
hi gh pressure swi tch fi tti ng on the di scharge l i ne i s
equi pped wi th an O-ri ng seal and contai ns a
Schrader-type val ve, whi ch al l ows the swi tch to be
servi ced wi thout di schargi ng the refri gerant system.
OPERATION
The A/C hi gh pressure swi tch i s el ectri cal l y con-
nected i n seri es wi th the A/C l ow pressure swi tch
between ground and the Powertrai n Control Modul e
(PCM). The swi tch contacts open and cl ose causi ng
the PCM to turn the A/C compressor cl utch on and
off. Thi s prevents compressor operati on when the di s-
charge l i ne pressure approaches hi gh l evel s.
The A/C hi gh pressure swi tch contacts open when
the di scharge l i ne pressure ri ses above 3100 to 3375
kPa (450 to 490 psi ). The swi tch contacts cl ose when
the di scharge l i ne pressure drops to 1860 to 2275
kPa (270 to 330 psi ).
The A/C hi gh pressure swi tch i s a factory-cal i -
brated uni t whi ch cannot be adjusted or repai red
and, i f faul ty or damaged, i t must be repl aced.
DIAGNOSIS AND TESTING
A/C HIGH PRESSURE SWITCH
Before performi ng di agnosi s of the A/C hi gh pres-
sure swi tch, veri fy that the refri gerant system has
the correct refri gerant charge (Refer to 24 - HEAT-
I NG & AI R CONDI TI ONI NG/PLUMBI NG - STAN-
DARD PROCEDURE).
For ci rcui t descri pti ons and di agrams, refer to the
appropri ate wi ri ng i nformati on. The wi ri ng i nforma-
ti on i ncl udes wi ri ng di agrams, proper wi re and con-
nector repai r procedures, further detai l s on wi re
harness routi ng and retenti on, as wel l as pi n-out and
l ocati on vi ews for the vari ous wi re harness connec-
tors, spl i ces and grounds.
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Di sconnect the wi re harness connector from the
A/C hi gh pressure swi tch.
(3) Check for conti nui ty between the two termi nal s
of the A/C hi gh pressure swi tch. There shoul d be con-
ti nui ty. I f OK, test and repai r the A/C hi gh pressure
swi tch ci rcui t as requi red. I f not OK, repl ace the
swi tch.
REMOVAL
NOTE: It is not necessary to discharge the refriger-
ant system to replace the A/C high pressure switch.
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Di sconnect the wi re harness connector from the
A/C hi gh pressure swi tch (Fi g. 15).
(3) Remove the A/C hi gh pressure swi tch from the
di scharge l i ne fi tti ng.
(4) Remove the O-ri ng seal from the di scharge l i ne
fi tti ng and di scard.
INSTALLATION
NOTE: Replace the O-ring seal before installing the
A/C high pressure switch.
(1) Lubri cate a new O-ri ng seal wi th cl ean refri g-
erant oi l and i nstal l i t on the di scharge l i ne fi tti ng.
Use onl y the speci fi ed O-ri ngs as they are made of a
speci al materi al for the R-134a refri gerant system.
Use onl y refri gerant oi l of the type recommended for
the A/C compressor i n the vehi cl e.
(2) I nstal l and ti ghten the A/C hi gh pressure
swi tch onto the di scharge l i ne fi tti ng. The swi tch
shoul d be hand-ti ghtened securel y onto the di scharge
l i ne fi tti ng.
(3) Connect the wi re harness connector i nto the
A/C hi gh pressure swi tch.
(4) Reconnect the battery negati ve cabl e.
Fig. 15 A/C High Pressure Switch - Typical
1 - SUCTION LINE
2 - SERVICE PORT
3 - A/C HIGH PRESSURE SWITCH
4 - A/C COMPRESSOR
5 - MOUNTING BRACKET
6 - DISCHARGE LINE
TJ CONTROLS 24 - 21
A/C LOW PRESSURE SWITCH
DESCRIPTION
The A/C l ow pressure swi tch i s a si ngl e pol e, si ngl e
throw, pressure actuated swi tch that i s i nstal l ed i n a
threaded port i nto the sucti on passage of the accu-
mul ator. The swi tch i s l ocated on the top of the accu-
mul ator i n a fi tti ng that contai ns a Schrader type
val ve, whi ch al l ows the swi tch to be servi ced wi thout
di schargi ng the refri gerant system. The accumul ator
fi tti ng i s equi pped wi th a O-ri ng to seal the swi tch
pl umbi ng connecti on.
The A/C l ow pressure swi tch i s a factory cal i brated
uni t. The swi tch cannot be adjusted or repai red and
i f faul ty or damaged i t must be repl aced.
OPERATION
The A/C l ow pressure swi tch moni tors the pressure
of the refri gerant l eavi ng the accumul ator to the
compressor. The A/C l ow pressure swi tch i s el ectri -
cal l y connected i n seri es wi th the A/C-heater control
mode swi tch and the A/C hi gh pressure swi tch,
between ground and the Powertrai n Control Modul e
(PCM). The A/C l ow pressure swi tch contact opens or
cl oses the path the ground, si gnal i ng the PCM to
turn the A/C compressor cl utch on and off. Thi s reg-
ul ates the refri gerant system pressure and control s
evaporator coi l temperature. Control l i ng the evapora-
tor temperature prevents condensate water on the
evaporator fi ns from freezi ng and obstructi ng ai r con-
di ti oni ng system ai r fl ow.
The A/C l ow pressure swi tch contacts are open
when the sucti on pressure i s approxi matel y 172 kPa
(25 psi ) or l ower. The swi tch contacts wi l l cl ose when
the sucti on pressure ri ses to approxi matel y 276 kPa
(40 psi ) or above. Lower ambi ent temperatures,
bel ow approxi matel y -1° C (30° F), wi l l al so cause the
swi tch contacts to open. Thi s i s due to the pressure/
temperature rel ati onshi p of the refri gerant i n the
system.
DIAGNOSIS AND TESTING
A/C LOW PRESSURE SWITCH
Before performi ng di agnosi s of the A/C l ow pres-
sure swi tch, be certai n that the swi tch i s properl y
i nstal l ed on the accumul ator fi tti ng. I f the swi tch i s
not properl y i nstal l ed, i t may not open the Schrader-
type val ve i n the accumul ator fi tti ng, whi ch wi l l pre-
vent the swi tch from correctl y moni tori ng the
refri gerant system pressure.
(1) Veri fy that the refri gerant system has the cor-
rect refri gerant charge (Refer to 24 - HEATI NG &
AI R CONDI TI ONI NG/PLUMBI NG - STANDARD
PROCEDURE).
(2) Wi th gear sel ector i n park or neutral and park
brake set, start engi ne and al l ow to i dl e.
(3) Pl ace the A/C-heater mode control swi tch i n
any A/C posi ti on.
(4) Rai se hood and di sconnect the wi re harness
connector from the A/C l ow pressure swi tch.
(5) Usi ng a sui tabl e jumper wi re, i nstal l the wi re
between the two termi nal cavi ti es of the A/C l ow
pressure swi tch wi re harness connector. The A/C
compressor cl utch shoul d engage.
(6) I f the A/C compressor cl utch does not engage,
the A/C compressor cl utch, A/C compressor cl utch
rel ay, A/C-heater mode control swi tch, A/C hi gh pres-
sure swi tch, PCM, fuses or rel ated wi ri ng ci rcui ts
may be defecti ve (Refer to 8 - ELECTRI CAL/WI RI NG
DI AGRAM I NFORMATI ON - DI AGNOSI S AND
TESTI NG).
(7) I f the A/C compressor cl utch does engage, con-
nect a mani fol d gauge set to the l ow si de refri gerant
system servi ce port (Refer to 24 - HEATI NG & AI R
CONDI TI ONI NG - STANDARD PROCEDURE).
(8) Check for conti nui ty between the two termi nal s
of the A/C l ow pressure swi tch. There shoul d be con-
ti nui ty wi th a sucti on pressure readi ng of 276 kPa
(40 psi ) or above, and no conti nui ty wi th a sucti on
pressure readi ng of 172 kPa (25 psi ) or bel ow. I f OK,
test and repai r the A/C compressor cl utch, A/C com-
pressor cl utch rel ay, A/C-heater mode control swi tch,
A/C hi gh pressure swi tch, PCM, fuses or rel ated wi r-
i ng ci rcui ts as requi red. I f not OK, repl ace the faul ty
A/C l ow pressure swi tch.
REMOVAL
NOTE: Note: It is not necessary to discharge the
refrigerant system to replace the A/C low pressure
switch.
(1) Di sconnect and i sol ate the battery negati ve cabl e.
(2) Di sconnect the wi re harness connector from the
A/C l ow pressure swi tch (Fi g. 16).
(3) Remove the A/C l ow pressure swi tch from the
fi tti ng on the top of the accumul ator.
(4) Remove the O-ri ng seal from the accumul ator
fi tti ng and di scard.
INSTALLATION
NOTE: Replace the O-ring seal before installing the
A/C low pressure switch.
(1) Lubri cate a new O-ri ng seal wi th cl ean refri g-
erant oi l and i nstal l i t on the accumul ator fi tti ng.
Use onl y the speci fi ed O-ri ngs as they are made of a
speci al materi al for the R-134a system. Use onl y
refri gerant oi l of the type recommended for the A/C
compressor i n the vehi cl e.
24 - 22 CONTROLS TJ
(2) I nstal l and ti ghten the A/C l ow pressure swi tch
on the accumul ator fi tti ng. The swi tch shoul d be
hand-ti ghtened securel y onto the accumul ator fi tti ng.
(3) Connect the wi re harness connector to the A/C
l ow pressure swi tch.
(4) Reconnect the battery negati ve cabl e.
BLEND DOOR ACTUATOR
DESCRIPTION
The bl end door actuator i s a motor/geartrai n
assembl y whi ch mechani cal l y posi ti ons the bl end
door. The actuator i s mounted to the bottom of the
HVAC housi ng i n the center.
OPERATION
The mode door actuator i s connected to the A/C-
heater control through the vehi cl e el ectri cal system
by a dedi cated three-wi re l ead and connector of the
HVAC wi re harness. The mode door actuator can
move the mode door i n two di recti ons. The posi ti on of
the mode door actuator i s control l ed by a potenti om-
eter i n the A/C-heater control . The bl end door actua-
tor cannot be adjusted or repai red and, i f faul ty or
damaged, i t must be repl aced.
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Di sconnect the wi re harness connector from the
el ectri cal connector of bl end door actuator (Fi g. 17).
(3) Remove the three screws that secure the bl end
door actuator to the HVAC housi ng.
(4) Remove the bl end door actuator from the
HVAC housi ng.
INSTALLATION
(1) Posi ti on the bl end door actuator onto the
HVAC housi ng. I f necessary, rotate the actuator
sl i ghtl y to al i gn the spl i nes on the actuator output
sl eeve wi th those on the bl end door l i nkage.
(2) I nstal l and ti ghten the screws that secures the
bl end door actuator to the housi ng. Ti ghten the
screws to 1.1 N·m (10 i n. l bs.).
(3) Connect the HVAC wi re harness connector to
the bl end door actuator.
(4) Reconnect the battery negati ve cabl e.
Fig. 16 A/C Low Pressure Switch - Typical
1 - WIRE HARNESS CONNECTOR
2 - ACCUMULATOR
3 - A/C LOW PRESSURE SWITCH
Fig. 17 Blend Door Actuator
1 - ELECTRICAL CONNECTOR
2 - BLEND DOOR ACTUATOR
3 - MOUNTING POINTS
TJ CONTROLS 24 - 23
A/C LOW PRESSURE SWITCH (Continued)
BLOWER MOTOR RELAY
DESCRIPTION
The bl ower motor rel ay (Fi g. 18) i s a I nternati onal
Standards Organi zati on (I SO)-type rel ay. Rel ays con-
formi ng to the I SO speci fi cati ons have common phys-
i cal di mensi ons, current capaci ti es, termi nal
patterns, and termi nal functi ons. The rel ay i s a el ec-
tromechani cal devi ce that swi tches battery current
from a fuse i n the power di stri buti on center (PDC)
di rectl y to the bl ower motor. The rel ay i s energi zed
when the rel ay coi l i s provi ded a vol tage si gnal by
the i gni ti on swi tch. The bl ower motor rel ay i s l ocated
i n the PDC i n the engi ne compartment. See the fuse
and rel ay l ayout l abel affi xed to the i nsi de surface of
the PDC cover for bl ower motor rel ay i denti fi cati on
and l ocati on.
The bl ower motor rel ay cannot be adjusted or
repai red. I f the rel ay i s damaged or faul ty, i t must be
repl aced.
OPERATION
When the bl ower motor swi tch i s i n any posi ti on
except off, and the i gni ti on i s turned on, the bl ower
motor rel ay i s energi zed and provi des battery feed to
the bl ower motor from a fuse i n the Power Di stri bu-
ti on Center (PDC) i n the engi ne compartment.
The bl ower motor rel ay coi l i s control l ed by a vol t-
age si gnal from the A/C-heater control .
The bl ower motor rel ay i s i nstal l ed i n a wi re har-
ness connector l ocated near the passenger si de out-
board end of the HVAC housi ng i n the passenger
compartment, next to the HVAC wi re harness con-
nector.
Refer to the appropri ate wi ri ng i nformati on for
di agnosi s and testi ng of the bl ower motor rel ay and
for compl ete HVAC wi ri ng di agrams.
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the gl ove box from the i nstrument
panel (Refer to 23 - BODY/I NSTRUMENT PANEL/
GLOVE BOX - REMOVAL).
(3) Locate the bl ower motor rel ay through the
i nstrument panel gl ove box openi ng. The rel ay i s
mounted upri ght and to the ri ght of the i nstrument
panel harness (Fi g. 19).
(4) Remove the bl ower motor rel ay from i ts wi re
harness connector.
Fig. 18 Blower Motor Relay
30 - COMMON FEED
85 - COIL GROUND
86 - COIL BATTERY
87 - NORMALLY OPEN
87A - NORMALLY CLOSED
Fig. 19 Blower Motor Relay
1 - AIR INTAKE
2 - RECIRCULATION DOOR LINKAGE
3 - RECIRCULATION DOOR ACTUATOR
4 - BLOWER MOTOR RELAY
5 - HVAC ELECTRICAL CONNECTOR
6 - HVAC VACUUM CONNECTOR
7 - HVAC HOUSING
24 - 24 CONTROLS TJ
INSTALLATION
(1) Al i gn the bl ower motor rel ay termi nal s wi th
the termi nal cavi ti es i n the wi re harness connector.
(2) Push down fi rml y on the bl ower motor rel ay
unti l the termi nal s are ful l y seated i n the connector
receptacl es.
(3) Rei nstal l the gl ove box (Refer to 23 - BODY/I N-
STRUMENT PANEL/GLOVE BOX - I NSTALLA-
TI ON).
(4) Reconnect the battery negati ve cabl e.
BLOWER MOTOR RESISTOR
BLOCK
DESCRIPTION
The bl ower motor resi stor i s mounted to the si de of
the HVAC housi ng near the bl ower motor on the pas-
senger si de of the vehi cl e behi nd the i nstrument
panel . I t can be accessed for servi ce by removi ng the
gl ove box from the i nstrument panel .
OPERATION
The resi stor has mul ti pl e resi stor wi res, each of
whi ch wi l l reduce the current fl ow to the bl ower
motor to change the bl ower motor speed by changi ng
the resi stance i n the bl ower motor ground path. The
bl ower motor swi tch di rects the ground path through
the correct resi stor wi re to obtai n the sel ected speed.
Wi th the bl ower motor swi tch i n the l owest speed
posi ti on, the ground path for the motor i s appl i ed
through al l of the resi stor wi res. Each hi gher speed
sel ected wi th the bl ower motor swi tch appl i es the
bl ower motor ground path through fewer of the resi s-
tor wi res, i ncreasi ng the bl ower motor speed. When
the bl ower motor swi tch i s i n the hi ghest speed posi -
ti on, the bl ower motor resi stor i s bypassed and the
bl ower motor recei ves a di rect path to ground.
The bl ower motor resi stor cannot be repai red and,
i f faul ty or damaged, i t must be repl aced.
DIAGNOSIS AND TESTING
BLOWER MOTOR RESISTOR BLOCK
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
For ci rcui t descri pti ons and di agrams, refer to the
appropri ate wi ri ng i nformati on. The wi ri ng i nforma-
ti on i ncl udes wi ri ng di agrams, proper wi re and con-
nector repai r procedures, further detai l s on wi re
harness routi ng and retenti on, as wel l as pi n-out and
l ocati on vi ews for the vari ous wi re harness connec-
tors, spl i ces and grounds.
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the gl ove box from the i nstrument
panel (Refer to 23 - BODY/I NSTRUMENT PANEL/
GLOVE BOX - REMOVAL).
(3) Di sconnect the wi re harness connector from the
bl ower motor resi stor bl ock.
(4) Check for conti nui ty between each of the
bl ower motor swi tch i nput termi nal s of the resi stor
and the resi stor output termi nal . I n each case there
shoul d be conti nui ty. I f OK, repai r the wi re harness
ci rcui ts between the bl ower motor swi tch and the
bl ower motor resi stor, bl ower motor or bl ower motor
rel ay as requi red. I f not OK, repl ace the faul ty
bl ower motor resi stor bl ock.
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
CAUTION: Stay clear of the blower motor and resis-
tor block (Hot). Do not operate the blower motor
with the resistor block removed.
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the gl ove box from the i nstrument
panel (Refer to 23 - BODY/I NSTRUMENT PANEL/
GLOVE BOX - REMOVAL).
(3) Pul l out the l ock on the bl ower motor resi stor
wi re harness connector to unl ock the connector l atch
(Fi g. 20).
TJ CONTROLS 24 - 25
BLOWER MOTOR RELAY (Continued)
(4) Depress the l atch on the bl ower motor resi stor
wi re harness connector and di sconnect the connector
from the resi stor.
(5) Remove the two screws that secure the bl ower
motor resi stor bl ock to the HVAC housi ng.
(6) Remove the resi stor bl ock from the HVAC
housi ng.
INSTALLATION
(1) Posi ti on the bl ower motor resi stor bl ock i nto
the HVAC housi ng.
(2) I nstal l the two screws that secure the resi stor
bl ock to the HVAC housi ng. Ti ghten the screws to 2.2
N·m (20 i n. l bs.).
(3) Connect the wi re harness connector to the
resi stor bl ock.
(4) Push i n the l ock on the bl ower motor resi stor
wi re harness connector to l ock the connector l atch.
(5) I nstal l the gl ove box (Refer to 23 - BODY/I N-
STRUMENT PANEL/GLOVE BOX - I NSTALLA-
TI ON).
(6) Reconnect the battery negati ve cabl e.
BLOWER MOTOR SWITCH
DESCRIPTION
The bl ower motor for the heater-onl y or heater-A/C
system i s control l ed by a rotary-type bl ower motor
swi tch, mounted i n the A/C-heater control panel . The
swi tch al l ows the sel ecti on of four di fferent bl ower
motor speeds and i ncl udes an Off posi ti on.
OPERATION
The bl ower motor swi tch provi des a bl ower motor
ground path through the A/C-heater mode control
swi tch. The bl ower motor swi tch di rects thi s ground
path through or around the bl ower motor resi stor
wi res, as requi red to achi eve the sel ected bl ower
motor speed.
The bl ower motor swi tch cannot be repai red and, i f
faul ty or damaged, i t must be repl aced. The bl ower
motor swi tch knob i s avai l abl e for servi ce repl ace-
ment.
DIAGNOSIS AND TESTING
BLOWER MOTOR SWITCH
For ci rcui t descri pti ons and di agrams, refer to the
appropri ate wi ri ng i nformati on. The wi ri ng i nforma-
ti on i ncl udes wi ri ng di agrams, proper wi re and con-
nector repai r procedures, further detai l s on wi re
harness routi ng and retenti on, as wel l as pi n-out and
l ocati on vi ews for the vari ous wi re harness connec-
tors, spl i ces and grounds.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Check for battery vol tage at the fuse i n the
Power Di stri buti on Center (PDC). I f OK, go to Step
2. I f not OK, repai r the shorted ci rcui t or component
as requi red and repl ace the faul ty fuse.
(2) Turn the i gni ti on swi tch to the Off posi ti on.
Di sconnect and i sol ate the battery negati ve cabl e.
Remove the A/C-heater control from the i nstrument
panel (Refer to 24 - HEATI NG & AI R CONDI TI ON-
I NG/CONTROLS/A/C HEATER CONTROL -
REMOVAL). Check for conti nui ty between the
ground ci rcui t cavi ty of the A/C-heater wi re harness
connector and a good ground. There shoul d be conti -
nui ty. I f OK, go to Step 3. I f not OK, repai r the open
ci rcui t to ground as requi red.
Fig. 20 Blower Motor Resistor Block- Typical
1 - SCREW (2)
2 - WIRE HARNESS CONNECTOR
3 - CONNECTOR LOCK
4 - HVAC HOUSING
5 - BLOWER MOTOR RESISTOR BLOCK
24 - 26 CONTROLS TJ
BLOWER MOTOR RESISTOR BLOCK (Continued)
(3) Wi th the A/C-heater control wi re harness con-
nector di sconnected, pl ace the A/C-heater mode con-
trol swi tch i n any posi ti on except the Off posi ti on.
Check for conti nui ty between the ground ci rcui t ter-
mi nal and each of the bl ower motor dri ver ci rcui t ter-
mi nal s of the A/C-heater control as you move the
bl ower motor swi tch to each of the four speed posi -
ti ons. There shoul d be conti nui ty at each dri ver ci r-
cui t termi nal i n onl y one bl ower motor swi tch speed
posi ti on. I f OK, test and repai r the bl ower dri ver ci r-
cui ts between the A/C-heater control connector and
the bl ower motor resi stor as requi red. I f not OK,
repl ace the faul ty A/C-heater control uni t.
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Usi ng a tri m sti ck or another sui tabl e wi de
fl at-bl aded tool , gentl y pry the bl ower motor swi tch
knob off of the swi tch stem from the front of the A/C-
heater control .
(3) Remove the A/C-heater control from the i nstru-
ment panel (Refer to 24 - HEATI NG & AI R CONDI -
TI ONI NG/CONTROLS/A/C HEATER CONTROL -
REMOVAL).
(4) Remove the screw that secures the bl ower
motor swi tch to the rear of the A/C-heater control
(Fi g. 21).
(5) Remove the bl ower motor swi tch from the A/C-
heater control .
INSTALLATION
(1) Posi ti on the bl ower motor swi tch i nto the rear
of the A/C-heater control .
(2) I nstal l the screw that secures the bl ower motor
swi tch to the A/C-heater control . Ti ghten the screw to
2.2 N·m (20 i n. l bs.).
(3) I nstal l the A/C-heater control (Refer to 24 -
HEATI NG & AI R CONDI TI ONI NG/CONTROLS/A/C
HEATER CONTROL - I NSTALLATI ON).
(4) I nstal l the bl ower motor swi tch knob onto the
swi tch stem on the front of the A/C-heater control .
(5) Reconnect the battery negati ve cabl e.
MODE DOOR ACTUATOR
DESCRIPTION
The actuators used to operate the defrost, fl oor and
panel /demi ster doors i n the HVAC housi ng are two-
posi ti on vacuum operated. When vacuum i s suppl i ed
by the A/C-heater control to the defrost, fl oor or pan-
el /demi ster actuators, the actuator l i nkage i s pul l ed
i nto the actuator, whi ch moves the mode door l ever
and mode door to one of the two posi ti ons. The actua-
tor for the fl oor and panel /demi ster doors are spri ng
l oaded, so when vacuum i s rel eased from the actua-
tor, the l i nkage moves the mode door back to i ts
stati c posi ti on. The actuator for the defroster door i s
vacuum operated i n both di recti ons. The defrost, fl oor
or panel /demi ster actuators are not servi ceabl e and
must be repl aced i f found to be defecti ve.
Fig. 21 Blower Motor Switch
1 - A/C-HEATER CONTROL
2 - SCREW
3 - BLOWER MOTOR SWITCH
4 - VACUUM HARNESS
5 - MODE CONTROL SWITCH
TJ CONTROLS 24 - 27
BLOWER MOTOR SWITCH (Continued)
REMOVAL
DEFROST DOOR ACTUATOR
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the knee bl ocker from the i nstrument
panel .
(3) Unpl ug the two vacuum harness connectors
from the defrost door actuator (Fi g. 22).
(4) I nsert a tri m sti ck or another sui tabl e wi de
fl at-bl aded tool i nto the l atch hol e on the HVAC
housi ng actuator mount (Fi g. 23). Gentl y pry the
actuator l atch whi l e pul l i ng fi rml y outwards on the
actuator to remove the actuator from the mount.
(5) Rotate and ti l t the vacuum actuator as
requi red to di sengage the hol e on the end of the
actuator l i nk from the hooked pi n on the end of the
defrost door l ever.
(6) Remove the defrost door vacuum actuator from
the vehi cl e.
FLOOR DOOR ACTUATOR
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the knee bl ocker from the i nstrument
panel .
Fig. 22 Defrost, Floor, and Panel/Demist Door
Vacuum Actuators - Typical
1 - PANEL/DEMIST DOOR ACTUATOR
2 - DEFROST DOOR ACTUATOR
3 - FLOOR DOOR ACTUATOR
Fig. 23 Vacuum Actuator Remove/Install - Typical
1 - ACTUATOR MOUNT LATCH HOLE
2 - TRIM STICK
3 - ACTUATOR LATCH
24 - 28 CONTROLS TJ
MODE DOOR ACTUATOR (Continued)
(3) Remove the defrost door actuator from the
HVAC housi ng.
(4) Unpl ug the vacuum harness connector from the
fl oor door actuator (Fi g. 22).
(5) I nsert a tri m sti ck or another sui tabl e wi de
fl at-bl aded tool i nto the l atch hol e on the HVAC
housi ng actuator mount (Fi g. 23). Gentl y pry the
actuator l atch whi l e pul l i ng fi rml y outwards on the
actuator to remove the actuator from the mount.
(6) Rotate and ti l t the vacuum actuator as
requi red to di sengage the hol e on the end of the
actuator l i nk from the hooked pi n on the end of the
fl oor door l ever.
(7) Remove the fl oor door vacuum actuator from
the vehi cl e.
PANEL/DEMIST DOOR ACTUATOR
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the knee bl ocker from the i nstrument
panel .
(3) Unpl ug the vacuum harness connector from the
panel /demi st door actuator (Fi g. 22).
(4) Remove the push nut fasteni ng the panel /de-
mi st door vacuum actuator l i nkage to the panel /de-
mi st door l ever.
(5) I nsert a tri m sti ck or another sui tabl e wi de
fl at-bl aded tool i nto the l atch hol e on the HVAC
housi ng actuator mount (Fi g. 23). Gentl y pry the
actuator l atch whi l e pul l i ng fi rml y outwards on the
actuator to remove the actuator from the mount.
(6) Remove the panel /demi st door vacuum actuator
from the vehi cl e.
INSTALLATION
DEFROST DOOR ACTUATOR
(1) Rotate and ti l t the vacuum actuator as
requi red to engage the hol e on the end of the actua-
tor l i nk to the hooked pi n on the end of the defrost
door l ever.
(2) Push the actuator onto the mounti ng boss unti l
i ts snaps i nto the l ocked posi ti on.
(3) Connect the two vacuum hoses to the actuator.
(4) I nstal l the i nstrument panel knee bl ocker.
(5) Reconnect the battery negati ve cabl e.
FLOOR DOOR ACTUATOR
(1) Rotate and ti l t the vacuum actuator as
requi red to engage the hol e on the end of the actua-
tor l i nk to the hooked pi n on the end of the fl oor door
l ever.
(2) Push the actuator onto the mounti ng boss unti l
i t snaps i nto the l ocked posi ti on.
(3) Connect the vacuum hose to the actuator.
(4) I nstal l the defrost door actuator.
(5) I nstal l the i nstrument panel knee bl ocker.
(6) Reconnect the battery negati ve cabl e.
PANEL/DEMIST DOOR ACTUATOR
(1) Push the actuator onto the mounti ng boss unti l
i t snaps i nto the l ocked posi ti on.
(2) Engage the hol e on the end of the actuator l i nk
to the pi n on the end of the panel /demi st door l ever
and i nstal l the push nut.
(3) Connect the vacuum hose to the actuator.
(4) I nstal l the i nstrument panel knee bl ocker.
(5) Reconnect the battery negati ve cabl e.
RECIRCULATION DOOR
ACTUATOR
DESCRIPTION
The actuator used to operate the reci rcul ati on door
i n the HVAC housi ng i s two-posi ti on vacuum oper-
ated. When vacuum i s suppl i ed by the A/C-heater
mode control to the reci rcul ati on door actuator, the
actuator l i nkage i s pul l ed i nto the actuator, whi ch
moves the reci rcul ati on door l ever and door to the
reci rcul ati on posi ti on. The actuator i s spri ng l oaded,
so when vacuum i s rel eased from the actuator, the
l i nkage moves the reci rcul ati on door back to i ts stati c
posi ti on.
The reci rcul ati on door actuator i s not servi ceabl e
and must be repl aced i f found to be defecti ve.
TJ CONTROLS 24 - 29
MODE DOOR ACTUATOR (Continued)
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
NOTE: The recirculation door and actuator are used
only on models equipped with air conditioning.
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the gl ove box (Refer to 23 - BODY/I N-
STRUMENT PANEL/GLOVE BOX - REMOVAL).
(3) Remove the dash si de panel (end cap).
(4) Remove the speaker.
(5) Remove the ri ght vent duct.
(6) Unpl ug the vacuum harness connector from the
reci rcul ati on door actuator (Fi g. 24).
(7) I nsert a tri m sti ck or another sui tabl e wi de
fl at-bl aded tool i nto the l atch hol e on the HVAC
housi ng actuator mount (Fi g. 25). Gentl y pry the
actuator l atch whi l e pul l i ng fi rml y outwards on the
actuator to remove the actuator from the mount.
(8) Rotate and ti l t the vacuum actuator as
requi red to di sengage the hol e on the end of the
actuator l i nk from the hooked pi n on the end of the
reci rcul ati on door l ever.
(9) Remove the reci rcul ati on door vacuum from the
vehi cl e.
INSTALLATION
(1) Rotate and ti l t the vacuum actuator as
requi red to engage the hol e on the end of the actua-
tor l i nk to the hooked pi n on the end of the reci rcu-
l ati on door l ever.
(2) Push the actuator onto the mounti ng boss unti l
i t snaps i nto the l ocked posi ti on.
(3) Connect the vacuum hose to the actuator.
(4) I nstal l the ri ght vent duct.
(5) I nstal l the speaker.
(6) I nstal l the dash si de panel (end cap).
(7) I nstal l the gl ove box (Refer to 23 - BODY/I N-
STRUMENT PANEL/GLOVE BOX - I NSTALLA-
TI ON).
(8) Reconnect the battery negati ve cabl e.
Fig. 24 Recirculation Door Actuator - Typical
1 - HOOKED PIN
2 - RECIRCULATION DOOR LEVER
3 - RECIRCULATION DOOR ACTUATOR
4 - BLOWER MOTOR RESISTOR BLOCK
Fig. 25 Vacuum Actuator Remove/Install - Typical
1 - ACTUATOR MOUNT LATCH HOLE
2 - TRIM STICK
3 - ACTUATOR LATCH
24 - 30 CONTROLS TJ
RECIRCULATION DOOR ACTUATOR (Continued)
VACUUM CHECK VALVE
DESCRIPTION
Two vacuum check val ves are i nstal l ed i n the
accessory vacuum suppl y system. One i s on the
accessory vacuum suppl y l i ne i n the engi ne compart-
ment, near the vacuum tap on the engi ne i ntake
mani fol d. A second vacuum check val ve i s l ocated at
the HVAC system takeout. The vacuum check val ves
are desi gned to al l ow vacuum to fl ow i n onl y one
di recti on through the vacuum suppl y ci rcui ts.
OPERATION
The use of the two vacuum check val ves hel p to
mai ntai n the system vacuum needed to retai n the
sel ected A/C-heater mode setti ngs. The check val ves
prevent the engi ne from bl eedi ng down system vac-
uum through the i ntake mani fol d duri ng extended
heavy engi ne l oad (l ow engi ne vacuum) operati on.
The vacuum check val ves cannot be repai red and,
i f faul ty or damaged, must be repl aced.
REMOVAL
NOTE: Note the orientation of the check valves in
the vacuum supply line for correct reinstallation.
(1) Remove the vacuum check val ve from the fi t-
ti ng at the engi ne i ntake mani fol d and the accessory
vacuum suppl y l i ne (Fi g. 26).
(2) Remove the vacuum check val ve from the
HVAC vacuum suppl y l i ne fi tti ng and the accessory
vacuum suppl y l i ne.
INSTALLATION
(1) Usi ng the ori entati on noted when removed,
pl ug the vacuum check val ve i nto the HVAC vacuum
suppl y l i ne fi tti ng and the accessory vacuum suppl y
l i ne.
(2) Usi ng the ori entati on noted when removed,
pl ug the vacuum check val ve i nto the fi tti ng at the
engi ne i ntake mani fol d and the accessory vacuum
suppl y l i ne.
Fig. 26 Vacuum Check Valves - Typical
1 - SCREW
2 - VACUUM CHECK VALVE (2)
3 - VACUUM LINE RETAINER (2)
4 - ACCESSORY VACUUM SUPPLY LINE
5 - ENGINE VACUUM FITTING
6 - HVAC VACUUM SUPPLY LINE
7 - INNER FENDER
8 - VACUUM RESERVOIR
TJ CONTROLS 24 - 31
VACUUM RESERVOIR
DESCRIPTION
The vacuum reservoi r i s mounted to the rear of the
ri ght front i nner fender wheel house i n the engi ne
compartment, under the battery tray. The battery
and battery tray must be removed from the vehi cl e to
access the vacuum reservoi r for servi ce.
OPERATION
Engi ne vacuum i s stored i n the vacuum reservoi r.
The stored vacuum i s used to operate the vacuum-
control l ed vehi cl e accessori es duri ng peri ods of l ow
engi ne vacuum such as when the vehi cl e i s cl i mbi ng
a steep grade, or under other hi gh engi ne l oad oper-
ati ng condi ti ons.
The vacuum reservoi r cannot be repai red and, i f
faul ty or damaged, i t must be repl aced.
REMOVAL
(1) Remove the battery and battery tray from the
engi ne compartment (Refer to 8 - ELECTRI CAL/BAT-
TERY SYSTEM/BATTERY - REMOVAL) and (Refer
to 8 - ELECTRI CAL/BATTERY SYSTEM/TRAY -
REMOVAL).
(2) Unpl ug the accessory vacuum suppl y l i ne from
the vacuum reservoi r (Fi g. 27).
(3) Remove the one screw that secures the reser-
voi r to the i nner fender panel .
(4) Remove the vacuum reservoi r from the engi ne
compartment.
INSTALLATION
(1) Posi ti on the vacuum reservoi r i nto the engi ne
compartment.
(2) I nstal l the screw that secures the reservoi r to
the i nner fender panel . Ti ghten the screw to 2.2 N·m
(20 i n. l bs.).
(3) Connect the accessory vacuum suppl y l i ne to
the vacuum reservoi r.
(4) I nstal l the battery tray and battery (Refer to 8
- ELECTRI CAL/BATTERY SYSTEM/TRAY -
I NSTALLATI ON) and (Refer to 8 - ELECTRI CAL/
BATTERY SYSTEM/BATTERY - I NSTALLATI ON).
Fig. 27 Vacuum Reservoir - Typical
1 - SCREW
2 - VACUUM CHECK VALVE (2)
3 - VACUUM LINE RETAINER (2)
4 - ACCESSORY VACUUM SUPPLY LINE
5 - ENGINE VACUUM FITTING
6 - HVAC VACUUM SUPPLY LINE
7 - INNER FENDER
8 - VACUUM RESERVOIR
24 - 32 CONTROLS TJ
DISTRIBUTION
TABLE OF CONTENTS
page page
AIR OUTLETS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 33
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 33
BLEND DOOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 34
BLOWER MOTOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 34
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 34
DIAGNOSIS AND TESTING
BLOWER MOTOR . . . . . . . . . . . . . . . . . . . 35
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 38
DEFROSTER DUCT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 39
FLOOR DISTRIBUTION DUCT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 39
HVAC HOUSING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . 40
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 41
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 42
INSTRUMENT PANEL DEMISTER DUCTS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 43
INSTRUMENT PANEL DUCTS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 44
MODE DOOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 45
RECIRCULATION AIR DOOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
AIR OUTLETS
DESCRIPTION
There are four panel outl ets i n the i nstrument
panel , one l ocated near each outboard end of the
i nstrument panel faci ng the rear of the vehi cl e, and
two l ocated near the top of the i nstrument panel cen-
ter bezel . The ai r outl ets can be removed i ndi vi dual l y
for servi ce repl acement.
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
NOTE: The instrument panel air outlets are retained
into the outlet housings by a light snap fit.
(1) Usi ng a tri m sti ck or another sui tabl e wi de
fl at-bl aded tool , gentl y pry the panel ai r outl et(s) out
of the panel outl et housi ng(s).
INSTALLATION
(1) Posi ti on the ai r outl et(s) onto the outl et hous-
i ng(s).
(2) Gentl y push the ai r outl et i nto the housi ng
unti l i t snaps i nto posi ti on.
TJ DISTRIBUTION 24 - 33
BLEND DOOR
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Remove the HVAC housi ng from the vehi cl e
(Refer to 24 - HEATI NG & AI R CONDI TI ONI NG/
DI STRI BUTI ON/HVAC HOUSI NG - REMOVAL).
(2) Di sassembl e the HVAC housi ng (Refer to 24 -
HEATI NG & AI R CONDI TI ONI NG/DI STRI BUTI ON/
HVAC HOUSI NG - DI SASSEMBLY).
(3) Li ft the bl end door pi vot shaft out of the actua-
tor and pi vot hol e i n the bottom of the l ower hal f of
the HVAC housi ng (Fi g. 1).
INSTALLATION
(1) Posi ti on the bl end door pi vot shaft i nto the
pi vot hol e and actuator i n the bottom of the l ower
hal f of the HVAC housi ng.
(2) Assembl e the HVAC housi ng (Refer to 24 -
HEATI NG & AI R CONDI TI ONI NG/DI STRI BUTI ON/
HVAC HOUSI NG - ASSEMBLY).
(3) I nstal l the HVAC housi ng (Refer to 24 - HEAT-
I NG & AI R CONDI TI ONI NG/DI STRI BUTI ON/HVAC
HOUSI NG - I NSTALLATI ON).
BLOWER MOTOR
DESCRIPTION
The bl ower motor and bl ower wheel are l ocated i n
the passenger si de end of the HVAC housi ng, bel ow
the gl ove box. The bl ower motor control s the vel oci ty
of ai r fl owi ng through the HVAC housi ng by spi nni ng
a squi rrel cage-type bl ower wheel wi thi n the housi ng
at the sel ected speed. The bl ower motor and wheel
can be removed from i nsi de the vehi cl e wi thout
removi ng the i nstrument panel or HVAC housi ng.
OPERATION
The bl ower motor wi l l operate onl y when the i gni -
ti on swi tch i s i n the On posi ti on, and wi th the A/C-
heater mode control swi tch i n any posi ti on, except
Off. The bl ower motor recei ves a fused battery feed
through the bl ower motor rel ay whenever the i gni -
ti on swi tch i s i n the On posi ti on. The bl ower motor
battery feed ci rcui t i s protected by a fuse i n the
Power Di stri buti on Center (PDC). Bl ower motor
speed i s control l ed by regul ati ng the ground path
through the bl ower motor swi tch and the bl ower
motor resi stor.
The bl ower motor and bl ower wheel are servi ced
onl y as a uni t and cannot be repai red and, i f faul ty
or damaged, must be repl aced.
Fig. 1 Blend Door - Typical
1 - BLEND DOOR
2 - EVAPORATOR COIL
3 - PIVOT HOLE
4 - HEATER CORE
24 - 34 DISTRIBUTION TJ
DIAGNOSIS AND TESTING
BLOWER MOTOR
BLOWER MOTOR INOPERATIVE
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
For ci rcui t descri pti ons and di agrams, refer to the
appropri ate wi ri ng i nformati on. The wi ri ng i nforma-
ti on i ncl udes wi ri ng, di agrams, proper wi re and con-
nector repai r procedures, further detai l s on wi re
harness routi ng and retenti on, as wel l as pi n-out and
l ocati on vi ews for the vari ous wi re harness connec-
tors, spl i ces and grounds.
BLOWER MOTOR ELECTRICAL DIAGNOSIS
Refer to the Bl ower Motor El ectri cal Di agnosi s
chart for basi c checks of the bl ower motor ci rcui t
(Fi g. 2).
BLOWER MOTOR NOISE OR VIBRATION
Refer to the Bl ower Motor Noi se/Vi brati on Di agno-
si s chart for basi c checks of the bl ower motor when a
vi brati on or noi se i s present (Fi g. 3).
TJ DISTRIBUTION 24 - 35
BLOWER MOTOR (Continued)
Fig. 2 Blower Motor Electrical Diagnosis
24 - 36 DISTRIBUTION TJ
BLOWER MOTOR (Continued)
Fig. 3 Blower Motor Noise/Vibration Diagnosis
TJ DISTRIBUTION 24 - 37
BLOWER MOTOR (Continued)
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
The bl ower motor i s l ocated on the passenger si de
of the vehi cl e under the dash. The bl ower motor can
be removed from the vehi cl e wi thout havi ng to
remove the HVAC housi ng.
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Unpl ug the bl ower motor wi re harness connec-
tor (Fi g. 4).
(3) Rel ease bl ower motor retai ner-l ocki ng tab and
rotate bl ower motor countercl ockwi se.
(4) Remove bl ower motor from the HVAC housi ng.
INSTALLATION
NOTE: Failure to install the blower motor assembly
correctly could result in an air leak or the blower
motor assembly becoming completely disengaged
from the HVAC housing.
(1) Al i gn and i nstal l the bl ower motor i nto the
HVAC housi ng.
(2) Rotate the bl ower motor unti l al l of the l ocki ng
tabs have secured the bl ower motor assembl y to the
HVAC housi ng.
(3) Connect the wi re harness connector to the
bl ower motor.
(4) Reconnect the battery negati ve cabl e.
(5) Test the bl ower motor for proper i nstal l ati on by
turni ng the bl ower motor speed to i ts fastest posi ti on
and checki ng around the outer edges of the bl ower
assembl y for ai r l eaks. I f any ai r l eaks are found,
remove and rei nstal l the bl ower motor.
DEFROSTER DUCT
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Remove the i nstrument panel from the vehi cl e
(Refer to 23 - BODY/I NSTRUMENT PANEL/I N-
STRUMENT PANEL ASSEMBLY - REMOVAL).
(2) Remove the two nuts that secure the defroster
duct to the studs on the dash panel (Fi g. 5).
(3) Remove the defroster duct from the studs on
the dash panel .
Fig. 4 HVAC Blower Motor - Typical
1 - HVAC HOUSING
2 - BLOWER MOTOR
3 - RETAINER-LOCKING TAB
4 - WIRE HARNESS CONNECTOR
24 - 38 DISTRIBUTION TJ
BLOWER MOTOR (Continued)
INSTALLATION
(1) I nstal l the defroster duct onto the dash panel
studs.
(2) I nstal l the two push-nuts that secure the
defroster duct on the studs.
(3) I nstal l the i nstrument panel (Refer to 23 -
BODY/I NSTRUMENT PANEL/I NSTRUMENT
PANEL ASSEMBLY - I NSTALLATI ON).
FLOOR DISTRIBUTION DUCT
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Remove the i nstrument panel from the vehi cl e
(Refer to 23 - BODY/I NSTRUMENT PANEL/I N-
STRUMENT PANEL ASSEMBLY - REMOVAL).
(2) Remove the three screws that secure the fl oor
di stri buti on duct to the bottom of the HVAC housi ng
(Fi g. 6).
(3) Remove the screw that secures the fl oor di stri -
buti on duct to the si de of the HVAC housi ng.
(4) Sl i de the fl oor duct out from under the HVAC
housi ng.
INSTALLATION
(1) Posi ti on the fl oor di stri buti on duct to the bot-
tom of the HVAC housi ng.
(2) I nstal l the screw that secures the fl oor di stri -
buti on duct to the si de of the HVAC housi ng. Ti ghten
the screw to 2.2 N·m (20 i n. l bs.).
(3) I nstal l the three screws that secure the fl oor
di stri buti on duct to the bottom of the HVAC housi ng.
Ti ghten the screws to 2.2 N·m (20 i n. l bs.).
(4) I nstal l the i nstrument panel (Refer to 23 -
BODY/I NSTRUMENT PANEL/I NSTRUMENT
PANEL ASSEMBLY - I NSTALLATI ON).
(5) Reconnect the battery negati ve cabl e.
Fig. 5 Defroster Duct - LHD Shown, RHD Typical
1 - DEFROSTER DUCT
2 - COLLAR
3 - FRESH AIR DUCT
4 - HVAC HOUSING
5 - SCREW
6 - FLOOR DUCT
7 - NUT (2)
8 - NUT (5)
Fig. 6 Floor Distribution Duct - LHD Shown, RHD
Typical
1 - DEFROSTER DUCT
2 - COLLAR
3 - FRESH AIR DUCT
4 - HVAC HOUSING
5 - SCREW
6 - FLOOR DUCT
7 - NUT (2)
8 - NUT (5)
TJ DISTRIBUTION 24 - 39
DEFROSTER DUCT (Continued)
HVAC HOUSING
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
NOTE: The HVAC housing must be removed from
the vehicle and the two halves of the housing sep-
arated for service access of the heater core, evap-
orator coil, blend door, and each of the various
mode doors.
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) I f the vehi cl e i s not equi pped wi th ai r condi -
ti oni ng, go to Step 5. I f the vehi cl e i s equi pped wi th
ai r condi ti oni ng, recover the refri gerant from the
refri gerant system (Refer to 24 - HEATI NG & AI R
CONDI TI ONI NG/PLUMBI NG - STANDARD PRO-
CEDURE).
(3) Di sconnect the l i qui d refri gerant l i ne fi tti ng
from the evaporator i nl et tube (Refer to 24 - HEAT-
I NG & AI R CONDI TI ONI NG/PLUMBI NG/REFRI G-
ERANT LI NE COUPLER - REMOVAL). Di scard the
O-ri ng seal and i nstal l pl ugs i n, or tape over the
opened l i qui d refri gerant l i ne fi tti ng and evaporator
i nl et tube.
(4) Di sconnect the accumul ator i nl et fi tti ng from
the evaporator outl et tube (Refer to 24 - HEATI NG &
AI R CONDI TI ONI NG/PLUMBI NG/REFRI GERANT
LI NE COUPLER - REMOVAL). Di scard the O-ri ng
seal and i nstal l pl ugs i n, or tape over the opened
accumul ator i nl et fi tti ng and evaporator outl et tube.
(5) Drai n the engi ne cool i ng system (Refer to 7 -
COOLI NG - STANDARD PROCEDURE).
(6) Di sconnect the heater hoses from the heater
core tubes. I nstal l pl ugs i n, or tape over the opened
heater core tubes.
(7) Unpl ug the HVAC system vacuum suppl y l i ne
connector from the tee fi tti ng near the heater core
tubes.
(8) Remove the fi ve nuts from the HVAC housi ng
mounti ng studs i n the engi ne compartment. I f neces-
sary, l oosen the battery hol d-downs and reposi ti on
the battery for addi ti onal access (Refer to 8 - ELEC-
TRI CAL/BATTERY SYSTEM/BATTERY -
REMOVAL).
(9) Remove the cowl pl enum drai n tube from the
HVAC housi ng mounti ng stud on the dash panel
di rectl y behi nd the engi ne cyl i nder head.
(10) Remove the i nstrument panel from the vehi cl e
(Refer to 23 - BODY/I NSTRUMENT PANEL/I N-
STRUMENT PANEL ASSEMBLY - REMOVAL).
(11) Remove the fl oor di stri buti on duct from the
bottom of the HVAC housi ng (Refer to 24 - HEATI NG
& AI R CONDI TI ONI NG/DI STRI BUTI ON/FLOOR
DI STRI BUTI ON DUCTS - REMOVAL).
(12) Remove the screw that secures the HVAC
housi ng to the dash panel bracket l ocated on the pas-
senger si de of vehi cl e (Fi g. 7).
(13) Pul l the HVAC housi ng down far enough to
cl ear the defroster and fresh ai r ducts, and rearward
far enough for the mounti ng studs and the evapora-
tor condensate drai n tube to cl ear the dash panel .
(14) Remove the HVAC housi ng from the vehi cl e.
DISASSEMBLY
(1) Remove the HVAC housi ng from the vehi cl e
and pl ace i t on a work bench (Refer to 24 - HEAT-
I NG & AI R CONDI TI ONI NG/DI STRI BUTI ON/HVAC
HOUSI NG - REMOVAL).
(2) Unpl ug the vacuum harness connectors from
the panel /demi st door actuator, defrost door actuator,
fl oor door actuator and reci rcul ati on door actuator (i f
equi pped) (Fi g. 8).
Fig. 7 HVAC Housing - LHD Shown, RHD Typical
1 - DEFROSTER DUCT
2 - COLLAR
3 - FRESH AIR DUCT
4 - HVAC HOUSING
5 - SCREW
6 - FLOOR DUCT
7 - NUT (2)
8 - NUT (5)
24 - 40 DISTRIBUTION TJ
(3) Di sengage the vacuum harness from any rout-
i ng cl i ps l ocated on the l ower hal f of the HVAC hous-
i ng.
(4) Di sengage the HVAC wi re harness connector
and the bl ower motor rel ay wi re harness connector
push-i n retai ners from thei r mounti ng hol es i n the
HVAC housi ng.
(5) Remove the bl ower motor from the HVAC hous-
i ng (Refer to 24 - HEATI NG & AI R CONDI TI ON-
I NG/DI STRI BUTI ON/BLOWER MOTOR -
REMOVAL).
(6) Pul l the vacuum suppl y l i ne and connector
through the foam seal on the heater core and evapo-
rator coi l tube mounti ng fl ange (Fi g. 9).
(7) Remove the screw that secures the evaporator
tube cl amp and remove the cl amp from the evapora-
tor tubes.
(8) Careful l y remove the foam seal from the heater
core and evaporator coi l tubes and mounti ng fl ange
of the HVAC housi ng. I f the seal i s deformed or dam-
aged, i t must be repl aced.
(9) Remove the two snap cl i ps that hel p secure the
upper and l ower HVAC housi ng hal ves together.
(10) Remove the screws that secure the upper and
l ower HVAC housi ng hal ves to each other and those
that hol d the reci rcul ati on housi ng to the upper
housi ng.
(11) Careful l y separate the reci rcul ati on housi ng
and the upper HVAC housi ng hal f from the l ower
housi ng.
ASSEMBLY
(1) Posi ti on the upper HVAC housi ng to the l ower
housi ng. Duri ng assembl y, be certai n of the fol l owi ng:
(a) That each of the mode door pi vot shaft ends
i s properl y engaged i n i ts pi vot hol e.
(b) I f the uni t i s equi pped wi th ai r condi ti oni ng,
that the evaporator coi l tube rubber seal i s prop-
erl y posi ti oned i n the grooves i n both the upper
and l ower HVAC housi ng hal ves.
(2) I nstal l the screws that secure the upper and
l ower HVAC housi ng hal ves to each other and those
that hol d the reci rcul ati on housi ng to the upper
housi ng. Ti ghten the screws to 2.2 N·m (20 i n. l bs.).
(3) I nstal l the two snap cl i ps that hel p secure the
upper and l ower HVAC housi ng hal ves together.
(4) I nstal l the foam seal s on the heater core and
evaporator coi l tubes and mounti ng fl ange of the
HVAC housi ng.
(5) I f the uni t i s equi pped wi th ai r condi ti oni ng,
rei nstal l the evaporator tube cl amp and retai ni ng
screw. Ti ghten the screw to 2.2 N·m (20 i n. l bs.).
(6) I nsert the vacuum suppl y l i ne and connector
through the foam seal on the heater core and evapo-
rator coi l tube mounti ng fl ange.
(7) I nstal l the bl ower motor (Refer to 24 - HEAT-
I NG & AI R CONDI TI ONI NG/DI STRI BUTI ON/
BLOWER MOTOR - I NSTALLATI ON).
(8) Engage the HVAC wi re harness connector and
bl ower motor rel ay wi re harness connector push-i n
retai ners i n the mounti ng hol es of the HVAC hous-
i ng.
Fig. 8 Defrost, Floor, and Panel/Demist Door
Vacuum Actuators - Typical
1 - PANEL/DEMIST DOOR ACTUATOR
2 - DEFROST DOOR ACTUATOR
3 - FLOOR DOOR ACTUATOR
Fig. 9 HVAC Housing Disassembly - Typical
1 - FOAM SEALS
2 - EVAPORATOR TUBE CLAMP
3 - CLIPS
4 - HEATER CORE TUBES
5 - VACUUM SUPPLY LINE
6 - BLOWER MOTOR
TJ DISTRIBUTION 24 - 41
HVAC HOUSING (Continued)
(9) Engage the vacuum harness to the routi ng
cl i ps l ocated on the l ower hal f of the HVAC housi ng.
(10) Pl ug i n the vacuum harness connectors to the
panel /demi st door actuator, defrost door actuator,
fl oor door actuator and reci rcul ati on door actuator (i f
equi pped).
INSTALLATION
(1) Posi ti on the HVAC housi ng to the dash panel .
Be certai n that the evaporator condensate drai n tube
and the housi ng mounti ng studs are i nserted i nto
thei r correct mounti ng hol es, and that the openi ngs
on the top of the housi ng are properl y al i gned wi th
the defroster and fresh ai r ducts.
(2) I nstal l and ti ghten the screw that secures the
HVAC housi ng to the dash panel bracket on the pas-
senger si de of the vehi cl e. Ti ghten the screw to 3.4
N·m (30 i n. l bs.).
(3) I nstal l the fl oor di stri buti on duct to the bottom
of the HVAC housi ng (Refer to 24 - HEATI NG & AI R
CONDI TI ONI NG/DI STRI BUTI ON/FLOOR DI STRI -
BUTI ON DUCTS - I NSTALLATI ON).
(4) I nstal l the cowl drai n tube onto the HVAC
housi ng mounti ng stud on the dash panel di rectl y
behi nd the engi ne cyl i nder head.
(5) I nstal l and ti ghten the fi ve nuts onto the
HVAC housi ng mounti ng studs i n the engi ne com-
partment. Ti ghten the nuts to 6.2 N·m (55 i n. l bs.).
(6) I nstal l the i nstrument panel i n the vehi cl e
(Refer to 23 - BODY/I NSTRUMENT PANEL/I N-
STRUMENT PANEL ASSEMBLY - I NSTALLA-
TI ON).
(7) I f the battery was reposi ti oned duri ng the
removal procedure, posi ti on the battery and ti ghten
the hol d-downs (Refer to 8 - ELECTRI CAL/BAT-
TERY SYSTEM/BATTERY - I NSTALLATI ON).
(8) Connect the HVAC system vacuum suppl y l i ne
connector to the tee fi tti ng near the heater core
tubes.
(9) Unpl ug or remove the tape from the heater
core tubes and connect the heater hoses to the heater
core tubes.
(10) Fi l l the engi ne cool i ng system (Refer to 24 -
HEATI NG & AI R CONDI TI ONI NG/PLUMBI NG/
HEATER CORE - I NSTALLATI ON).
(11) I f the vehi cl e i s not equi pped wi th ai r condi -
ti oni ng, go to Step 15. I f the vehi cl e i s equi pped wi th
ai r condi ti oni ng, unpl ug or remove the tape from the
accumul ator i nl et tube fi tti ng and the evaporator
outl et tube. Usi ng a new O-ri ng seal , connect the
accumul ator i nl et tube fi tti ng to the evaporator out-
l et tube (Refer to 24 - HEATI NG & AI R CONDI -
TI ONI NG/PLUMBI NG/REFRI GERANT LI NE
COUPLER - I NSTALLATI ON).
(12) Unpl ug or remove the tape from the l i qui d
l i ne fi tti ng and the evaporator i nl et tube. Usi ng a
new O-ri ng seal , connect the l i qui d l i ne to the evap-
orator i nl et tube (Refer to 24 - HEATI NG & AI R
CONDI TI ONI NG/PLUMBI NG/REFRI GERANT LI NE
COUPLER - I NSTALLATI ON).
(13) Evacuate the refri gerant system (Refer to 24 -
HEATI NG & AI R CONDI TI ONI NG/PLUMBI NG -
STANDARD PROCEDURE).
(14) Charge the refri gerant system (Refer to 24 -
HEATI NG & AI R CONDI TI ONI NG/PLUMBI NG -
STANDARD PROCEDURE).
(15) Reconnect the battery negati ve cabl e.
(16) Start the engi ne and check for proper opera-
ti on of the heati ng and ai r condi ti oni ng systems.
INSTRUMENT PANEL
DEMISTER DUCTS
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the gl ove box from the i nstrument
panel to gai n access to the passenger si de demi ster
hose (Refer to 23 - BODY/I NSTRUMENT PANEL/
GLOVE BOX - REMOVAL).
(3) Remove the knee bl ocker from the i nstrument
panel to gai n access to the dri ver si de demi ster hose
(Refer to 23 - BODY/I NSTRUMENT PANEL/KNEE
BLOCKER - REMOVAL).
(4) Reach through the gl ove box openi ng and/or
the steeri ng col umn openi ng of the i nstrument panel
and di sconnect the demi ster hose(s) from the demi s-
ter outl et(s) and the defroster duct (Fi g. 10).
24 - 42 DISTRIBUTION TJ
HVAC HOUSING (Continued)
INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Reach through the gl ove box openi ng and/or
the steeri ng col umn openi ng of the i nstrument panel
to connect the demi ster hose(s) to the demi ster out-
l et(s) and the defroster duct.
(2) I f removed, i nstal l the knee bl ocker (Refer to
23 - BODY/I NSTRUMENT PANEL/KNEE BLOCKER
- I NSTALLATI ON).
(3) I f removed, i nstal l the gl ove box (Refer to 23 -
BODY/I NSTRUMENT PANEL/GLOVE BOX -
I NSTALLATI ON).
(4) Reconnect the battery negati ve cabl e.
INSTRUMENT PANEL DUCTS
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Remove the i nstrument panel from the vehi cl e
(Refer to 23 - BODY/I NSTRUMENT PANEL/I N-
STRUMENT PANEL ASSEMBLY - REMOVAL).
(2) Remove the demi ster hoses from the demi ster
outl ets (Fi g. 11).
(3) Remove the two screws that secure the mai n
panel duct to the i nstrument panel .
(4) Remove the one screw that secures each end
panel duct and/or the center panel duct to the i nstru-
ment panel .
(5) Remove the i nstrument panel ducts as neces-
sary from the i nstrument panel
Fig. 10 Instrument Panel Ducts - LHD Shown, RHD
Typical
1 - CENTER PANEL DUCT
2 - DEMISTER HOSE
3 - DEMISTER HOSE
4 - END PANEL DUCT
5 - MAIN PANEL DUCT
6 - END PANEL DUCT
Fig. 11 Instrument Panel Ducts - LHD Shown, RHD
Typical
1 - CENTER PANEL DUCT
2 - DEMISTER HOSE
3 - DEMISTER HOSE
4 - END PANEL DUCT
5 - MAIN PANEL DUCT
6 - END PANEL DUCT
TJ DISTRIBUTION 24 - 43
INSTRUMENT PANEL DEMISTER DUCTS (Continued)
INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Posi ti on the i nstrument panel ducts i nto the
i nstrument panel .
(2) I nstal l the screw that secures each end panel
duct and/or the center panel duct to the i nstrument
panel . Ti ghten the screw to 2.2 N·m (20 i n. l bs.).
(3) I nstal l the two screws that secure the mai n
panel duct to the i nstrument panel . Ti ghten the
screws to 2.2 N·m (20 i n. l bs.).
(4) I nstal l the demi ster hoses to the demi ster out-
l ets.
(5) I nstal l the i nstrument panel (Refer to 23 -
BODY/I NSTRUMENT PANEL/I NSTRUMENT
PANEL ASSEMBLY - I NSTALLATI ON).
(6) Reconnect the battery negati ve cabl e.
MODE DOOR
REMOVAL
DEFROST DOOR
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Remove the HVAC housi ng (Refer to 24 -
HEATI NG & AI R CONDI TI ONI NG/DI STRI BUTI ON/
HVAC HOUSI NG - REMOVAL).
(2) Remove the defrost door actuator (Refer to 24 -
HEATI NG & AI R CONDI TI ONI NG/CONTROLS/
MODE DOOR ACTUATOR - REMOVAL).
(3) Di sassembl e the HVAC housi ng (Refer to 24 -
HEATI NG & AI R CONDI TI ONI NG/DI STRI BUTI ON/
HVAC HOUSI NG - DI SASSEMBLY).
(4) Remove the defrost door from the HVAC hous-
i ng (Fi g. 12).
FLOOR DOOR
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Remove the HVAC housi ng (Refer to 24 -
HEATI NG & AI R CONDI TI ONI NG/DI STRI BUTI ON/
HVAC HOUSI NG - REMOVAL).
(2) Remove the fl oor door actuator (Refer to 24 -
HEATI NG & AI R CONDI TI ONI NG/CONTROLS/
MODE DOOR ACTUATOR - REMOVAL).
(3) Di sassembl e the HVAC housi ng (Refer to 24 -
HEATI NG & AI R CONDI TI ONI NG/DI STRI BUTI ON/
HVAC HOUSI NG - DI SASSEMBLY).
Fig. 12 Panel/Demist and Defrost Doors - Typical
1 - PANEL/DEMIST DOOR
2 - UPPER HVAC HOUSING
3 - DEFROST DOOR
24 - 44 DISTRIBUTION TJ
INSTRUMENT PANEL DUCTS (Continued)
(4) Remove the fl oor door l ever l ocated on the out-
si de of the l ower hal f of the HVAC housi ng from the
fl oor door pi vot shaft.
(5) Reach i nsi de the l ower hal f of the HVAC hous-
i ng and l i ft out the fl oor door.
PANEL/DEMIST DOOR
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Remove the HVAC housi ng (Refer to 24 -
HEATI NG & AI R CONDI TI ONI NG/DI STRI BUTI ON/
HVAC HOUSI NG - REMOVAL).
(2) Remove the defrost and panel /demi st door
actuators (Refer to 24 - HEATI NG & AI R CONDI -
TI ONI NG/CONTROLS/MODE DOOR ACTUATOR -
REMOVAL).
(3) Di sassembl e the HVAC housi ng (Refer to 24 -
HEATI NG & AI R CONDI TI ONI NG/DI STRI BUTI ON/
HVAC HOUSI NG - DI SASSEMBLY).
(4) I nsert a screwdri ver i nto the l atch hol e (Fi g.
13) of the panel /demi st door pi vot shaft to rel ease the
l atch of the panel door l ever.
(5) Remove the panel door l ever l ocated on the out-
si de of the l ower hal f of the HVAC housi ng from the
pi vot shaft.
(6) Reach i nsi de the l ower hal f of the HVAC hous-
i ng and l i ft out the panel /demi st door (Fi g. 12).
INSTALLATION
DEFROST DOOR
(1) Posi ti on the defrost door i nsi de the l ower hal f
of the HVAC housi ng.
(2) Assembl e the HVAC housi ng (Refer to 24 -
HEATI NG & AI R CONDI TI ONI NG/DI STRI BUTI ON/
HVAC HOUSI NG - ASSEMBLY).
(3) I nstal l the defrost door actuator (Refer to 24 -
HEATI NG & AI R CONDI TI ONI NG/CONTROLS/
MODE DOOR ACTUATOR - I NSTALLATI ON).
(4) I nstal l the HVAC housi ng (Refer to 24 - HEAT-
I NG & AI R CONDI TI ONI NG/DI STRI BUTI ON/HVAC
HOUSI NG - I NSTALLATI ON).
FLOOR DOOR
(1) Posi ti on the fl oor door i nsi de the l ower hal f of
the HVAC housi ng.
(2) I nstal l the fl oor door l ever onto the fl oor door
pi vot shaft.
(3) Assembl e the HVAC housi ng (Refer to 24 -
HEATI NG & AI R CONDI TI ONI NG/DI STRI BUTI ON/
HVAC HOUSI NG - ASSEMBLY).
(4) I nstal l the fl oor door actuator (Refer to 24 -
HEATI NG & AI R CONDI TI ONI NG/CONTROLS/
MODE DOOR ACTUATOR - I NSTALLATI ON).
(5) I nstal l the HVAC housi ng (Refer to 24 - HEAT-
I NG & AI R CONDI TI ONI NG/DI STRI BUTI ON/HVAC
HOUSI NG - I NSTALLATI ON).
PANEL/DEMIST DOOR
(1) Posi ti on the panel /demi st door i nsi de the l ower
hal f of the HVAC housi ng.
(2) I nstal l the panel l ever onto the pi vot shaft of
the panel door i n the l ower hal f of the HVAC hous-
i ng.
(3) Assembl e the HVAC housi ng (Refer to 24 -
HEATI NG & AI R CONDI TI ONI NG/DI STRI BUTI ON/
HVAC HOUSI NG - ASSEMBLY).
(4) I nstal l the panel /demi st and defrost door actua-
tors (Refer to 24 - HEATI NG & AI R CONDI TI ON-
I NG/CONTROLS/MODE DOOR ACTUATOR -
I NSTALLATI ON).
(5) I nstal l the HVAC housi ng (Refer to 24 - HEAT-
I NG & AI R CONDI TI ONI NG/DI STRI BUTI ON/HVAC
HOUSI NG - I NSTALLATI ON).
Fig. 13 Panel Door Lever - Typical
1 - DOOR PIVOT SHAFT
2 - LATCH HOLE
3 - CRANK ARM LATCH
4 - FLAT BLADE PRY TOOL
TJ DISTRIBUTION 24 - 45
MODE DOOR (Continued)
RECIRCULATION AIR DOOR
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
NOTE: The recirculation air door is only servicable
by replacing the complete air intake housing
assembly.
24 - 46 DISTRIBUTION TJ
PLUMBING
TABLE OF CONTENTS
page page
PLUMBING
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 48
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 48
WARNING
ENGINE COOLING SYSTEM . . . . . . . . . . . 48
A/C SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 48
CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
DIAGNOSIS AND TESTING
REFRIGERANT SYSTEM LEAKS . . . . . . . . 49
STANDARD PROCEDURE
REFRIGERANT SYSTEM SERVICE
EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . 50
REFRIGERANT CHARGE LEVEL TEST . . . 51
REFRIGERANT SYSTEM RECOVERY . . . . 51
REFRIGERANT SYSTEM EVACUATE . . . . . 51
REFRIGERANT SYSTEM CHARGE . . . . . . 53
A/C COMPRESSOR
DESCRIPTION
A/C COMPRESSOR . . . . . . . . . . . . . . . . . . 53
HIGH PRESSURE RELIEF VALVE . . . . . . . 53
OPERATION
A/C COMPRESSOR . . . . . . . . . . . . . . . . . . 54
HIGH PRESSURE RELIEF VALVE . . . . . . . 54
DIAGNOSIS AND TESTING
A/C COMPRESSOR NOISE . . . . . . . . . . . . 54
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 55
A/C CONDENSER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 56
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 56
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 57
A/C DISCHARGE LINE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 58
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 59
A/C EVAPORATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 59
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 59
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 60
A/C ORIFICE TUBE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 60
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 60
DIAGNOSIS AND TESTING
A/C ORIFICE TUBE . . . . . . . . . . . . . . . . . . 60
ACCUMULATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 61
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 61
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 62
HEATER CORE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 62
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 62
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 63
LIQUID LINE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 63
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 64
REFRIGERANT
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 64
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 64
REFRIGERANT LINE COUPLER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 64
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 64
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 65
REFRIGERANT OIL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 66
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 66
STANDARD PROCEDURE
REFRIGERANT OIL LEVEL . . . . . . . . . . . . . 66
SERVICE PORT VALVE CORE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 66
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 67
SUCTION LINE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 67
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 68
TJ PLUMBING 24 - 47
PLUMBING
DESCRIPTION
The refri gerant l i nes and hoses are used to carry
the refri gerant between the vari ous A/C system com-
ponents. A barri er hose desi gn wi th a nyl on tube,
whi ch i s sandwi ched between rubber l ayers, i s used
for the R-134a A/C system on thi s vehi cl e. Thi s nyl on
tube hel ps to further contai n the R-134a refri gerant,
whi ch has a smal l er mol ecul ar structure than R-12
refri gerant. The ends of the refri gerant hoses are
made from l i ghtwei ght al umi num or steel , and com-
monl y use braze-l ess fi tti ngs.
Any ki nks or sharp bends i n the refri gerant pl umb-
i ng wi l l reduce the capaci ty of the enti re A/C system.
Ki nks and sharp bends reduce the fl ow of refri gerant
i n the system. A good rul e for the fl exi bl e hose refri g-
erant l i nes i s to keep the radi us of al l bends at l east
ten ti mes the di ameter of the hose. I n addi ti on, the
fl exi bl e hose refri gerant l i nes shoul d be routed so
they are at l east 80 mi l l i meters (3 i nches) from the
exhaust mani fol d.
OPERATION
Hi gh pressures are produced i n the refri gerant sys-
tem when the A/C compressor i s operati ng. Extreme
care must be exerci sed to make sure that each of the
refri gerant system connecti ons i s pressure-ti ght and
l eak free. I t i s a good practi ce to i nspect al l fl exi bl e
hose refri gerant l i nes at l east once a year to make
sure they are i n good condi ti on and properl y routed.
The refri gerant l i nes and hoses cannot be repai red
and, i f faul ty or damaged, they must be repl aced.
WARNING
ENGINE COOLING SYSTEM
WARNING: The engine cooling system is designed
to develop internal pressures of 97 to 123 kilopas-
cals (14 to 18 pounds per square inch). Do not
remove or loosen the coolant pressure cap, cylin-
der block drain plugs, radiator drain, radiator
hoses, heater hoses, or hose clamps while the
engine cooling system is hot and under pressure.
Allow the vehicle to cool for a minimum of 15 min-
utes before opening the cooling system for service.
Failure to observe this warning can result in seri-
ous burns from the heated engine coolant.
A/C SYSTEM
WARNING: The A/C system contains refrigerant
under high pressure. Repairs should only be per-
formed by qualified service personnel. Severe per-
sonal injury or death may result from improper
service procedures.
Avoid breathing the refrigerant and refrigerant oil
vapor or mist. Exposure may irritate the eyes, nose,
and/or throat. Wear eye protection when servicing
the air conditioning refrigerant system. Serious eye
injury can result from direct contact with the refrig-
erant. If eye contact occurs, seek medical attention
immediately.
Do not expose the refrigerant to open flame. Poison-
ous gas is created when refrigerant is burned. An elec-
tronic leak detector is recommended.
If accidental system discharge occurs, ventilate the
work area before resuming service. Large amounts of
refrigerant released in a closed work area will displace
the oxygen and cause suffocation and death.
The evaporation rate of R-134a refrigerant at average
temperature and altitude is extremely high. As a result,
anything that comes in contact with the refrigerant will
freeze. Always protect the skin or delicate objects
from direct contact with the refrigerant.
The R-134a service equipment or the vehicle refriger-
ant system should not be pressure tested or leak
tested with compressed air. Some mixtures of air and
R-134a have been shown to be combustible at ele-
vated pressures. These mixtures are potentially dan-
gerous, and may result in fire or explosion causing
property damage, personal injury or death.
24 - 48 PLUMBING TJ
CAUTION
CAUTION: Liquid refrigerant is corrosive to metal
surfaces. Follow the operating instructions supplied
with the service equipment being used.
Never add R-12 to a refrigerant system designed to
use R-134a and do not use R-12 equipment or parts
on the R-134a system. They are not compatible and
damage to the refrigerant system will result.
Do not overcharge the refrigerant system. Over-
charging will cause excessive compressor head
pressure and can cause noise and system failure.
Recover the refrigerant before removing any sec-
ondary retaining clips, if equipped. Recover the
refrigerant before opening any fitting or connection.
Before disconnecting a refrigerant line or hose,
clean the outside of the fittings thoroughly to pre-
vent contamination from entering the refrigerant
system. Open the fittings with caution, even after
the system has been discharged.
Do not open the refrigerant system or uncap a
replacement component until you are ready to ser-
vice the system. This will prevent contamination in
the system. Immediately after disconnecting a com-
ponent from the refrigerant system, seal the open
fittings with a cap or plug.
The internal parts of the A/C system will remain sta-
ble as long as moisture-free refrigerant and refrig-
erant oil is used. Abnormal amounts of dirt,
moisture or air can upset the chemical stability.
This may cause operational troubles or even seri-
ous damage if present in more than very small
quantities.
Refrigerant oil will absorb moisture from the atmo-
sphere if left uncapped. Do not open a container of
refrigerant oil until you are ready to use it. Replace
the cap on the oil container immediately after using.
Store refrigerant oil only in a clean, airtight, and
moisture-free container.
All tools, including the refrigerant dispensing mani-
fold, manifold gauge set and test hoses should be
kept clean and dry. Keep the work area clean. Con-
tamination of the refrigerant system must be
avoided to ensure proper A/C system operation.
CAUTION: The use of A/C system sealers may
result in damage to A/C refrigerant recovery/evacu-
ation/recharging equipment and/or A/C systems.
Many federal, state/provincial and local regulations
prohibit the recharge of A/C systems with known
leaks. DaimlerChrysler recommends the detection
of A/C system leaks through the use of approved
leak detectors and fluorescent leak detection dyes.
Vehicles found with A/C system sealers should be
treated as contaminated and replacement of the
entire A/C refrigerant system is recommended. A/C
systems found to be contaminated with A/C system
sealers, A/C stop-leak products or seal conditioners
voids the warranty for the A/C system.
DIAGNOSIS AND TESTING
REFRIGERANT SYSTEM LEAKS
WARNING: R-134a SERVICE EQUIPMENT OR VEHI-
CLE A/C SYSTEM SHOULD NOT BE PRESSURE
TESTED OR LEAK TESTED WITH COMPRESSED
AIR. MIXTURE OF AIR and R-134a CAN BE COM-
BUSTIBLE AT ELEVATED PRESSURES. THESE MIX-
TURES ARE POTENTIALLY DANGEROUS AND MAY
RESULT IN FIRE OR EXPLOSION CAUSING INJURY
OR PROPERTY DAMAGE.
AVOID BREATHING A/C REFRIGERANT AND LUBRI-
CANT VAPOR OR MIST. EXPOSURE MAY IRRITATE
EYES, NOSE AND THROAT. USE ONLY APPROVED
SERVICE EQUIPMENT MEETING SAE REQUIRE-
MENTS TO DISCHARGE R-134a SYSTEM. IF ACCI-
DENTAL SYSTEM DISCHARGE OCCURS,
VENTILATE WORK AREA BEFORE RESUMING SER-
VICE.
I f the A/C system i s not cool i ng properl y, determi ne
i f the refri gerant system i s ful l y charged wi th
R-134a. Thi s i s accompl i shed by performi ng a system
Charge Level -Check or Fi l l . I f whi l e performi ng thi s
test A/C l i qui d l i ne pressure i s l ess than 345 kPa (50
psi ) proceed to System Empty procedure. I f l i qui d
l i ne pressure i s greater than 345 kPa (50 psi ) proceed
to System Low procedure. I f the refri gerant system i s
empty or l ow i n refri gerant charge, a l eak at any l i ne
fi tti ng or component seal i s l i kel y. A revi ew of the fi t-
ti ngs, l i nes and components for oi l y resi due i s an
i ndi cati on of the l eak l ocati on. To detect a l eak i n the
refri gerant system, perform one of the fol l owi ng pro-
cedures as i ndi cated by the symptoms.
SYSTEM EMPTY
(1) Evacuate the refri gerant system to the l owest
degree of vacuum possi bl e (approxi matel y 28 i n Hg.).
Determi ne i f the system hol ds a vacuum for 15 mi n-
utes. I f vacuum i s hel d, a l eak i s probabl y not
present. I f system wi l l not mai ntai n vacuum l evel ,
proceed to Step 2.
(2) Prepare a 0.284 Kg. (10 oz.) refri gerant charge
to be i njected i nto the refri gerant system.
(3) Connect and di spense 0.284 Kg. (10 oz.) of
refri gerant i nto the evacuated refri gerant system.
(4) Proceed to Step 2 of System Low procedure.
SYSTEM LOW
(1) Determi ne i f there i s any R-134a refri gerant i n
the system.
TJ PLUMBING 24 - 49
PLUMBING (Continued)
(2) Posi ti on the vehi cl e i n a wi nd free work area.
Thi s wi l l ai d i n detecti ng smal l l eaks.
(3) Bri ng the refri gerant system up to operati ng
temperature and pressure. Thi s i s done by al l owi ng
the engi ne to run for fi ve mi nutes wi th the A/C sys-
tem set to the fol l owi ng:
• Transmi ssi on i n Park or Neutral wi th parki ng
brake set
• Engi ne i dl i ng
• Mode control set to the outsi de ai r posi ti on
• Bl ower control set to the hi gh speed posi ti on
• A/C set to the ON posi ti on
• Al l wi ndows open
CAUTION: A leak detector only designed for R-12
refrigerant will not detect leaks in a R-134a refriger-
ant system.
(4) Shut the vehi cl e Off and wai t 2-7 mi nutes.
Then use an el ectroni c l eak detector that i s desi gned
to detect R-134a refri gerant and search for l eaks. Fi t-
ti ngs, l i nes or components that appear to be oi l y usu-
al l y i ndi cate a refri gerant l eak. To i nspect the A/C
evaporator for l eaks, i nsert the l eak detector probe
i nto the drai n tube openi ng or an ai r outl et. A dye for
R-134a i s avai l abl e to ai d i n l eak detecti on. Use onl y
Dai ml erChrysl er approved refri gerant dye.
STANDARD PROCEDURE
REFRIGERANT SYSTEM SERVICE EQUIPMENT
WARNING: EYE PROTECTION MUST BE WORN
WHEN SERVICING AN AIR CONDITIONING REFRIG-
ERANT SYSTEM. TURN OFF (ROTATE CLOCKWISE)
ALL VALVES ON THE EQUIPMENT BEING USED
BEFORE CONNECTING TO, OR DISCONNECTING
FROM THE REFRIGERANT SYSTEM. FAILURE TO
OBSERVE THESE WARNINGS MAY RESULT IN PER-
SONAL INJURY.
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS SECTION BEFORE
PERFORMING THE FOLLOWING OPERATION (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING -
WARNING) and (Refer to 24 - HEATING & AIR CON-
DITIONING/PLUMBING - CAUTION).
When servi ci ng the ai r condi ti oni ng system, a
R-134a refri gerant recovery/recycl i ng/chargi ng sta-
ti on that meets SAE Standard J2210 must be used
(Fi g. 1). Contact an automoti ve servi ce equi pment
suppl i er for refri gerant recovery/recycl i ng/chargi ng
equi pment. Refer to the operati ng i nstructi ons sup-
pl i ed by the equi pment manufacturer for proper care
and use of thi s equi pment.
A mani fol d gauge set may be needed wi th some
recovery/recycl i ng/chargi ng equi pment (Fi g. 2). The
servi ce hoses on the gauge set bei ng used shoul d
have manual (turn wheel ), or automati c back-fl ow
val ves at the servi ce port connector ends. Thi s wi l l
prevent refri gerant from bei ng rel eased i nto the
atmosphere.
Fig. 1 Refrigerant Recovery/Recycling Station -
Typical
1 - R-134a REFRIGERANT STATION
Fig. 2 Manifold Gauge Set - Typical
1 - HIGH PRESSURE GAUGE
2 - VALVE
3 - VACUUM/REFRIGERANT HOSE (YELLOW W/BLACK STRIPE)
4 - HIGH PRESSURE HOSE (RED W/BLACK STRIPE)
5 - LOW PRESSURE HOSE (BLUE W/BLACK STRIPE)
6 - VALVE
7 - LOW PRESSURE GAUGE
24 - 50 PLUMBING TJ
PLUMBING (Continued)
MANIFOLD GAUGE SET CONNECTIONS
CAUTION: Do not use an R-12 manifold gauge set
on an R-134a system. The refrigerants are not com-
patible and system damage will result.
LOW PRESSURE GAUGE HOSE The l ow pressure
hose (Bl ue wi th Bl ack stri pe) attaches to the sucti on
servi ce port. Thi s port i s l ocated on the l i qui d l i ne
near the evaporator i nl et tube at the rear of the
engi ne compartment.
HI GH PRESSURE GAUGE HOSE The hi gh pres-
sure hose (Red wi th Bl ack stri pe) attaches to the di s-
charge servi ce port. Thi s port i s l ocated on the
mani fol d di rectl y over the di scharge port of the com-
pressor.
RECOVERY/RECYCLI NG/EVACUATI ON/CHARG-
I NG HOSE The center mani fol d hose (Yel l ow, or
Whi te, wi th Bl ack stri pe) i s used to recover, evacu-
ate, and charge the refri gerant system. When the l ow
or hi gh pressure val ves on the mani fol d gauge set
are opened, the refri gerant i n the system wi l l escape
through thi s hose.
REFRIGERANT CHARGE LEVEL TEST
WARNING: AVOID BREATHING A/C REFRIGERANT
AND LUBRICANT VAPOR OR MIST. EXPOSURE
MAY IRRITATE EYES, NOSE AND THROAT. USE
ONLY APPROVED SERVICE EQUIPMENT MEETING
SAE REQUIREMENTS TO DISCHARGE R-134a SYS-
TEM. IF ACCIDENTAL SYSTEM DISCHARGE
OCCURS, VENTILATE WORK AREA BEFORE
RESUMING SERVICE.
R-134a SERVICE EQUIPMENT OR VEHICLE A/C
SYSTEM SHOULD NOT BE PRESSURE TESTED OR
LEAK TESTED WITH COMPRESSED AIR. MIXTURE
OF AIR and R-134a CAN BE COMBUSTIBLE AT ELE-
VATED PRESSURES. THESE MIXTURES ARE
POTENTIALLY DANGEROUS AND MAY RESULT IN
FIRE OR EXPLOSION CAUSING INJURY OR PROP-
ERTY DAMAGE.
NOTE: Refer to the underhood HVAC specification
tag for the proper charge level.
The procedure bel ow shoul d be used to check the
refri gerant charge l evel i n the ai r condi ti oni ng sys-
tem.
I t i s recommended to use a mani fol d gauge set or
recl ai m/recycl e equi pment.
(1) Use a mani fol d gauge set and check the l i qui d
l i ne pressure.
(2) Attach a cl amp-on thermocoupl e to the l i qui d
l i ne near the evaporator.
(3) The vehi cl e must be i n the fol l owi ng modes:
• Automati c transmi ssi on i n park or manual
transmi ssi on i n neutral .
• Engi ne at i dl e
• A/C mode control set to outsi de ai r
• A/C mode control set to panel mode
• A/C temperature control set to ful l cool
• Bl ower motor control set on hi ghest speed
• Vehi cl e wi ndows cl osed
(4) Operate the A/C system for at l east two mi n-
utes to al l ow the system to stabi l i ze.
(5) Observe l i qui d l i ne pressure and temperature.
Usi ng the Charge Determi nati on Chart (Fi g. 3) deter-
mi ne where the system i s currentl y operati ng. I f the
system i s not i n the proper range, recl ai m al l the
refri gerant and recharge per A/C l abel .
REFRIGERANT SYSTEM RECOVERY
WARNING: (Refer to 24 - HEATING & AIR CONDI-
TIONING - WARNING) AND (Refer to 24 - HEATING
& AIR CONDITIONING - CAUTION) BEFORE PER-
FORMING THIS OPERATION.
A R-134a refri gerant recovery/recycl i ng/chargi ng
stati on that meets SAE Standard J2210 must be
used to recover the refri gerant from an R-134a refri g-
erant system. Refer to the operati ng i nstructi ons sup-
pl i ed by the equi pment manufacturer for the proper
care and use of thi s equi pment.
REFRIGERANT SYSTEM EVACUATE
NOTE: Special effort must be used to prevent mois-
ture from entering the A/C system oil. Moisture in
the oil is very difficult to remove and will cause a
reliability problem with the compressor.
I f a compressor desi gned to use R-134a refri gerant
i s l eft open to the atmosphere for an extended peri od
of ti me. I t i s recommended that the refri gerant oi l be
drai ned and repl aced wi th new oi l or a new compres-
sor be used. Thi s wi l l el i mi nate the possi bi l i ty of con-
tami nati ng the refri gerant system.
TJ PLUMBING 24 - 51
PLUMBING (Continued)
I f the refri gerant system has been open to the
atmosphere, i t must be evacuated before the system
can be fi l l ed. Moi sture and ai r mi xed wi th the refri g-
erant wi l l rai se the compressor head pressure above
acceptabl e operati ng l evel s. Thi s wi l l reduce the per-
formance of the ai r condi ti oner and damage the com-
pressor. Moi sture wi l l boi l at near room temperature
when exposed to vacuum. To evacuate the refri gerant
system:
NOTE: When connecting the service equipment
coupling to the line fitting, verify that the valve of
the coupling is fully closed. This will reduce the
amount of effort required to make the connection.
(1) Recover the refri gerant system (Refer to 24 -
HEATI NG & AI R CONDI TI ONI NG/PLUMBI NG -
STANDARD PROCEDURE).
(2) Connect a sui tabl e chargi ng stati on, refri gerant
recovery machi ne or a mani fol d gauge set wi th vac-
uum pump and refri gerant recovery equi pment.
(3) Open the sucti on and di scharge val ves and
start the vacuum pump. The vacuum pump shoul d
run a mi ni mum of 45 mi nutes pri or to charge to
el i mi nate al l moi sture i n system. When the sucti on
gauge reads -88 kPa (- 26 i n. Hg) vacuum or greater
for 30 mi nutes, cl ose al l val ves and turn off vacuum
pump. I f the system fai l s to reach speci fi ed vacuum,
the refri gerant system l i kel y has a l eak that must be
corrected. I f the refri gerant system mai ntai ns speci -
fi ed vacuum for at l east 30 mi nutes, start the vac-
uum pump, open the sucti on and di scharge val ves.
Then al l ow the system to evacuate an addi ti onal 10
mi nutes.
(4) Cl ose al l val ves. Turn off and di sconnect the
vacuum pump.
(5) Charge the refri gerant system (Refer to 24 -
HEATI NG & AI R CONDI TI ONI NG/PLUMBI NG -
STANDARD PROCEDURE).
Fig. 3 Charge Determination Chart
24 - 52 PLUMBING TJ
PLUMBING (Continued)
REFRIGERANT SYSTEM CHARGE
WARNING: REVIEW SAFETY PRECAUTIONS AND
WARNINGS IN THIS GROUP BEFORE CHARGING
THE REFRIGERANT SYSTEM.
AVOID BREATHING A/C REFRIGERANT AND LUBRI-
CANT VAPOR OR MIST. EXPOSURE MAY IRRITATE
EYES, NOSE AND THROAT. USE ONLY APPROVED
SERVICE EQUIPMENT MEETING SAE REQUIRE-
MENTS TO DISCHARGE R-134a SYSTEM. IF ACCI-
DENTAL SYSTEM DISCHARGE OCCURS,
VENTILATE WORK AREA BEFORE RESUMING SER-
VICE.
R-134a SERVICE EQUIPMENT OR VEHICLE A/C
SYSTEM SHOULD NOT BE PRESSURE TESTED OR
LEAK TESTED WITH COMPRESSED AIR. MIXTURE
OF AIR and R-134a CAN BE COMBUSTIBLE AT ELE-
VATED PRESSURES. THESE MIXTURES ARE
POTENTIALLY DANGEROUS AND MAY RESULT IN
FIRE OR EXPLOSION CAUSING INJURY OR PROP-
ERTY DAMAGE.
CAUTION: A small amount of refrigerant oil is
removed from the A/C system each time the refrig-
erant system is recovered and evacuated. Before
charging the A/C system, you MUST replenish any
oil lost during the recovery process. Refer the
equipment manufacturer instructions for more infor-
mation.
CAUTION: Do not overcharge refrigerant system, as
excessive compressor head pressure can cause
noise and system failure.
After the system has been tested for l eaks and
evacuated, a refri gerant (R-134a) charge can be
i njected i nto the system.
NOTE: When connecting the service equipment
coupling to the line fitting, verify that the valve of
the coupling is fully closed. This will reduce the
amount of effort required to make the connection.
The procedure bel ow shoul d be used to fi l l the
refri gerant charge i n the ai r condi ti oni ng system.
Thi s A/C system does not have or use a si ght gl ass to
check or charge the system.
(1) I f usi ng a separate vacuum pump cl ose al l
val ves before di sconnecti ng pump. Connect mani fol d
gauge set to the A/C servi ce ports.
NOTE: Always refer to the underhood HVAC Speci-
fication label for the refrigerant fill level of the vehi-
cle being serviced.
(2) Measure refri gerant (refer to capaci ti es). Refer
to the i nstructi ons provi ded wi th the equi pment
bei ng used.
(3) Veri fy engi ne i s shut off. Open the sucti on and
di scharge val ves. Open the charge val ve to al l ow the
refri gerant to fl ow i nto the system. When the trans-
fer of refri gerant has stopped, cl ose the sucti on and
di scharge val ve.
(4) I f al l of the charge di d not transfer from the
di spensi ng devi ce, put vehi cl e control s i nto the fol -
l owi ng mode:
• Automati c transmi ssi on i n park or manual
transmi ssi on i n neutral
• Engi ne at i dl e
• A/C mode control set to outsi de ai r
• A/C mode control set to panel mode
• A/C temperature control set to ful l cool
• Bl ower motor control set on hi ghest speed
• Vehi cl e wi ndows cl osed
I f the A/C compressor does not engage, test the
compressor cl utch control ci rcui t and correct any fai l -
ure (Refer to 8 - ELECTRI CAL/WI RI NG DI AGRAM
I NFORMATI ON - DI AGNOSI S AND TESTI NG).
(5) Open the sucti on val ve to al l ow the remai ni ng
refri gerant to transfer to the system.
WARNING: TAKE CARE NOT TO OPEN THE DIS-
CHARGE (HIGH-PRESSURE) VALVE AT THIS TIME.
(6) Cl ose al l val ves and test the A/C system perfor-
mance.
(7) Di sconnect the chargi ng stati on or mani fol d
gauge set. I nstal l the servi ce port caps.
A/C COMPRESSOR
DESCRIPTION
A/C COMPRESSOR
The A/C system uses a Denso 10PA17 seven cyl i nder,
reci procati ng wobbl e pl ate-type A/C compressor on al l
model s. Thi s A/C compressor has a fi xed di spl acement of
150 cubi c centi meters (9.375 cubi c i nches), and has both
the sucti on and di scharge ports l ocated on the cyl i nder
head. A l abel i denti fyi ng the use of R-134a refri gerant i s
l ocated on the A/C compressor.
HIGH PRESSURE RELIEF VALVE
A hi gh pressure rel i ef val ve i s l ocated on the com-
pressor mani fol d. Thi s mechani cal val ve i s desi gned
to vent refri gerant from the A/C system to protect
agai nst damage to the A/C compressor and other A/C
system components, caused by a restri cti on i n ai r
fl ow through the A/C condenser or, an overcharge of
refri gerant.
TJ PLUMBING 24 - 53
PLUMBING (Continued)
OPERATION
A/C COMPRESSOR
The A/C compressor i s dri ven by the engi ne
through an el ectri c cl utch, dri ve pul l ey and bel t
arrangement. The A/C compressor i s l ubri cated by
refri gerant oi l that i s ci rcul ated throughout the
refri gerant system wi th the refri gerant.
The A/C compressor draws i n l ow-pressure refri g-
erant vapor from the A/C evaporator through i ts suc-
ti on port. I t then compresses the refri gerant i nto a
hi gh-pressure, hi gh-temperature refri gerant vapor.
The A/C compressor pumps the hi gh-pressure refri g-
erant vapor to the A/C condenser through the com-
pressor di scharge port.
The A/C compressor cannot be repai red. I f faul ty or
damaged, the enti re compressor assembl y must be
repl aced. The compressor cl utch, pul l ey and cl utch
coi l are avai l abl e for servi ce.
HIGH PRESSURE RELIEF VALVE
The hi gh pressure rel i ef val ve vents the A/C sys-
tem when a di scharge pressure of 3445 to 4135 kPa
(500 to 600 psi ) or above i s reached. The hi gh pres-
sure rel i ef val ve cl oses when a mi ni mum di scharge
pressure of 2756 kPa (400 psi ) i s reached.
The hi gh pressure rel i ef val ve vents onl y enough
refri gerant to reduce the A/C system pressure, and
then re-seats i tsel f. The majori ty of the refri gerant i s
conserved i n the A/C system. I f the val ve vents
refri gerant, i t does not mean that the val ve i s faul ty.
The hi gh pressure rel i ef val ve i s factory-cal i brated.
The hi gh pressure rel i ef val ve cannot be adjusted or
repai red, and must not be removed or otherwi se di s-
turbed. The hi gh pressure rel i ef val ve i s onl y ser-
vi ced as a part of the A/C compressor.
DIAGNOSIS AND TESTING
A/C COMPRESSOR NOISE
When i nvesti gati ng an ai r condi ti oni ng rel ated
noi se, you must fi rst know the condi ti ons under
whi ch the noi se occurs. These condi ti ons i ncl ude:
weather, vehi cl e speed, transmi ssi on i n gear or neu-
tral , engi ne speed, engi ne temperature, and any
other speci al condi ti ons. Noi ses that devel op duri ng
ai r condi ti oni ng operati on can often be mi sl eadi ng.
For exampl e: What sounds l i ke a fai l ed front beari ng
or connecti ng rod, may be caused by l oose bol ts, nuts,
mounti ng brackets, or a l oose compressor cl utch
assembl y.
Dri ve bel ts are speed sensi ti ve. At di fferent engi ne
speeds and dependi ng upon bel t tensi on, bel ts can
devel op noi ses that are mi staken for a compressor
noi se. I mproper bel t tensi on can cause a mi sl eadi ng
noi se when the compressor cl utch i s engaged, whi ch
may not occur when the compressor cl utch i s di sen-
gaged. Check the serpenti ne dri ve bel t condi ti on and
tensi on (Refer to 7 - COOLI NG/ACCESSORY DRI VE/
DRI VE BELTS - DI AGNOSI S AND TESTI NG) before
begi nni ng thi s procedure.
(1) Sel ect a qui et area for testi ng. Dupl i cate the
compl ai nt condi ti ons as much as possi bl e. Swi tch the
compressor on and off several ti mes to cl earl y i den-
ti fy the compressor noi se. Li sten to the compressor
whi l e the cl utch i s engaged and di sengaged. Probe
the compressor wi th an engi ne stethoscope or a l ong
screwdri ver wi th the handl e hel d to your ear to bet-
ter l ocal i ze the source of the noi se.
(2) Loosen al l of the compressor mounti ng hard-
ware and reti ghten. Ti ghten the compressor cl utch
mounti ng nut. Be certai n that the cl utch coi l i s
mounted securel y to the compressor, and that the
cl utch pl ate and pul l ey are properl y al i gned and have
the correct ai r gap(Refer to 24 - HEATI NG & AI R
CONDI TI ONI NG/CONTROLS/A/C COMPRESSOR
CLUTCH - I NSTALLATI ON).
(3) To dupl i cate a hi gh-ambi ent temperature condi -
ti on (hi gh head pressure), restri ct the ai r fl ow
through the condenser. I nstal l a mani fol d gauge set
to be certai n that the di scharge pressure does not
exceed 2760 kPa (400 psi ).
(4) Check the refri gerant system pl umbi ng for
i ncorrect routi ng, rubbi ng or i nterference, whi ch can
cause unusual noi ses. Al so check the refri gerant l i nes
for ki nks or sharp bends that wi l l restri ct refri gerant
fl ow, whi ch can cause noi ses (Refer to 24 - HEATI NG
& AI R CONDI TI ONI NG/PLUMBI NG - STANDARD
PROCEDURE).
(5) I f the noi se i s from openi ng and cl osi ng of the
hi gh pressure rel i ef val ve, recl ai m, evacuate and
recharge the refri gerant system (Refer to 24 - HEAT-
I NG & AI R CONDI TI ONI NG/PLUMBI NG - STAN-
DARD PROCEDURE) and (Refer to 24 - HEATI NG
& AI R CONDI TI ONI NG/PLUMBI NG - STANDARD
PROCEDURE) and (Refer to 24 - HEATI NG & AI R
CONDI TI ONI NG/PLUMBI NG - STANDARD PRO-
CEDURE). I f the hi gh pressure rel i ef val ve sti l l does
not seat properl y, repl ace the compressor (Refer to 24
- HEATI NG & AI R CONDI TI ONI NG/PLUMBI NG/
A/C COMPRESSOR - REMOVAL).
(6) I f the noi se i s from l i qui d sl uggi ng on the sucti on
l i ne, repl ace the accumul ator (Refer to 24 - HEATI NG &
AI R CONDI TI ONI NG/PLUMBI NG/ACCUMULATOR -
REMOVAL) and check the refri gerant oi l l evel and the
refri gerant system charge (Refer to 24 - HEATI NG &
AI R CONDI TI ONI NG/PLUMBI NG/REFRI GERANT
OI L - STANDARD PROCEDURE).
(7) I f the l i qui d sl uggi ng condi ti on conti nues fol -
l owi ng accumul ator repl acement, repl ace the com-
pressor and repeat Step 1.
24 - 54 PLUMBING TJ
A/C COMPRESSOR (Continued)
REMOVAL
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS SECTION BEFORE
PERFORMING THE FOLLOWING OPERATION (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING -
WARNING) and (Refer to 24 - HEATING & AIR CON-
DITIONING/PLUMBING - CAUTION).
(1) Recover the refri gerant from the refri gerant
system (Refer to 24 - HEATI NG & AI R CONDI TI ON-
I NG/PLUMBI NG - STANDARD PROCEDURE).
(2) Di sconnect and i sol ate the battery negati ve
cabl e.
(3) Remove the serpenti ne dri ve bel t (Refer to 7 -
COOLI NG/ACCESSORY DRI VE/DRI VE BELTS -
REMOVAL) or (Refer to 7 - COOLI NG/ACCESSORY
DRI VE/DRI VE BELTS - REMOVAL) 4.0L.
(4) Di sconnect the compressor cl utch coi l wi re har-
ness connector.
(5) Dependi ng on the engi ne usage, remove the
bol ts or nuts that secure the sucti on and di scharge
l i ne fi tti ngs to the compressor. I nstal l pl ugs i n, or
tape over al l of the opened refri gerant l i ne fi tti ngs
and compressor ports (Fi g. 4).
(6) Remove the bol ts and nuts that secure the com-
pressor and brackets (Fi g. 5) or (Fi g. 6).
(7) Remove the A/C compressor from the engi ne
compartment.
INSTALLATION
NOTE: If a replacement compressor is being
installed, be certain to check the refrigerant oil
level. See Refrigerant Oil Level in this group for the
procedures. Use only refrigerant oil of the type rec-
ommended for the compressor in the vehicle.
(1) Posi ti on the A/C compressor i nto the engi ne
compartment.
(2) I nstal l the bol ts that secure the compressor.
• Ti ghten the 4.0L bol ts fasteni ng the compressor
to the cyl i nder bl ock to 45-65 N·m (35-50 ft. l bs.).
• Ti ghten the 4.0L bol ts fasteni ng the rear brace
to the compressor and cyl i nder bl ock to 40-55 N·m
(30-40 ft. l bs.).
• Ti ghten the 2.4L bol ts fasteni ng the compressor
to the cyl i nder bl ock to 28 N·m (21 ft. l bs.).
(3) Remove the tape or pl ugs from the opened
refri gerant l i ne fi tti ngs and compressor ports.
Fig. 4 Compressor and Lines – 2.4L Shown, 4.0L
Typical
1 - UPPER COMPRESSOR MOUNTING BOLTS (2)
2 - DISCHARGE LINE NUT
3 - SUCTION LINE NUT
4 - DISCHARGE LINE
5 - A/C COMPRESSOR CLUTCH
6 - A/C HIGH PRESSURE SWITCH
7 - A/C COMPRESSOR
8 - SUCTION LINE
9 - LOWER COMPRESSOR MOUNTING BOLTS (2)
Fig. 5 A/C Compressor - 2.4L Engine
1 - A/C CLUTCH WIRE HARNESS CONNECTOR
2 - LOWER COMPRESSOR MOUNTING BOLTS (2)
3 - A/C COMPRESSOR AND CLUTCH ASSEMBLY
4 - UPPER COMPRESSOR MOUNTING BOLTS (2)
TJ PLUMBING 24 - 55
A/C COMPRESSOR (Continued)
(4) Lubri cate new rubber O-ri ng seal s wi th cl ean
refri gerant oi l and i nstal l them on the di scharge and
l i qui d l i ne fi tti ngs. Use onl y the speci fi ed O-ri ngs as
they are made of a speci al materi al for the R-134a
system. Use onl y refri gerant oi l of the type recom-
mended for the A/C compressor i n the vehi cl e.
(5) I nstal l the sucti on l i ne and di scharge l i ne fi t-
ti ngs onto the compressor.
(6) I nstal l the bol ts or nuts (dependi ng on engi ne
appl i cati on) that secure the sucti on and di scharge
l i ne fi tti ngs to the compressor. Ti ghten the bol ts or
nuts to 25.4 N·m (20 ft. l bs.).
(7) Connect the wi re harness connector to the com-
pressor cl utch coi l .
(8) I nstal l the serpenti ne dri ve bel t (Refer to 7 -
COOLI NG/ACCESSORY DRI VE/DRI VE BELTS -
I NSTALLATI ON) or (Refer to 7 - COOLI NG/ACCES-
SORY DRI VE/DRI VE BELTS - I NSTALLATI ON)
4.0L.
(9) Reconnect the battery negati ve cabl e.
(10) Evacuate the refri gerant system (Refer to 24 -
HEATI NG & AI R CONDI TI ONI NG/PLUMBI NG -
STANDARD PROCEDURE).
(11) Charge the refri gerant system (Refer to 24 -
HEATI NG & AI R CONDI TI ONI NG/PLUMBI NG -
STANDARD PROCEDURE).
A/C CONDENSER
DESCRIPTION
The A/C condenser i s l ocated i n the ai r fl ow i n
front of the radi ator. The A/C condenser i s a heat
exchanger that al l ows the hi gh-pressure refri gerant
gas bei ng di scharged by the A/C compressor to gi ve
up i ts heat to the ai r passi ng over the condenser fi ns.
OPERATION
When the refri gerant gas gi ves up i ts heat, i t con-
denses. When the refri gerant l eaves the condenser, i t
has become a hi gh-pressure l i qui d refri gerant. The
vol ume of ai r fl owi ng over the condenser fi ns i s cri t-
i cal to the proper cool i ng performance of the ai r con-
di ti oni ng system. Therefore, i t i s i mportant that
there are no objects pl aced i n front of the radi ator
gri l l e openi ngs i n the front of the vehi cl e or forei gn
materi al on the condenser fi ns that mi ght obstruct
proper ai r fl ow. Al so, any factory-i nstal l ed ai r seal s or
shrouds must be properl y rei nstal l ed fol l owi ng radi a-
tor or condenser servi ce.
The condenser cannot be repai red and, i f faul ty or
damaged, i t must be repl aced.
REMOVAL
WARNING: Review the warnings and cautions in the
front of this section before performing the following
operation (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - WARNING) and (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING - CAU-
TION).
CAUTION: Before removing the A/C condenser, note
the location of each of the radiator/condenser air
seals. These air seals are used to direct air through
the A/C condenser and radiator. The air seals must
be reinstalled in their proper locations in order for
the A/C and engine cooling systems to perform as
designed.
(1) Di sconnect and i sol ate the negati ve battery
cabl e.
(2) Recover the refri gerant from the refri gerant
system (Refer to 24 - HEATI NG & AI R CONDI TI ON-
I NG/PLUMBI NG - STANDARD PROCEDURE -
REFRI GERANT SYSTEM RECOVERY).
(3) Parti al l y drai n the engi ne cool i ng system(Refer
to 7 - COOLI NG - STANDARD PROCEDURE -
COOLI NG SYSTEM DRAI NI NG).
(4) Remove the cool i ng recovery contai ner (Refer to
7 - COOLI NG/ENGI NE/COOLANT RECOVERY
CONTAI NER - REMOVAL.
Fig. 6 A/C Compressor and Brackets - 4.0L Engine
1 - A/C COMPRESSOR
2 - A/C COMPRESSOR MOUNTING NUT
3 - A/C COMPRESSOR UPPER MOUNTING BRACKET
4 - ENGINE BLOCK LOWER MOUNTING POINT
5 - A/C COMPRESSOR LOWER BRACKET MOUNTING BOLT
6 - A/C COMPRESSOR LOWER MOUNTING BRACKET
7 - LOWER BRACKET TO ENGINE BLOCK BOLT
8 - A/C COMPRESSOR UPPER BRACKET MOUNTING BOLT
9 - A/C COMPRESSOR LOWER MOUNTING POINT
10 - A/C COMPRESSOR TO BLOCK BOLT
24 - 56 PLUMBING TJ
A/C COMPRESSOR (Continued)
(5) Di sconnect the upper radi ator hose from the
radi ator and posi ti on the hose out of the way (Refer
to 7 - COOLI NG - OPERATI ON - HOSE CLAMPS).
(6) Remove the radi ator cool i ng fan and fan shroud
(Refer to 7 - COOLI NG/ENGI NE/FAN DRI VE VI S-
COUS CLUTCH - REMOVAL).
(7) Rai se and support the vehi cl e.
(8) Posi ti on the l ower condenser/radi ator ai r seal
out of the way and remove the two bol ts that secure
the l ower condenser mounti ng bracket to the bottom
of the gri l l e panel .
(9) Lower the vehi cl e.
(10) I f equi pped, remove the upper condenser/radi -
ator ai r seal (Fi g. 7).
(11) Remove the nuts that secure the di scharge
and l i qui d l i nes to the condenser tappi ng bl ock.
(12) Di sconnect the di scharge and l i qui d l i nes from
the condenser tappi ng bl ock and remove and di scard
the O-ri ng seal s.
(13) I nstal l pl ugs i n, or tape over the opened
refri gerant l i ne fi tti ngs and the condenser ports.
(14) Remove the two bol ts that secure the upper
condenser mounti ng brackets to the top of the gri l l e
panel .
(15) Remove the three bol ts on each si de of the
radi ator that secure the radi ator mounti ng brackets
to the gri l l e panel .
(16) Ti l t the radi ator back towards the engi ne. Use
care to prevent damagi ng the radi ator fi ns.
(17) Careful l y remove the A/C condenser from the
engi ne compartment.
INSTALLATION
NOTE: If the A/C condenser is being replaced, add
22 milliliters (0.75 fluid ounce) of refrigerant oil to
the refrigerant system. Use only refrigerant oil of
the type recommended for the A/C compressor in
the vehicle.
(1) Careful l y posi ti on the A/C condenser i nto the
engi ne compartment.
(2) I nstal l the two bol ts that secure the upper con-
denser mounti ng brackets to the top of the gri l l e
panel . Ti ghten the bol ts to 2.2 N·m (20 i n. l bs.).
(3) Al i gn the radi ator mounti ng brackets to the
gri l l e panel and i nstal l the si x bol ts that secure the
radi ator to the gri l l e panel . Ti ghten the bol ts to 8
N·m (72 i n. l bs.).
(4) Rai se and support the vehi cl e.
(5) Posi ti on the l ower condenser/radi ator ai r seal
out of the way and i nstal l the two bol ts that secure
the l ower condenser mounti ng bracket to the bottom
of the gri l l e panel . Ti ghten the bol ts to 2.2 N·m (20
i n. l bs.).
(6) Lower the vehi cl e.
(7) Remove the tape or pl ugs from the di scharge
and l i qui d l i ne fi tti ngs and the condenser ports.
(8) Lubri cate new rubber O-ri ng seal s wi th cl ean
refri gerant oi l and i nstal l them onto the di scharge
and l i qui d l i ne fi tti ngs. Use onl y the speci fi ed O-ri ngs
as they are made of a speci al materi al for the R-134a
system. Use onl y refri gerant oi l of the type recom-
mended for the A/C compressor i n the vehi cl e.
(9) I nstal l the di scharge and l i qui d l i nes onto the
condenser tappi ng bl ock.
(10) I nstal l the nuts that secures the di scharge
and l i qui d l i ne fi tti ngs to the condenser tappi ng
bl ock. Ti ghten the nuts to 12 N·m (105 i n. l bs.).
(11) I f equi pped, i nstal l the upper condenser/radi a-
tor ai r seal .
(12) I nstal l the radi ator cool i ng fan and fan shroud
(Refer to 7 - COOLI NG/ENGI NE/FAN DRI VE VI S-
COUS CLUTCH - I NSTALLATI ON).
(13) Connect the upper radi ator hose to the radi a-
tor and i nstal l the hose cl amp (Refer to 7 - COOL-
I NG - OPERATI ON - HOSE CLAMPS).
(14) I nstal l the cool ant recovery contai ner (Refer to
7 - COOLI NG/ENGI NE/COOLANT RECOVERY
CONTAI NER - I NSTALLATI ON).
(15) Reconnect the battery negati ve cabl e.
(16) Fi l l the engi ne cool i ng system (Refer to 7 -
COOLI NG - STANDARD PROCEDURE - COOLI NG
SYSTEM REFI LLI NG)
(17) Evacuate the refri gerant system (Refer to 24 -
HEATI NG & AI R CONDI TI ONI NG/PLUMBI NG -
STANDARD PROCEDURE - REFRI GERANT SYS-
TEM EVACUATE).
(18) Charge the refri gerant system (Refer to 24 -
HEATI NG & AI R CONDI TI ONI NG/PLUMBI NG -
STANDARD PROCEDURE - REFRI GERANT SYS-
TEM CHARGE).
TJ PLUMBING 24 - 57
A/C CONDENSER (Continued)
A/C DISCHARGE LINE
DESCRIPTION
The A/C di scharge l i ne i s the refri gerant l i ne that
goes from the A/C compressor to the A/C condenser.
The di scharge l i ne has no servi ceabl e parts except
the rubber O-ri ngs. The di scharge l i ne cannot be
repai red and, i f found to be l eaki ng or damaged, i t
must be repl aced.
REMOVAL
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS SECTION BEFORE
PERFORMING THE FOLLOWING OPERATION (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING -
WARNING) and (Refer to 24 - HEATING & AIR CON-
DITIONING/PLUMBING - CAUTION).
(1) Di sconnect and i sol ate the negati ve battery
cabl e.
(2) Recover the refri gerant from the refri gerant
system (Refer to 24 - HEATI NG & AI R CONDI TI ON-
I NG/PLUMBI NG - STANDARD PROCEDURE -
REFRI GERANT RECOVERY).
(3) On vehi cl es equi pped wi th the 4.0L engi ne,
remove the bol t that secures the refri gerant l i ne sup-
port bracket to the top of the engi ne and remove the
di scharge l i ne from the bracket (Fi g. 8).
(4) Remove the bol t that secures the di scharge l i ne
fi tti ng to the top of the compressor.
(5) Di sconnect the di scharge l i ne fi tti ng from the
compressor di scharge port.
Fig. 7 A/C Condenser
1 - PUSH-PIN RETAINER
2 - UPPER AIR SEAL
3 - GRILLE PANEL
4 - AIR SEAL
5 - FRAME RAIL
6 - PUSH-PIN RETAINER
7 - LOWER AIR SEAL
8 - CONDENSER TAPPING BLOCK
9 - A/C CONDENSER
10 - REFRIGERANT LINE FITTING
11 - LIQUID LINE
12 - SERVICE PORT
13 - BOLTS
14 - AIR SEAL
24 - 58 PLUMBING TJ
A/C CONDENSER (Continued)
(6) Remove the seal from the di scharge l i ne fi tti ng
and di scard.
(7) I nstal l pl ug i n, or tape over the opened di s-
charge l i ne fi tti ng and the compressor di scharge port.
(8) Remove the nut that secures the di scharge l i ne
fi tti ng to the condenser.
(9) Di sconnect the di scharge l i ne fi tti ng from the
condenser i nl et port and remove the di scharge l i ne
from the vehi cl e.
(10) Remove the O-ri ng seal from the di scharge
l i ne fi tti ng and di scard.
(11) I nstal l pl ug i n, or tape over the opened di s-
charge l i ne fi tti ng and the condenser i nl et port.
INSTALLATION
NOTE: Replacement of the refrigerant line O-ring
seals is required anytime a refrigerant line is
opened. Failure to replace the rubber O-ring seals
could result in a refrigerant system leak.
(1) Posi ti on the di scharge l i ne i nto the engi ne com-
partment.
(2) Remove the tape or pl ugs from the condenser
i nl et port and the di scharge l i ne fi tti ng.
(3) Lubri cate a new rubber O-ri ng seal wi th cl ean
refri gerant oi l and i nstal l i t on the di scharge l i ne fi t-
ti ng.
(4) Connect the di scharge l i ne fi tti ng to the con-
denser i nl et port.
(5) I nstal l the nut that secures the di scharge l i ne
fi tti ng to the condenser. Ti ghten the nut to 12 N·m
(105 i n. l bs.).
(6) Remove the tape or pl ugs from the compressor
di scharge port and the di scharge l i ne fi tti ng.
(7) Lubri cate a new rubber O-ri ng seal wi th cl ean
refri gerant oi l and i nstal l i t on the di scharge l i ne fi t-
ti ng.
(8) Connect the di scharge l i ne fi tti ng to the com-
pressor di scharge port on the top of the compressor.
(9) I nstal l the bol t that secures the di scharge l i ne
fi tti ng to the compressor. Ti ghten the bol t to 25.4
N·m (20 ft. l bs.).
(10) I nstal l the di scharge l i ne i nto the refri gerant
l i ne support bracket and i nstal l the support bracket
bol t. Ti ghten the bol t to 28 N·m (21 ft. l bs.).
(11) Evacuate the refri gerant system (Refer to 24 -
HEATI NG & AI R CONDI TI ONI NG - STANDARD
PROCEDURE).
(12) Recharge the refri gerant system (Refer to 24 -
HEATI NG & AI R CONDI TI ONI NG - STANDARD
PROCEDURE).
(13) Reconnect the negati ve battery cabl e.
A/C EVAPORATOR
DESCRIPTION
The evaporator coi l i s l ocated i n the HVAC hous-
i ng, behi nd the i nstrument panel . The evaporator i s
posi ti oned i n the housi ng so that al l ai r that enters
the housi ng must pass over the fi ns of the evaporator
coi l s before i t i s di stri buted through the system ducts
and outl ets. However, ai r passi ng over the evaporator
fi ns wi l l onl y be condi ti oned when the compressor i s
engaged and ci rcul ati ng refri gerant through the
evaporator tubes.
OPERATION
Refri gerant enters the evaporator from the fi xed
ori fi ce tube as a l ow-temperature, l ow-pressure l i q-
ui d. As ai r fl ows over the fi ns of the evaporator, the
humi di ty i n the ai r condenses on the fi ns, and the
heat from the ai r i s absorbed by the refri gerant. Heat
absorpti on causes the refri gerant to boi l and vapor-
i ze. The refri gerant becomes a l ow-pressure gas when
i t l eaves the evaporator.
The evaporator coi l cannot be repai red and, i f
faul ty or damaged, i t must be repl aced.
Fig. 8 Suction and Discharge Lines - 4.0L Shown,
2.4L Typical
1 - SUCTION LINE
2 - SERVICE PORT
3 - A/C HIGH PRESSURE SWITCH
4 - A/C COMPRESSOR
5 - MOUNTING BRACKET
6 - DISCHARGE LINE
TJ PLUMBING 24 - 59
A/C DISCHARGE LINE (Continued)
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Remove the HVAC housi ng (Refer to 24 -
HEATI NG & AI R CONDI TI ONI NG/DI STRI BUTI ON/
HVAC HOUSI NG - REMOVAL).
(2) Di sassembl e the HVAC housi ng to access the
evaporator (Refer to 24 - HEATI NG & AI R CONDI -
TI ONI NG/DI STRI BUTI ON/HVAC HOUSI NG - DI S-
ASSEMBLY).
(3) Li ft the evaporator out of the l ower hal f of the
housi ng.
INSTALLATION
NOTE: If the evaporator is being replaced, add 45
milliliters (1.5 fluid ounces) of refrigerant oil to the
refrigerant system. Use only refrigerant oil of the
type recommended for the compressor in the vehi-
cle.
(1) I nstal l the evaporator coi l i nto the bottom hal f
of the HVAC housi ng.
(2) Assembl e the HVAC housi ng (Refer to 24 -
HEATI NG & AI R CONDI TI ONI NG/DI STRI BUTI ON/
HVAC HOUSI NG - ASSEMBLY).
(3) I nstal l the HVAC housi ng (Refer to 24 - HEAT-
I NG & AI R CONDI TI ONI NG/DI STRI BUTI ON/HVAC
HOUSI NG - I NSTALLATI ON).
A/C ORIFICE TUBE
DESCRIPTION
The fi xed ori fi ce tube i s factory i nstal l ed i n the l i q-
ui d l i ne between the outl et of the condenser and the
i nl et of the evaporator. The ori fi ce tube i s l ocated i n
the end of the l i qui d l i ne that i s cl osest to the con-
denser outl et tube.
The i nl et end of the fi xed ori fi ce tube has a nyl on
mesh fi l ter screen, whi ch fi l ters the refri gerant and
hel ps to reduce the potenti al for bl ockage of the
meteri ng ori fi ce by refri gerant system contami nants
(Fi g. 9). The outl et end of the tube has a nyl on mesh
di ffuser screen. The O-ri ngs on the pl asti c body of
the fi xed ori fi ce tube seal the tube to the i nsi de of
the l i qui d l i ne and prevent the refri gerant from
bypassi ng the fi xed meteri ng ori fi ce.
OPERATION
The fi xed A/C ori fi ce tube i s used to meter the fl ow
of l i qui d refri gerant i nto the A/C evaporator. The
hi gh-pressure l i qui d refri gerant from the A/C con-
denser expands i nto a l ow-pressure l i qui d as i t
passes through the meteri ng ori fi ce and di ffuser
screen of the A/C ori fi ce tube.
The A/C ori fi ce tube i s not servi ceabl e. I t cannot be
repai red, and i f faul ty or pl ugged, i t must be repl aced
as part of the l i qui d l i ne (Refer to 24 - HEATI NG &
AI R CONDI TI ONI NG/PLUMBI NG/LI QUI D LI NE -
REMOVAL) and (Refer to 24 - HEATI NG & AI R
CONDI TI ONI NG/PLUMBI NG/LI QUI D LI NE -
I NSTALLATI ON).
DIAGNOSIS AND TESTING
A/C ORIFICE TUBE
The fi xed A/C ori fi ce tube can be checked for
proper operati on usi ng the fol l owi ng procedure. How-
ever, the fi xed ori fi ce tube i s onl y servi ced as a part
of the l i qui d l i ne uni t. I f the resul ts of thi s test i ndi -
cate that the A/C ori fi ce tube i s obstructed or mi ss-
i ng, the enti re l i qui d l i ne must be repl aced.
WARNING: THE LIQUID LINE BETWEEN THE CON-
DENSER OUTLET AND THE A/C ORIFICE TUBE
CAN BECOME HOT ENOUGH TO BURN THE SKIN.
USE EXTREME CAUTION WHEN PERFORMING THE
FOLLOWING TEST.
(1) Confi rm that the refri gerant system i s properl y
charged (Refer to 24 - HEATI NG & AI R CONDI -
TI ONI NG - DI AGNOSI S AND TESTI NG - A/C PER-
FORMANCE).
Fig. 9 Fixed Orifice Tube - Typical
1 - DIFFUSER SCREEN
2 - O-RING SEALS
3 - INLET FILTER SCREEN
4 - ORIFICE
24 - 60 PLUMBING TJ
A/C EVAPORATOR (Continued)
(2) Start the engi ne. Turn on the ai r condi ti oni ng
system and confi rm that the compressor cl utch i s
engaged.
(3) Al l ow the ai r condi ti oni ng system to operate for
fi ve mi nutes.
(4) Li ghtl y and cauti ousl y touch the l i qui d l i ne
near the condenser outl et at the front of the engi ne
compartment. The l i qui d l i ne shoul d be hot to the
touch.
(5) Touch the l i qui d l i ne near the evaporator i nl et
at the rear of the engi ne compartment. The l i qui d
l i ne shoul d be col d to the touch.
(6) I f there i s a di sti nct temperature di fferenti al
between the two ends of the l i qui d l i ne, the A/C ori -
fi ce tube i s i n good condi ti on. I f there i s l i ttl e or no
detectabl e temperature di fferenti al between the two
ends of the l i qui d l i ne, the A/C ori fi ce tube i s
obstructed or mi ssi ng and the l i qui d l i ne must be
repl aced.
ACCUMULATOR
DESCRIPTION
The accumul ator (Fi g. 10) i s mounted i n the engi ne
compartment between the evaporator outl et and the
compressor sucti on port. An i ntegral mounti ng
bracket i s used to secure the accumul ator to the ri ght
si de rai l wi th a bol t. A threaded fi tti ng on the top of
the accumul ator cani ster provi des the port through
whi ch the A/C l ow pressure swi tch moni tors the
refri gerant system pressures.
The accumul ator cannot be repai red and, i f faul ty
or damaged, i t must be repl aced. The refri gerant
l i nes, rubber O-ri ngs and the A/C l ow pressure
swi tch are avai l abl e for servi ce repl acement.
OPERATION
Refri gerant enters the accumul ator cani ster as a
l ow pressure vapor through the i nl et tube. Any l i q-
ui d, oi l -l aden refri gerant fal l s to the bottom of the
cani ster, whi ch acts as a separator. A desi ccant bag i s
mounted i nsi de the accumul ator cani ster to absorb
any moi sture whi ch may have entered and become
trapped wi thi n the refri gerant system.
REMOVAL
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS SECTION BEFORE
PERFORMING THE FOLLOWING OPERATION (Refer
to 24 - HEATING & AIR CONDITIONING - CAUTION)
AND (Refer to 24 - HEATING & AIR CONDITIONING -
WARNING).
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Recover the refri gerant from the refri gerant
system (Refer to 24 - HEATI NG & AI R CONDI TI ON-
I NG/PLUMBI NG - STANDARD PROCEDURE).
(3) Di sconnect the wi re harness connector from the
A/C l ow pressure swi tch.
(4) Remove the pl asti c retai ni ng cl i p that secures
the sucti on l i ne to the l i qui d l i ne near the accumul a-
tor.
(5) Remove the two nuts that secure the refri ger-
ant l i nes to the accumul ator (Fi g. 11).
(6) Di sconnect the refri gerant l i nes from the accu-
mul ator.
(7) Remove the O-ri ng seal s from the opened
refri gerant l i ne fi tti ngs and di scard.
(8) I nstal l pl ugs i n, or tape over the opened refri g-
erant l i ne fi tti ngs and accumul ator ports.
(9) Loosen the bol t that secures the accumul ator
retai ni ng band to the support bracket l ocated on the
dash panel .
Fig. 10 Accumulator - Typical
1 - A/C LOW PRESSURE SWITCH
2 - PRESSURE SWITCH FITTING
3 - OUTLET TO COMPRESSOR
4 - ANTI-SIPHON HOLE
5 - DESICCANT BAG
6 - OIL RETURN ORIFICE FILTER
7 - VAPOR RETURN TUBE
8 - ACCUMULATOR DOME
9 - O-RING SEAL
10 - INLET FROM EVAPORATOR
TJ PLUMBING 24 - 61
A/C ORIFICE TUBE (Continued)
(10) Pul l the accumul ator and retai ni ng band for-
ward unti l the bol t i n the band i s cl ear of the sl otted
hol e i n the support bracket.
(11) Remove the accumul ator from the engi ne com-
partment and remove the retai ni ng band from the
accumul ator.
(12) I f necessary, remove the A/C l ow pressure
swi tch from the accumul ator.
INSTALLATION
NOTE: If the accumulator is being replaced, add 90
milliliters (3 fluid ounces) of refrigerant oil to the
refrigerant system. Use only refrigerant oil of the
type recommended for the compressor in the vehi-
cle.
(1) I f removed, i nstal l the A/C l ow pressure swi tch
onto the accumul ator usi ng a new O-ri ng seal .
Ti ghten the swi tch securel y.
(2) I nstal l the retai ni ng band onto the accumul ator
and posi ti on the accumul ator i nto the sl otted hol e of
the support bracket i n the engi ne compartment.
(3) Ti ghten the bol t that secures the accumul ator
retai ni ng band to the support bracket. Ti ghten the
bol t to 4.5 N·m (40 i n. l bs.).
(4) Remove the tape or pl ugs from the opened
refri gerant l i ne fi tti ngs and the accumul ator ports.
(5) Lubri cate new rubber O-ri ng seal s wi th cl ean
refri gerant oi l and i nstal l them on the refri gerant
l i ne fi tti ngs. Use onl y the speci fi ed O-ri ngs as they
are made of a speci al materi al for the R-134a system.
Use onl y refri gerant oi l of the type recommended for
the compressor i n the vehi cl e.
(6) Reconnect the refri gerant l i nes to the accumu-
l ator.
(7) I nstal l two nuts that secure the refri gerant l i ne
fi tti ngs to the accumul ator. Ti ghten the nuts to 2.2
N·m (20 i n. l bs.).
(8) I nstal l the pl asti c retai ni ng cl i p that secures
the sucti on l i ne to the l i qui d l i ne near the accumul a-
tor.
(9) Connect the wi re harness connector to the A/C
l ow pressure swi tch.
(10) Reconnect the battery negati ve cabl e.
(11) Evacuate the refri gerant system (Refer to 24 -
HEATI NG & AI R CONDI TI ONI NG/PLUMBI NG -
STANDARD PROCEDURE).
(12) Charge the refri gerant system (Refer to 24 -
HEATI NG & AI R CONDI TI ONI NG/PLUMBI NG -
STANDARD PROCEDURE).
HEATER CORE
DESCRIPTION
The heater core i s l ocated i n the HVAC housi ng,
behi nd the i nstrument panel . I t i s a heat exchanger
made of rows of tubes and fi ns.
OPERATION
Engi ne cool ant i s ci rcul ated through the heater
hoses and heater core at al l ti mes. As the cool ant
fl ows through the heater core, heat removed from the
engi ne i s transferred to the heater core fi ns and
tubes. Ai r di rected through the heater core pi cks up
the heat from the heater core fi ns. The bl end door
al l ows control of the heater output ai r temperature
by regul ati ng the amount of ai r that i s fl owi ng
through the heater core wi thi n the HVAC housi ng.
The bl ower motor speed control s the vol ume of ai r
fl owi ng through the HVAC housi ng.
The heater core cannot be repai red and, i f faul ty or
damaged, i t must be repl aced.
Fig. 11 A/C Accumulator - Typical
1 - SUCTION LINE (EVAPORATOR SIDE)
2 - SUPPORT BRACKET
3 - BOLT
4 - RETAINING BAND
5 - ACCUMULATOR
6 - SUCTION LINE (COMPRESSOR SIDE)
24 - 62 PLUMBING TJ
ACCUMULATOR (Continued)
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Remove the HVAC housi ng (Refer to 24 -
HEATI NG & AI R CONDI TI ONI NG/DI STRI BUTI ON/
HVAC HOUSI NG - REMOVAL).
(2) Di sassembl e the HVAC housi ng to access the
heater core (Refer to 24 - HEATI NG & AI R CONDI -
TI ONI NG/DI STRI BUTI ON/HVAC HOUSI NG - DI S-
ASSEMBLY).
(3) Li ft the heater core out of the l ower hal f of the
housi ng.
INSTALLATION
(1) I nstal l the heater core i nto the bottom hal f of
the HVAC housi ng.
(2) Assembl e the HVAC housi ng(Refer to 24 -
HEATI NG & AI R CONDI TI ONI NG/DI STRI BUTI ON/
HVAC HOUSI NG - ASSEMBLY).
(3) I nstal l the HVAC housi ng (Refer to 24 - HEAT-
I NG & AI R CONDI TI ONI NG/DI STRI BUTI ON/HVAC
HOUSI NG - I NSTALLATI ON).
LIQUID LINE
DESCRIPTION
The l i qui d l i ne i s the refri gerant l i ne that carri es
refri gerant from the A/C condenser to the evaporator.
The l i qui d l i ne i s made from l i ghtwei ght al umi num
or steel , and uses braze-l ess fi tti ngs.
The l i qui d l i ne contai ns the fi xed ori fi ce tube and
i s onl y servi ced as an assembl y, except for the rubber
O-ri ng seal s used on the end fi tti ngs. The l i qui d l i ne
cannot be adjusted or repai red and, i f found to be
l eaki ng or damaged, i t must be repl aced.
REMOVAL
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS SECTION BEFORE
PERFORMING THE FOLLOWING OPERATION (Refer
to 24 - HEATING & AIR CONDITIONING - WARNING)
AND (Refer to 24 - HEATING & AIR CONDITIONING -
CAUTION).
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Recover the refri gerant from the refri gerant
system (Refer to 24 - HEATI NG & AI R CONDI TI ON-
I NG/PLUMBI NG - STANDARD PROCEDURE).
(3) Remove the secondary retai ni ng cl i p from the
spri ng-l ock coupl er that secures the l i qui d l i ne to the
evaporator i nl et tube (Fi g. 12).
(4) Usi ng the proper A/C l i ne di sconnect tool , di s-
connect the l i qui d l i ne fi tti ng from the evaporator
i nl et tube (outboard fi tti ng) (Refer to 24 - HEATI NG
& AI R CONDI TI ONI NG/PLUMBI NG/REFRI GER-
ANT LI NE COUPLER - REMOVAL). I nstal l pl ugs i n,
or tape over al l of the opened refri gerant l i ne fi tti ngs.
(5) Remove the O-ri ng seal from the l i qui d l i ne fi t-
ti ng and di scard.
(6) I nstal l pl ugs i n, or tape over the opened l i qui d
l i ne fi tti ng and the evaporator i nl et port.
(7) Remove the l i qui d l i ne from the pl asti c retai n-
i ng cl i ps l ocated on the ri ght i nner fender.
(8) Remove the nut that secures the l i qui d l i ne fi t-
ti ng to the condenser outl et port (l ower fi tti ng).
(9) Remove the O-ri ng seal from the l i qui d l i ne fi t-
ti ng and di scard.
(10) I nstal l pl ugs i n, or tape over the opened l i qui d
l i ne fi tti ng and the condenser outl et port.
(11) Remove the l i qui d l i ne from the engi ne com-
partment.
Fig. 12 Liquid Line - 4.0L Shown, 2.4L Typical
1 - LIQUID LINE
2 - SERVICE PORT
3 - A/C CONDENSER
4 - PLASTIC RETAINING CLIP (2)
TJ PLUMBING 24 - 63
HEATER CORE (Continued)
INSTALLATION
NOTE: Replacement of the refrigerant line O-ring
seals is required anytime a refrigerant line is
opened. Failure to replace the rubber O-ring seals
could result in a refrigerant system leak.
(1) Posi ti on the l i qui d l i ne i nto the engi ne com-
partment.
(2) Remove the tape or pl ugs from the l i qui d l i ne
fi tti ng and the condenser outl et port.
(3) Lubri cate a new rubber O-ri ng seal wi th cl ean
refri gerant oi l and i nstal l i t on the l i qui d l i ne fi tti ng.
Use onl y the speci fi ed O-ri ngs as they are made of a
speci al materi al for the R-134a system. Use onl y
refri gerant oi l of the type recommended for the com-
pressor i n the vehi cl e.
(4) Connect the l i qui d l i ne to the condenser outl et
port.
(5) I nstal l the nut that secures the l i qui d l i ne fi t-
ti ng to the stud on the condenser outl et port. Ti ghten
the nut to 9 N·m (80 i n. l bs.).
(6) I nstal l the l i qui d l i ne i nto the pl asti c retai ni ng
cl i ps l ocated on the ri ght i nner fender
(7) Remove the tape or pl ugs from the l i qui d l i ne
fi tti ng and the evaporator i nl et port.
(8) Lubri cate a new rubber O-ri ng seal wi th cl ean
refri gerant oi l and i nstal l i t on the l i qui d l i ne fi tti ng.
Use onl y the speci fi ed O-ri ngs as they are made of a
speci al materi al for the R-134a system. Use onl y
refri gerant oi l of the type recommended for the com-
pressor i n the vehi cl e.
(9) Connect the l i qui d l i ne to the evaporator i nl et
port (Refer to 24 - HEATI NG & AI R CONDI TI ON-
I NG/PLUMBI NG/REFRI GERANT LI NE COUPLER -
I NSTALLATI ON).
(10) I nstal l the secondary retai ni ng cl i p onto the
spri ng-l ock coupl er that secures the l i qui d l i ne to the
evaporator i nl et tube.
(11) Reconnect the battery negati ve cabl e.
(12) Evacuate the refri gerant system (Refer to 24 -
HEATI NG & AI R CONDI TI ONI NG/PLUMBI NG -
STANDARD PROCEDURE).
(13) Charge the refri gerant system (Refer to 24 -
HEATI NG & AI R CONDI TI ONI NG/PLUMBI NG -
STANDARD PROCEDURE).
REFRIGERANT
DESCRIPTION
The refri gerant used i n thi s ai r condi ti oni ng sys-
tem i s a HydroFl uoroCarbon (HFC), type R-134a.
Unl i ke R-12, whi ch i s a Chl oroFl uoroCarbon (CFC),
R-134a refri gerant does not contai n ozone-depl eti ng
chl ori ne. R-134a refri gerant i s a non-toxi c, non-fl am-
mabl e, cl ear, and col orl ess l i quefi ed gas.
Even though R-134a does not contai n chl ori ne, i t
must be recl ai med and recycl ed just l i ke CFC-type
refri gerants. Thi s i s because R-134a i s a greenhouse
gas and can contri bute to gl obal warmi ng.
OPERATION
R-134a refri gerant i s not compati bl e wi th R-12
refri gerant i n an ai r condi ti oni ng system. Even a
smal l amount of R-12 added to an R-134a refri gerant
system wi l l cause compressor fai l ure, refri gerant oi l
sl udge or poor ai r condi ti oni ng system performance.
I n addi ti on, the Pol yAl kyl ene Gl ycol (PAG) syntheti c
refri gerant oi l s used i n an R-134a refri gerant system
are not compati bl e wi th the mi neral -based refri ger-
ant oi l s used i n an R-12 refri gerant system.
R-134a refri gerant system servi ce ports, servi ce
tool coupl ers and refri gerant di spensi ng bottl es have
al l been desi gned wi th uni que fi tti ngs to ensure that
an R-134a system i s not acci dental l y contami nated
wi th the wrong refri gerant (R-12). There are al so
l abel s posted i n the engi ne compartment of the vehi -
cl e and on the compressor i denti fyi ng to servi ce tech-
ni ci ans that the ai r condi ti oni ng system i s equi pped
wi th R-134a.
REFRIGERANT LINE COUPLER
DESCRIPTION
Spri ng-l ock type refri gerant l i ne coupl ers are used to
connect many of the refri gerant l i nes and other compo-
nents to the refri gerant system. These coupl ers requi re
a speci al tool for di sengagi ng the two coupl er hal ves.
OPERATION
The spri ng-l ock coupl er i s hel d together by a garter
spri ng i nsi de a ci rcul ar cage on the mal e hal f of the
fi tti ng (Fi g. 13). When the two coupl er hal ves are
connected, the fl ared end of the femal e fi tti ng sl i ps
behi nd the garter spri ng i nsi de the cage on the mal e
fi tti ng. The garter spri ng and cage prevent the fl ared
end of the femal e fi tti ng from pul l i ng out of the cage.
Two O-ri ngs on the mal e hal f of the fi tti ng are
used to seal the connecti on. These O-ri ngs are com-
pati bl e wi th R-134a refri gerant and must be repl aced
wi th O-ri ngs made of the same materi al .
Secondary cl i ps are i nstal l ed over the two con-
nected coupl er hal ves at the factory for added bl owoff
protecti on. I n addi ti on, some model s have a pl asti c
ri ng that i s used at the factory as a vi sual i ndi cator
to confi rm that these coupl ers are connected. After
the coupl er i s connected, the pl asti c i ndi cator ri ng i s
no l onger needed; however, i t wi l l remai n on the
refri gerant l i ne near the coupl er cage.
24 - 64 PLUMBING TJ
LIQUID LINE (Continued)
REMOVAL
(1) Recover the refri gerant from the refri gerant
system (Refer to 24 - HEATI NG & AI R CONDI TI ON-
I NG/PLUMBI NG - STANDARD PROCEDURE).
(2) Remove the secondary retai ni ng cl i p from the
spri ng-l ock coupl er.
(3) Fi t the proper si ze A/C l i ne di sconnect tool
(Speci al Tool Ki t 7193) over the spri ng-l ock coupl er
cage (Fi g. 14).
(4) Cl ose the two hal ves of the A/C l i ne di sconnect
tool around the spri ng-l ock coupl er.
(5) Push the A/C l i ne di sconnect tool i nto the open
si de of the coupl er cage to expand the garter spri ng.
Once the garter spri ng i s expanded and whi l e sti l l
pushi ng the di sconnect tool i nto the open si de of the
coupl er cage, pul l on the refri gerant l i ne attached to
the femal e hal f of the coupl er fi tti ng unti l the fl ange
on the femal e fi tti ng i s separated from the garter
spri ng and cage on the mal e fi tti ng wi thi n the di s-
connect tool .
NOTE: The garter spring may not release if the A/C
line disconnect tool is cocked while pushing it into
the coupler cage opening.
(6) Open and remove the A/C l i ne di sconnect tool
from the di sconnected spri ng-l ock coupl er.
(7) Compl ete the separati on of the two hal ves of
the coupl er fi tti ng.
INSTALLATION
(1) Check to ensure that the garter spri ng i s
l ocated wi thi n the cage of the mal e coupl er fi tti ng,
and that the garter spri ng i s not damaged.
(a) I f the garter spri ng i s mi ssi ng, i nstal l a new
spri ng by pushi ng i t i nto the coupl er cage openi ng.
(b) I f the garter spri ng i s damaged, remove i t
from the coupl er cage wi th a smal l wi re hook (DO
NOT use a screwdri ver) and i nstal l a new garter
spri ng.
(2) Cl ean any di rt or forei gn materi al from both
hal ves of the coupl er fi tti ng.
(3) I nstal l new O-ri ngs on the mal e hal f of the cou-
pl er fi tti ng.
CAUTION: Use only the specified O-rings as they are
made of a special material for the R-134a system. The
use of any other O-rings may allow the connection to
leak intermittently during vehicle operation.
(4) Lubri cate the mal e fi tti ng and O-ri ngs, and the
i nsi de of the femal e fi tti ng wi th cl ean R-134a refri g-
erant oi l . Use onl y refri gerant oi l of the type recom-
mended for the compressor i n the vehi cl e.
(5) Fi t the femal e hal f of the coupl er fi tti ng over
the mal e hal f of the fi tti ng.
(6) Push together fi rml y on the two hal ves of the
coupl er fi tti ng unti l the garter spri ng i n the cage on
the mal e hal f of the fi tti ng snaps over the fl anged
end on the femal e hal f of the fi tti ng.
(7) Ensure that the spri ng-l ock coupl er i s ful l y
engaged by tryi ng to separate the two coupl er hal ves.
Thi s i s done by pul l i ng the refri gerant l i nes on ei ther
si de of the coupl er away from each other.
(8) Rei nstal l the secondary retai ni ng cl i p over the
spri ng-l ock coupl er cage.
Fig. 13 Spring-Lock Coupler - Typical
1 - MALE HALF SPRING-LOCK COUPLER
2 - FEMALE HALF SPRING-LOCK COUPLER
3 - SECONDARY CLIP
4 - CONNECTION INDICATOR RING
5 - COUPLER CAGE
6 - GARTER SPRING
7 - COUPLER CAGE
8 - O-RING SEALS
Fig. 14 Refrigerant Line Spring-Lock Coupler
Disconnect
TJ PLUMBING 24 - 65
REFRIGERANT LINE COUPLER (Continued)
REFRIGERANT OIL
DESCRIPTION
The refri gerant oi l used i n R-134a refri gerant sys-
tems i s a syntheti c-based, Pol yAl kyl ene Gl ycol (PAG),
wax-free l ubri cant. Mi neral -based R-12 refri gerant
oi l s are not compati bl e wi th PAG oi l s, and shoul d
never be i ntroduced to an R-134a refri gerant system.
There are di fferent PAG oi l s avai l abl e, and each
contai ns a di fferent addi ti ve package. The 10PA17
compressor used i n thi s vehi cl e i s desi gned to use an
ND-8 PAG refri gerant oi l . Use onl y refri gerant oi l of
thi s same type to servi ce the refri gerant system.
OPERATION
After performi ng any refri gerant recovery or recy-
cl i ng operati on, al ways repl eni sh the refri gerant sys-
tem wi th the same amount of the recommended
refri gerant oi l as was removed. Too l i ttl e refri gerant
oi l can cause compressor damage, and too much can
reduce ai r condi ti oni ng system performance.
PAG refri gerant oi l i s much more hygroscopi c than
mi neral oi l , and wi l l absorb any moi sture i t comes
i nto contact wi th, even moi sture i n the ai r. The PAG
oi l contai ner shoul d al ways be kept ti ghtl y capped
unti l i t i s ready to be used. After use, recap the oi l
contai ner i mmedi atel y to prevent moi sture contami -
nati on.
STANDARD PROCEDURE
REFRIGERANT OIL LEVEL
When an ai r condi ti oni ng system i s assembl ed at
the factory, al l components except the compressor are
refri gerant oi l free. After the refri gerant system has
been charged and operated, the refri gerant oi l i n the
compressor i s di spersed throughout the refri gerant
system. The accumul ator, evaporator, condenser, and
compressor wi l l each retai n a si gni fi cant amount of
the needed refri gerant oi l .
I t i s i mportant to have the correct amount of oi l i n
the refri gerant system. Thi s ensures proper l ubri ca-
ti on of the compressor. Too l i ttl e oi l wi l l resul t i n
damage to the compressor. Too much oi l wi l l reduce
the cool i ng capaci ty of the ai r condi ti oni ng system
and consequentl y resul t i n hi gher di scharge ai r tem-
peratures.
NOTE: The oil used in the compressor is ND-8 PAG
R-134a refrigerant oil. Only refrigerant oil of the
same type should be used to service the system.
Do not use any other oil. The oil container should
be kept tightly capped until it is ready for use.
Tightly cap afterwards to prevent contamination
from dirt and moisture. Refrigerant oil will quickly
absorb any moisture it comes in contact with. Spe-
cial effort must be used to keep all R-134a system
components moisture-free. Moisture in the oil is
very difficult to remove and will cause a reliability
problem with the compressor.
I t wi l l not be necessary to check the oi l l evel i n the
compressor or to add oi l , unl ess there has been an oi l
l oss. An oi l l oss may occur due to a rupture or l eak
from a refri gerant l i ne, a connector fi tti ng, a compo-
nent, or a component seal . I f a l eak occurs, add 30
mi l l i l i ters (1 fl ui d ounce) of refri gerant oi l to the
refri gerant system after the repai r has been made.
Refri gerant oi l l oss wi l l be evi dent at the l eak poi nt
by the presence of a wet, shi ny surface around the
l eak.
Refri gerant oi l must be added when a accumul ator,
evaporator coi l , or condenser are repl aced. See the
Refri gerant Oi l Capaci ti es chart. When a compressor
i s repl aced, the refri gerant oi l must be drai ned from
the ol d compressor and measured. Drai n al l of the
refri gerant oi l from the new compressor, then fi l l the
new compressor wi th the same amount of refri gerant
oi l that was drai ned out of the ol d compressor.
REFRIGERANT OIL CAPACITIES
Component ml oz
Total System Fill 180 6.1
Accumulator 90 3.0
Condenser 22 0.75
Evaporator 45 1.5
Compressor Drain and measure the
oil from the old
compressor - see text.
SERVICE PORT VALVE CORE
DESCRIPTION
The A/C servi ce port val ve cores are servi ceabl e
i tems. The hi gh si de val ve i s l ocated on the l ocated
on the mani fol d di rectl y over the di scharge port of
the A/C compressor. The l ow si de val ve i s l ocated on
the l i qui d l i ne near the evaporator i nl et tube at the
rear of the engi ne compartment.
REMOVAL
WARNING: REFER TO THE APPLICABLE WARN-
INGS AND CAUTIONS FOR THIS SYSTEM BEFORE
PERFORMING THE FOLLOWING OPERATION (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING -
WARNING) and (Refer to 24 - HEATING & AIR CON-
DITIONING/PLUMBING - CAUTION).
24 - 66 PLUMBING TJ
(1) Remove the protecti ve cap from the l ow and/or
hi gh si de servi ce port as necessary.
(2) Recover the refri gerant from the refri gerant
system (Refer to 24 - HEATI NG & AI R CONDI TI ON-
I NG/PLUMBI NG/REFRI GERANT - STANDARD
PROCEDURE).
(3) Usi ng a standard Schrader-type val ve core tool ,
remove the val ve core from the servi ce port as
requi red.
(4) I nstal l a pl ug i n or tape over the opened ser-
vi ce port.
INSTALLATION
WARNING: REFER TO THE APPLICABLE WARN-
INGS AND CAUTIONS FOR THIS SYSTEM BEFORE
PERFORMING THE FOLLOWING OPERATION (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING -
FRONT - WARNING - A/C PLUMBING) and (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING -
FRONT - CAUTION - A/C PLUMBING).
(1) Lubri cate the A/C servi ce port val ve core wi th
cl ean refri gerant oi l pri or to i nstal l ati on. Use onl y
refri gerant oi l of the type recommended for the com-
pressor i n the vehi cl e.
(2) Remove the tape or pl ug from the A/C servi ce
port.
(3) Usi ng a standard Schrader-type val ve core tool ,
i nstal l and ti ghten the repl acement val ve core i nto
the A/C servi ce ports as requi red.
CAUTION: A valve core that is not fully seated in
the A/C service port can result in damage to the
valve during refrigerant system evacuation and
charge. Such damage may result in a loss of sys-
tem refrigerant while uncoupling the charge adapt-
ers.
(4) Evacuate the refri gerant system (Refer to 24 -
HEATI NG & AI R CONDI TI ONI NG/PLUMBI NG -
FRONT/REFRI GERANT - STANDARD PROCE-
DURE - REFRI GERANT SYSTEM EVACUATE).
(5) Charge the refri gerant system (Refer to 24 -
HEATI NG & AI R CONDI TI ONI NG/PLUMBI NG -
FRONT/REFRI GERANT - STANDARD PROCE-
DURE - REFRI GERANT SYSTEM CHARGE).
(6) Rei nstal l the protecti ve cap onto the A/C ser-
vi ce ports as requi red.
SUCTION LINE
DESCRIPTION
The sucti on l i ne i s the refri gerant l i ne that goes
from the evaporator outl et tube to the compressor
i nl et port. The sucti on l i ne i s servi ced i n two sec-
ti ons. The front secti on connects between the accu-
mul ator and the A/C compressor. The rear secti on
connects between the evaporator and the accumul a-
tor.
The sucti on l i nes are servi ces onl y as assembl i es,
except for the rubber O-ri ng seal s. The sucti on l i nes
cannot be adjusted or repai red and, i f found to be
l eaki ng or damaged, must be repl aced.
REMOVAL
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS SECTION BEFORE
PERFORMING THE FOLLOWING OPERATION (Refer
to 24 - HEATING & AIR CONDITIONING - WARNING)
AND (Refer to 24 - HEATING & AIR CONDITIONING -
CAUTION).
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Recover the refri gerant from the refri gerant
system (Refer to 24 - HEATI NG & AI R CONDI TI ON-
I NG/PLUMBI NG - STANDARD PROCEDURE).
(3) Remove the sucti on l i ne from the pl asti c retai n-
i ng cl i p l ocated near the accumul ator.
(4) Remove the secondary retai ni ng cl i p from the
spri ng-l ock coupl er that secures the sucti on l i ne to
the evaporator outl et tube.
(5) Usi ng the proper A/C l i ne di sconnect tool , di s-
connect the sucti on l i ne fi tti ng from the evaporator
outl et tube (Fi g. 15) (Refer to 24 - HEATI NG & AI R
CONDI TI ONI NG/PLUMBI NG/REFRI GERANT LI NE
COUPLER - REMOVAL).
(6) Remove the O-ri ng seal from the sucti on l i ne
fi tti ng and di scard.
(7) I nstal l pl ugs i n, or tape over the opened suc-
ti on l i ne fi tti ng and the evaporator outl et port.
(8) Dependi ng on the engi ne usage, remove the
bol ts or nuts that secure the sucti on l i ne fi tti ng to
the compressor.
TJ PLUMBING 24 - 67
SERVICE PORT VALVE CORE (Continued)
(9) Remove the O-ri ng seal from the sucti on l i ne
fi tti ng and di scard.
(10) I nstal l pl ugs i n, or tape over the opened suc-
ti on l i ne fi tti ng and the compressor i nl et port.
(11) Remove the two nuts that secure the sucti on
l i nes to the accumul ator.
(12) Di sconnect the sucti on l i nes from the accumu-
l ator.
(13) Remove the O-ri ng seal s from the opened suc-
ti on l i ne fi tti ngs and di scard.
(14) I nstal l pl ugs i n, or tape over the opened suc-
ti on l i ne fi tti ngs and accumul ator ports.
(15) Remove the sucti on l i nes from the vehi cl e.
INSTALLATION
(1) Remove the tape or pl ugs from the opened suc-
ti on l i ne fi tti ngs and the accumul ator ports.
(2) Lubri cate new rubber O-ri ng seal s wi th cl ean
refri gerant oi l and i nstal l them on the sucti on l i ne
fi tti ngs. Use onl y the speci fi ed O-ri ngs as they are
made of a speci al materi al for the R-134a system.
Use onl y refri gerant oi l of the type recommended for
the compressor i n the vehi cl e.
(3) Reconnect the sucti on l i nes to the accumul ator.
(4) I nstal l two nuts that secure the sucti on l i ne fi t-
ti ngs to the accumul ator. Ti ghten the nuts to 2.2 N·m
(20 i n. l bs.).
(5) Remove the tape or pl ugs from the opened suc-
ti on l i ne fi tti ng and compressor i nl et port.
(6) Lubri cate a new rubber O-ri ng seal wi th cl ean
refri gerant oi l and i nstal l i t on the sucti on l i ne fi t-
ti ng. Use onl y the speci fi ed O-ri ng as i t i s made of a
speci al materi al for the R-134a system. Use onl y
refri gerant oi l of the type recommended for the A/C
compressor i n the vehi cl e.
(7) I nstal l the sucti on l i ne onto the compressor.
(8) I nstal l the bol t or nut (dependi ng on engi ne
appl i cati on) that secure the sucti on l i ne fi tti ng to the
compressor. Ti ghten the bol t or nut to 25.4 N·m (20
ft. l bs.).
(9) Remove the tape or pl ugs from the sucti on l i ne
fi tti ng and the accumul ator outl et tube.
(10) Lubri cate a new rubber O-ri ng seal wi th cl ean
refri gerant oi l and i nstal l i t on the sucti on l i ne fi t-
ti ng. Use onl y the speci fi ed O-ri ng as i t i s made of a
speci al materi al for the R-134a system. Use onl y
refri gerant oi l of the type recommended for the A/C
compressor i n the vehi cl e.
(11) Connect the sucti on l i ne spri ng-l ock coupl er to
the evaporator outl et tube (Refer to 24 - HEATI NG &
AI R CONDI TI ONI NG/PLUMBI NG/REFRI GERANT
LI NE COUPLER - I NSTALLATI ON).
(12) I nstal l the secondary retai ni ng cl i p onto the
spri ng-l ock coupl er that secures the sucti on l i ne to
the evaporator outl et tube.
(13) I nstal l the sucti on l i ne i nto the pl asti c retai n-
i ng cl i p l ocated near the accumul ator.
(14) Reconnect the battery negati ve cabl e.
(15) Evacuate the refri gerant system (Refer to 24 -
HEATI NG & AI R CONDI TI ONI NG/PLUMBI NG -
STANDARD PROCEDURE).
(16) Charge the refri gerant system (Refer to 24 -
HEATI NG & AI R CONDI TI ONI NG/PLUMBI NG -
STANDARD PROCEDURE).
Fig. 15 Suction Lines - 4.0L Shown, 2.4L Typical
1 - SUCTION LINE (EVAPORATOR SIDE)
2 - SUPPORT BRACKET
3 - BOLT
4 - RETAINING BAND
5 - ACCUMULATOR
6 - SUCTION LINE (COMPRESSOR SIDE)
24 - 68 PLUMBING TJ
SUCTION LINE (Continued)
EMISSIONS CONTROL
TABLE OF CONTENTS
page page
EMISSIONS CONTROL
DESCRIPTION
DESCRIPTION - EMISSION CONTROL
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DESCRIPTION - STATE DISPLAY TEST
MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DESCRIPTION - CIRCUIT ACTUATION TEST
MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DESCRIPTION - DIAGNOSTIC TROUBLE
CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DESCRIPTION - TASK MANAGER . . . . . . . . . . 2
DESCRIPTION - MONITORED SYSTEMS . . . . 2
DESCRIPTION - TRIP DEFINITION . . . . . . . . . 4
DESCRIPTION - COMPONENT MONITORS . . 5
DESCRIPTION - NON-MONITORED
CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
DESCRIPTION - HIGH AND LOW LIMITS . . . . 6
DESCRIPTION - LOAD VALUE . . . . . . . . . . . . 6
OPERATION - TASK MANAGER . . . . . . . . . . . . . 6
EVAPORATIVE EMISSIONS . . . . . . . . . . . . . . . . 10
EMISSIONS CONTROL
DESCRIPTION
DESCRIPTION - EMISSION CONTROL SYSTEM
The Powertrai n Control Modul e (PCM) moni tors
many di fferent ci rcui ts i n the fuel i njecti on, i gni ti on,
emi ssi on and engi ne systems. I f the PCM senses a
probl em wi th a moni tored ci rcui t often enough to
i ndi cate an actual probl em, i t stores a Di agnosti c
Troubl e Code (DTC) i n the PCM’s memory. I f the
code appl i es to a non-emi ssi ons rel ated component or
system, and the probl em i s repai red or ceases to
exi st, the PCM cancel s the code after 40 warm-up
cycl es. Di agnosti c troubl e codes that affect vehi cl e
emi ssi ons i l l umi nate the Mal functi on I ndi cator Lamp
(MI L). The MI L i s di spl ayed as an engi ne i con on the
i nstrument panel . Refer to Mal functi on I ndi cator
Lamp (MI L) i n thi s secti on.
Certai n cri teri a must be met before the PCM
stores a DTC i n memory. The cri teri a may be a spe-
ci fi c range of engi ne RPM, engi ne temperature,
and/or i nput vol tage to the PCM.
The PCM mi ght not store a DTC for a moni tored
ci rcui t even though a mal functi on has occurred. Thi s
may happen because one of the DTC cri teri a for the
ci rcui t has not been met. For example , assume the
di agnosti c troubl e code cri teri a requi res the PCM to
moni tor the ci rcui t onl y when the engi ne operates
between 750 and 2000 RPM. Suppose the sensor’s
output ci rcui t shorts to ground when engi ne operates
above 2400 RPM (resul ti ng i n 0 vol t i nput to the
PCM). Because the condi ti on happens at an engi ne
speed above the maxi mum threshol d (2000 rpm), the
PCM wi l l not store a DTC.
There are several operati ng condi ti ons for whi ch
the PCM moni tors and sets DTC’s. Refer to Moni -
tored Systems, Components, and Non-Moni tored Ci r-
cui ts i n thi s secti on.
Techni ci ans must retri eve stored DTC’s by connect-
i ng the DRB scan tool (or an equi val ent scan tool ) to
the 16–way data l i nk connector (Fi g. 1).
NOTE: Various diagnostic procedures may actually
cause a diagnostic monitor to set a DTC. For
instance, pulling a spark plug wire to perform a
spark test may set the misfire code. When a repair
is completed and verified, connect the DRB scan
tool to the 16–way data link connector to erase all
DTC’s and extinguish the MIL.
Fig. 1 DATA LINK (DIAGNOSTIC) CONNECTOR
LOCATION
1 - 16–WAY DATA LINK CONNECTOR
TJ EMISSIONS CONTROL 25 - 1
DESCRIPTION - STATE DISPLAY TEST MODE
The swi tch i nputs to the Powertrai n Control Mod-
ul e (PCM) have two recogni zed states; HI GH and
LOW. For thi s reason, the PCM cannot recogni ze the
di fference between a sel ected swi tch posi ti on versus
an open ci rcui t, a short ci rcui t, or a defecti ve swi tch.
I f the State Di spl ay screen shows the change from
HI GH to LOW or LOW to HI GH, assume the enti re
swi tch ci rcui t to the PCM functi ons properl y. Connect
the DRB scan tool to the data l i nk connector and
access the state di spl ay screen. Then access ei ther
State Di spl ay I nputs and Outputs or State Di spl ay
Sensors.
DESCRIPTION - CIRCUIT ACTUATION TEST
MODE
The Ci rcui t Actuati on Test Mode checks for proper
operati on of output ci rcui ts or devi ces the Powertrai n
Control Modul e (PCM) may not i nternal l y recogni ze.
The PCM attempts to acti vate these outputs and
al l ow an observer to veri fy proper operati on. Most of
the tests provi de an audi bl e or vi sual i ndi cati on of
devi ce operati on (cl i ck of rel ay contacts, fuel spray,
etc.). Except for i ntermi ttent condi ti ons, i f a devi ce
functi ons properl y duri ng testi ng, assume the devi ce,
i ts associ ated wi ri ng, and dri ver ci rcui t work cor-
rectl y. Connect the DRB scan tool to the data l i nk
connector and access the Actuators screen.
DESCRIPTION - DIAGNOSTIC TROUBLE CODES
A Di agnosti c Troubl e Code (DTC) i ndi cates the
PCM has recogni zed an abnormal condi ti on i n the
system.
Remember that DTC’s are the results of a sys-
tem or circuit failure, but do not directly iden-
tify the failed component or components.
BULB CHECK
Each ti me the i gni ti on key i s turned to the ON
posi ti on, the mal functi on i ndi cator (check engi ne)
l amp on the i nstrument panel shoul d i l l umi nate for
approxi matel y 2 seconds then go out. Thi s i s done for
a bul b check.
OBTAINING DTC’S USING DRB SCAN TOOL
(1) Obtai n the appl i cabl e Powertrai n Di agnosti c
Manual .
(2) Obtai n the DRB Scan Tool .
(3) Connect the DRB Scan Tool to the data l i nk
(di agnosti c) connector. Thi s connector i s l ocated i n
the passenger compartment; at the l ower edge of
i nstrument panel ; near the steeri ng col umn.
(4) Turn the i gni ti on swi tch on and access the
“Read Faul t” screen.
(5) Record al l the DTC’s and “freeze frame” i nfor-
mati on shown on the DRB scan tool .
(6) To erase DTC’s, use the “Erase Troubl e Code”
data screen on the DRB scan tool . Do not erase any
DTC’s until problems have been investigated
and repairs have been performed.
DESCRIPTION - TASK MANAGER
The PCM i s responsi bl e for effi ci entl y coordi nati ng
the operati on of al l the emi ssi ons-rel ated compo-
nents. The PCM i s al so responsi bl e for determi ni ng i f
the di agnosti c systems are operati ng properl y. The
software desi gned to carry out these responsi bi l i ti es
i s referred to as the ’Task Manager’.
DESCRIPTION - MONITORED SYSTEMS
There are new el ectroni c ci rcui t moni tors that
check fuel , emi ssi on, engi ne and i gni ti on perfor-
mance. These moni tors use i nformati on from vari ous
sensor ci rcui ts to i ndi cate the overal l operati on of the
fuel , engi ne, i gni ti on and emi ssi on systems and thus
the emi ssi ons performance of the vehi cl e.
The fuel , engi ne, i gni ti on and emi ssi on systems
moni tors do not i ndi cate a speci fi c component prob-
l em. They do i ndi cate that there i s an i mpl i ed prob-
l em wi thi n one of the systems and that a speci fi c
probl em must be di agnosed.
I f any of these moni tors detect a probl em affecti ng
vehi cl e emi ssi ons, the Mal functi on I ndi cator Lamp
(MI L) wi l l be i l l umi nated. These moni tors generate
Di agnosti c Troubl e Codes that can be di spl ayed wi th
the MI L or a scan tool .
The fol l owi ng i s a l i st of the system moni tors:
• Mi sfi re Moni tor
• Fuel System Moni tor
• Oxygen Sensor Moni tor
• Oxygen Sensor Heater Moni tor
• Catal yst Moni tor
• Leak Detecti on Pump Moni tor (i f equi pped)
Al l these system moni tors requi re two consecuti ve
tri ps wi th the mal functi on present to set a faul t.
Refer to the appropriate Powertrain Diagnos-
tics Procedures manual for diagnostic proce-
dures.
The fol l owi ng i s an operati on and descri pti on of
each system moni tor:
OXYGEN SENSOR (O2S) MONITOR
Effecti ve control of exhaust emi ssi ons i s achi eved
by an oxygen feedback system. The most i mportant
el ement of the feedback system i s the O2S. The O2S
i s l ocated i n the exhaust path. Once i t reaches oper-
ati ng temperature 300° to 350°C (572° to 662°F), the
sensor generates a vol tage that i s i nversel y propor-
ti onal to the amount of oxygen i n the exhaust. The
i nformati on obtai ned by the sensor i s used to cal cu-
l ate the fuel i njector pul se wi dth. Thi s mai ntai ns a
14.7 to 1 Ai r Fuel (A/F) rati o. At thi s mi xture rati o,
25 - 2 EMISSIONS CONTROL TJ
EMISSIONS CONTROL (Continued)
the catal yst works best to remove hydrocarbons (HC),
carbon monoxi de (CO) and ni trogen oxi de (NOx) from
the exhaust.
The O2S i s al so the mai n sensi ng el ement for the
Catal yst and Fuel Moni tors.
The O2S can fai l i n any or al l of the fol l owi ng
manners:
• sl ow response rate
• reduced output vol tage
• dynami c shi ft
• shorted or open ci rcui ts
Response rate i s the ti me requi red for the sensor to
swi tch from l ean to ri ch once i t i s exposed to a ri cher
than opti mum A/F mi xture or vi ce versa. As the sen-
sor starts mal functi oni ng, i t coul d take l onger to
detect the changes i n the oxygen content of the
exhaust gas.
The output vol tage of the O2S ranges from 0 to 1
vol t. A good sensor can easi l y generate any output
vol tage i n thi s range as i t i s exposed to di fferent con-
centrati ons of oxygen. To detect a shi ft i n the A/F
mi xture (l ean or ri ch), the output vol tage has to
change beyond a threshol d val ue. A mal functi oni ng
sensor coul d have di ffi cul ty changi ng beyond the
threshol d val ue.
OXYGEN SENSOR HEATER MONITOR
I f there i s an oxygen sensor (O2S) shorted to vol t-
age DTC, as wel l as a O2S heater DTC, the O2S
faul t MUST be repai red fi rst. Before checki ng the
O2S faul t, veri fy that the heater ci rcui t i s operati ng
correctl y.
Effecti ve control of exhaust emi ssi ons i s achi eved
by an oxygen feedback system. The most i mportant
el ement of the feedback system i s the O2S. The O2S
i s l ocated i n the exhaust path. Once i t reaches oper-
ati ng temperature 300° to 350°C (572 ° to 662°F), the
sensor generates a vol tage that i s i nversel y propor-
ti onal to the amount of oxygen i n the exhaust. The
i nformati on obtai ned by the sensor i s used to cal cu-
l ate the fuel i njector pul se wi dth. Thi s mai ntai ns a
14.7 to 1 Ai r Fuel (A/F) rati o. At thi s mi xture rati o,
the catal yst works best to remove hydrocarbons (HC),
carbon monoxi de (CO) and ni trogen oxi de (NOx) from
the exhaust.
The vol tage readi ngs taken from the O2S sensor
are very temperature sensi ti ve. The readi ngs are not
accurate bel ow 300°C. Heati ng of the O2S sensor i s
done to al l ow the engi ne control l er to shi ft to cl osed
l oop control as soon as possi bl e. The heati ng el ement
used to heat the O2S sensor must be tested to ensure
that i t i s heati ng the sensor properl y.
The O2S sensor ci rcui t i s moni tored for a drop i n
vol tage. The sensor output i s used to test the heater
by i sol ati ng the effect of the heater el ement on the
O2S sensor output vol tage from the other effects.
LEAK DETECTION PUMP MONITOR (IF EQUIPPED)
The l eak detecti on assembl y i ncorporates two pri -
mary functi ons: i t must detect a l eak i n the evapora-
ti ve system and seal the evaporati ve system so the
l eak detecti on test can be run.
The pri mary components wi thi n the assembl y are:
A three port sol enoi d that acti vates both of the func-
ti ons l i sted above; a pump whi ch contai ns a swi tch,
two check val ves and a spri ng/di aphragm, a cani ster
vent val ve (CVV) seal whi ch contai ns a spri ng l oaded
vent seal val ve.
I mmedi atel y after a col d start, between predeter-
mi ned temperature threshol ds l i mi ts, the three port
sol enoi d i s bri efl y energi zed. Thi s i ni ti al i zes the
pump by drawi ng ai r i nto the pump cavi ty and al so
cl oses the vent seal . Duri ng non test condi ti ons the
vent seal i s hel d open by the pump di aphragm
assembl y whi ch pushes i t open at the ful l travel posi -
ti on. The vent seal wi l l remai n cl osed whi l e the
pump i s cycl i ng due to the reed swi tch tri ggeri ng of
the three port sol enoi d that prevents the di aphragm
assembl y from reachi ng ful l travel . After the bri ef
i ni ti al i zati on peri od, the sol enoi d i s de-energi zed
al l owi ng atmospheri c pressure to enter the pump
cavi ty, thus permi tti ng the spri ng to dri ve the di a-
phragm whi ch forces ai r out of the pump cavi ty and
i nto the vent system. When the sol enoi d i s energi zed
and de energi zed, the cycl e i s repeated creati ng fl ow
i n typi cal di aphragm pump fashi on. The pump i s con-
trol l ed i n 2 modes:
Pump Mode: The pump i s cycl ed at a fi xed rate to
achi eve a rapi d pressure bui l d i n order to shorten the
overal l test l ength.
Test Mode: The sol enoi d i s energi zed wi th a fi xed
durati on pul se. Subsequent fi xed pul ses occur when
the di aphragm reaches the Swi tch cl osure poi nt.
The spri ng i n the pump i s set so that the system
wi l l achi eve an equal i zed pressure of about 7.5”
water. The cycl e rate of pump strokes i s qui te rapi d
as the system begi ns to pump up to thi s pressure. As
the pressure i ncreases, the cycl e rate starts to drop
off. I f there i s no l eak i n the system, the pump woul d
eventual l y stop pumpi ng at the equal i zed pressure. I f
there i s a l eak, i t wi l l conti nue to pump at a rate rep-
resentati ve of the fl ow characteri sti c of the si ze of the
l eak. From thi s i nformati on we can determi ne i f the
l eak i s l arger than the requi red detecti on l i mi t (cur-
rentl y set at .040” ori fi ce by CARB). I f a l eak i s
reveal ed duri ng the l eak test porti on of the test, the
test i s termi nated at the end of the test mode and no
further system checks wi l l be performed.
After passi ng the l eak detecti on phase of the test,
system pressure i s mai ntai ned by turni ng on the
LDP’s sol enoi d unti l the purge system i s acti vated.
Purge acti vati on i n effect creates a l eak. The cycl e
rate i s agai n i nterrogated and when i t i ncreases due
TJ EMISSIONS CONTROL 25 - 3
EMISSIONS CONTROL (Continued)
to the fl ow through the purge system, the l eak check
porti on of the di agnosti c i s compl ete.
The cani ster vent val ve wi l l unseal the system
after compl eti on of the test sequence as the pump
di aphragm assembl y moves to the ful l travel posi ti on.
Evaporati ve system functi onal i ty wi l l be veri fi ed by
usi ng the stri cter evap purge fl ow moni tor. At an
appropri ate warm i dl e the LDP wi l l be energi zed to
seal the cani ster vent. The purge fl ow wi l l be cl ocked
up from some smal l val ue i n an attempt to see a
shi ft i n the 02 control system. I f fuel vapor, i ndi cated
by a shi ft i n the 02 control , i s present the test i s
passed. I f not, i t i s assumed that the purge system i s
not functi oni ng i n some respect. The LDP i s agai n
turned off and the test i s ended.
MISFIRE MONITOR
Excessi ve engi ne mi sfi re resul ts i n i ncreased cata-
l yst temperature and causes an i ncrease i n HC emi s-
si ons. Severe mi sfi res coul d cause catal yst damage.
To prevent catal yti c convertor damage, the PCM
moni tors engi ne mi sfi re.
The Powertrai n Control Modul e (PCM) moni tors
for mi sfi re duri ng most engi ne operati ng condi ti ons
(posi ti ve torque) by l ooki ng at changes i n the crank-
shaft speed. I f a mi sfi re occurs the speed of the
crankshaft wi l l vary more than normal .
FUEL SYSTEM MONITOR
To compl y wi th cl ean ai r regul ati ons, vehi cl es are
equi pped wi th catal yti c converters. These converters
reduce the emi ssi on of hydrocarbons, oxi des of ni tro-
gen and carbon monoxi de. The catal yst works best
when the Ai r Fuel (A/F) rati o i s at or near the opti -
mum of 14.7 to 1.
The PCM i s programmed to mai ntai n the opti mum
ai r/fuel rati o of 14.7 to 1. Thi s i s done by maki ng
short term correcti ons i n the fuel i njector pul se wi dth
based on the O2S sensor output. The programmed
memory acts as a sel f cal i brati on tool that the engi ne
control l er uses to compensate for vari ati ons i n engi ne
speci fi cati ons, sensor tol erances and engi ne fati gue
over the l i fe span of the engi ne. By moni tori ng the
actual fuel -ai r rati o wi th the O2S sensor (short term)
and mul ti pl yi ng that wi th the program l ong-term
(adapti ve) memory and compari ng that to the l i mi t,
i t can be determi ned whether i t wi l l pass an emi s-
si ons test. I f a mal functi on occurs such that the PCM
cannot mai ntai n the opti mum A/F rati o, then the
MI L wi l l be i l l umi nated.
CATALYST MONITOR
To compl y wi th cl ean ai r regul ati ons, vehi cl es are
equi pped wi th catal yti c converters. These converters
reduce the emi ssi on of hydrocarbons, oxi des of ni tro-
gen and carbon monoxi de.
Normal vehi cl e mi l es or engi ne mi sfi re can cause a
catal yst to decay. Thi s can i ncrease vehi cl e emi ssi ons
and deteri orate engi ne performance, dri veabi l i ty and
fuel economy.
The catal yst moni tor uses dual oxygen sensors
(O2S’s) to moni tor the effi ci ency of the converter. The
dual O2S’s sensor strategy i s based on the fact that
as a catal yst deteri orates, i ts oxygen storage capaci ty
and i ts effi ci ency are both reduced. By moni tori ng
the oxygen storage capaci ty of a catal yst, i ts effi -
ci ency can be i ndi rectl y cal cul ated. The upstream
O2S i s used to detect the amount of oxygen i n the
exhaust gas before the gas enters the catal yti c con-
verter. The PCM cal cul ates the A/F mi xture from the
output of the O2S. A l ow vol tage i ndi cates hi gh oxy-
gen content (l ean mi xture). A hi gh vol tage i ndi cates a
l ow content of oxygen (ri ch mi xture).
When the upstream O2S detects a l ean condi ti on,
there i s an abundance of oxygen i n the exhaust gas.
A functi oni ng converter woul d store thi s oxygen so i t
can use i t for the oxi dati on of HC and CO. As the
converter absorbs the oxygen, there wi l l be a l ack of
oxygen downstream of the converter. The output of
the downstream O2S wi l l i ndi cate l i mi ted acti vi ty i n
thi s condi ti on.
As the converter l oses the abi l i ty to store oxygen,
the condi ti on can be detected from the behavi or of
the downstream O2S. When the effi ci ency drops, no
chemi cal reacti on takes pl ace. Thi s means the con-
centrati on of oxygen wi l l be the same downstream as
upstream. The output vol tage of the downstream
O2S copi es the vol tage of the upstream sensor. The
onl y di fference i s a ti me l ag (seen by the PCM)
between the swi tchi ng of the O2S’s.
To moni tor the system, the number of l ean-to-ri ch
swi tches of upstream and downstream O2S’s i s
counted. The rati o of downstream swi tches to
upstream swi tches i s used to determi ne whether the
catal yst i s operati ng properl y. An effecti ve catal yst
wi l l have fewer downstream swi tches than i t has
upstream swi tches i .e., a rati o cl oser to zero. For a
total l y i neffecti ve catal yst, thi s rati o wi l l be one-to-
one, i ndi cati ng that no oxi dati on occurs i n the devi ce.
The system must be moni tored so that when cata-
l yst effi ci ency deteri orates and exhaust emi ssi ons
i ncrease to over the l egal l i mi t, the MI L wi l l be i l l u-
mi nated.
DESCRIPTION - TRIP DEFINITION
The term “Tri p” has di fferent meani ngs dependi ng
on what the ci rcumstances are. I f the MI L (Mal func-
ti on I ndi cator Lamp) i s OFF, a Tri p i s defi ned as
when the Oxygen Sensor Moni tor and the Catal yst
Moni tor have been compl eted i n the same dri ve cycl e.
When any Emi ssi on DTC i s set, the MI L on the
dash i s turned ON. When the MI L i s ON, i t takes 3
25 - 4 EMISSIONS CONTROL TJ
EMISSIONS CONTROL (Continued)
good tri ps to turn the MI L OFF. I n thi s case, i t
depends on what type of DTC i s set to know what a
“Tri p” i s.
For the Fuel Moni tor or Mi s-Fi re Moni tor (conti n-
uous moni tor), the vehi cl e must be operated i n the
“Si mi l ar Condi ti on Wi ndow” for a speci fi ed amount of
ti me to be consi dered a Good Tri p.
I f a Non-Conti uous OBDI I Moni tor fai l s twi ce i n a
row and turns ON the MI L, re-runni ng that moni tor
whi ch previ ousl y fai l ed, on the next start-up and
passi ng the moni tor, i s consi dered to be a Good Tri p.
These wi l l i ncl ude the fol l owi ng:
• Oxygen Sensor
• Catal yst Moni tor
• Purge Fl ow Moni tor
• Leak Detecti on Pump Moni tor (i f equi pped)
• EGR Moni tor (i f equi pped)
• Oxygen Sensor Heater Moni tor
I f any other Emi ssi on DTC i s set (not an OBDI I
Moni tor), a Good Tri p i s consi dered to be when the
Oxygen Sensor Moni tor and Catal yst Moni tor have
been compl eted; or 2 Mi nutes of engi ne run ti me i f
the Oxygen Sensor Moni tor or Catal yst Moni tor have
been stopped from runni ng.
I t can take up to 2 Fai l ures i n a row to turn on the
MI L. After the MI L i s ON, i t takes 3 Good Tri ps to
turn the MI L OFF. After the MI L i s OFF, the PCM
wi l l sel f-erase the DTC after 40 Warm-up cycl es. A
Warm-up cycl e i s counted when the ECT (Engi ne
Cool ant Temperature Sensor) has crossed 160°F and
has ri sen by at l east 40°F si nce the engi ne has been
started.
DESCRIPTION - COMPONENT MONITORS
There are several components that wi l l affect vehi -
cl e emi ssi ons i f they mal functi on. I f one of these com-
ponents mal functi ons the Mal functi on I ndi cator
Lamp (MI L) wi l l i l l umi nate.
Some of the component moni tors are checki ng for
proper operati on of the part. El ectri cal l y operated
components now have i nput (rati onal i ty) and output
(functi onal i ty) checks. Previ ousl y, a component l i ke
the Throttl e Posi ti on sensor (TPS) was checked by
the PCM for an open or shorted ci rcui t. I f one of
these condi ti ons occurred, a DTC was set. Now there
i s a check to ensure that the component i s worki ng.
Thi s i s done by watchi ng for a TPS i ndi cati on of a
greater or l esser throttl e openi ng than MAP and
engi ne rpm i ndi cate. I n the case of the TPS, i f engi ne
vacuum i s hi gh and engi ne rpm i s 1600 or greater
and the TPS i ndi cates a l arge throttl e openi ng, a
DTC wi l l be set. The same appl i es to l ow vacuum i f
the TPS i ndi cates a smal l throttl e openi ng.
Al l open/short ci rcui t checks or any component that
has an associ ated l i mp i n wi l l set a faul t after 1 tri p
wi th the mal functi on present. Components wi thout
an associ ated l i mp i n wi l l take two tri ps to i l l umi -
nate the MI L.
Refer to the Di agnosti c Troubl e Codes Descri pti on
Charts i n thi s secti on and the appropri ate Power-
trai n Di agnosti c Procedure Manual for di agnosti c
procedures.
DESCRIPTION - NON-MONITORED CIRCUITS
The PCM does not moni tor the fol l owi ng ci rcui ts,
systems and condi ti ons that coul d have mal functi ons
causi ng dri veabi l i ty probl ems. The PCM mi ght not
store di agnosti c troubl e codes for these condi ti ons.
However, probl ems wi th these systems may cause the
PCM to store di agnosti c troubl e codes for other sys-
tems or components. For exampl e, a fuel pressure
probl em wi l l not regi ster a faul t di rectl y, but coul d
cause a ri ch/l ean condi ti on or mi sfi re. Thi s coul d
cause the PCM to store an oxygen sensor or mi sfi re
di agnosti c troubl e code
FUEL PRESSURE
The fuel pressure regul ator control s fuel system
pressure. The PCM cannot detect a cl ogged fuel
pump i nl et fi l ter, cl ogged i n-l i ne fuel fi l ter, or a
pi nched fuel suppl y or return l i ne. However, these
coul d resul t i n a ri ch or l ean condi ti on causi ng the
PCM to store an oxygen sensor or fuel system di ag-
nosti c troubl e code.
SECONDARY IGNITION CIRCUIT
The PCM cannot detect an i noperati ve i gni ti on coi l ,
foul ed or worn spark pl ugs, i gni ti on cross fi ri ng, or
open spark pl ug cabl es.
CYLINDER COMPRESSION
The PCM cannot detect uneven, l ow, or hi gh engi ne
cyl i nder compressi on.
EXHAUST SYSTEM
The PCM cannot detect a pl ugged, restri cted or
l eaki ng exhaust system, al though i t may set a fuel
system faul t.
FUEL INJECTOR MECHANICAL MALFUNCTIONS
The PCM cannot determi ne i f a fuel i njector i s
cl ogged, the needl e i s sti cki ng or i f the wrong i njector
i s i nstal l ed. However, these coul d resul t i n a ri ch or
l ean condi ti on causi ng the PCM to store a di agnosti c
troubl e code for ei ther mi sfi re, an oxygen sensor, or
the fuel system.
EXCESSIVE OIL CONSUMPTION
Al though the PCM moni tors engi ne exhaust oxygen
content when the system i s i n cl osed l oop, i t cannot
determi ne excessi ve oi l consumpti on.
TJ EMISSIONS CONTROL 25 - 5
EMISSIONS CONTROL (Continued)
THROTTLE BODY AIRFLOW
The PCM cannot detect a cl ogged or restri cted ai r
cl eaner i nl et or fi l ter el ement.
VACUUM ASSIST
The PCM cannot detect l eaks or restri cti ons i n the
vacuum ci rcui ts of vacuum assi sted engi ne control
system devi ces. However, these coul d cause the PCM
to store a MAP sensor di agnosti c troubl e code and
cause a hi gh i dl e condi ti on.
PCM SYSTEM GROUND
The PCM cannot determi ne a poor system ground.
However, one or more di agnosti c troubl e codes may
be generated as a resul t of thi s condi ti on. The mod-
ul e shoul d be mounted to the body at al l ti mes, al so
duri ng di agnosti c.
PCM CONNECTOR ENGAGEMENT
The PCM may not be abl e to determi ne spread or
damaged connector pi ns. However, i t mi ght store
di agnosti c troubl e codes as a resul t of spread connec-
tor pi ns.
DESCRIPTION - HIGH AND LOW LIMITS
The PCM compares i nput si gnal vol tages from each
i nput devi ce wi th establ i shed hi gh and l ow l i mi ts for
the devi ce. I f the i nput vol tage i s not wi thi n l i mi ts
and other cri teri a are met, the PCM stores a di agnos-
ti c troubl e code i n memory. Other di agnosti c troubl e
code cri teri a mi ght i ncl ude engi ne RPM l i mi ts or
i nput vol tages from other sensors or swi tches that
must be present before veri fyi ng a di agnosti c troubl e
code condi ti on.
DESCRIPTION - LOAD VALUE
ENGINE IDLE/NEUTRAL 2500 RPM/NEUTRAL
All Engines 2% to 8% of Maximum Load 9% to 17% of Maximum Load
OPERATION - TASK MANAGER
The Task Manager determi nes whi ch tests happen
when and whi ch functi ons occur when. Many of the
di agnosti c steps requi red by OBD I I must be per-
formed under speci fi c operati ng condi ti ons. The Task
Manager software organi zes and pri ori ti zes the di ag-
nosti c procedures. The job of the Task Manager i s to
determi ne i f condi ti ons are appropri ate for tests to be
run, moni tor the parameters for a tri p for each test,
and record the resul ts of the test. Fol l owi ng are the
responsi bi l i ti es of the Task Manager software:
• Test Sequence
• MI L I l l umi nati on
• Di agnosti c Troubl e Codes (DTCs)
• Tri p I ndi cator
• Freeze Frame Data Storage
• Si mi l ar Condi ti ons Wi ndow
Test Sequence
I n many i nstances, emi ssi ons systems must fai l
di agnosti c tests more than once before the PCM i l l u-
mi nates the MI L. These tests are know as ’two tri p
moni tors.’ Other tests that turn the MI L l amp on
after a si ngl e fai l ure are known as ’one tri p moni -
tors.’ A tri p i s defi ned as ’start the vehi cl e and oper-
ate i t to meet the cri teri a necessary to run the gi ven
moni tor.’
Many of the di agnosti c tests must be performed
under certai n operati ng condi ti ons. However, there
are ti mes when tests cannot be run because another
test i s i n progress (confl i ct), another test has fai l ed
(pendi ng) or the Task Manager has set a faul t that
may cause a fai l ure of the test (suspend).
• Pendi ng
Under some si tuati ons the Task Manager wi l l not
run a moni tor i f the MI L i s i l l umi nated and a faul t i s
stored from another moni tor. I n these si tuati ons, the
Task Manager postpones moni tors pending resol u-
ti on of the ori gi nal faul t. The Task Manager does not
run the test unti l the probl em i s remedi ed.
For exampl e, when the MI L i s i l l umi nated for an
Oxygen Sensor faul t, the Task Manager does not run
the Catal yst Moni tor unti l the Oxygen Sensor faul t i s
remedi ed. Si nce the Catal yst Moni tor i s based on si g-
nal s from the Oxygen Sensor, runni ng the test woul d
produce i naccurate resul ts.
• Confl i ct
There are si tuati ons when the Task Manager does
not run a test i f another moni tor i s i n progress. I n
these si tuati ons, the effects of another moni tor run-
ni ng coul d resul t i n an erroneous fai l ure. I f thi s con-
flict i s present, the moni tor i s not run unti l the
confl i cti ng condi ti on passes. Most l i kel y the moni tor
wi l l run l ater after the confl i cti ng moni tor has
passed.
For exampl e, i f the Fuel System Moni tor i s i n
progress, the Task Manager does not run the EGR
Moni tor. Si nce both tests moni tor changes i n ai r/fuel
rati o and adapti ve fuel compensati on, the moni tors
wi l l confl i ct wi th each other.
• Suspend
Occasi onal l y the Task Manager may not al l ow a two
tri p faul t to mature. The Task Manager wi l l sus-
25 - 6 EMISSIONS CONTROL TJ
EMISSIONS CONTROL (Continued)
pend the maturi ng of a faul t i f a condi ti on exi sts
that may i nduce an erroneous fai l ure. Thi s prevents
i l l umi nati ng the MI L for the wrong faul t and al l ows
more preci s di agnosi s.
For exampl e, i f the PCM i s stori ng a one tri p faul t
for the Oxygen Sensor and the EGR moni tor, the
Task Manager may sti l l run the EGR Moni tor but
wi l l suspend the resul ts unti l the Oxygen Sensor
Moni tor ei ther passes or fai l s. At that poi nt the Task
Manager can determi ne i f the EGR system i s actu-
al l y fai l i ng or i f an Oxygen Sensor i s fai l i ng.
MIL Illumination
The PCM Task Manager carri es out the i l l umi na-
ti on of the MI L. The Task Manager tri ggers MI L i l l u-
mi nati on upon test fai l ure, dependi ng on moni tor
fai l ure cri teri a.
The Task Manager Screen shows both a Requested
MI L state and an Actual MI L state. When the MI L i s
i l l umi nated upon compl eti on of a test for a thi rd tri p,
the Requested MI L state changes to OFF. However,
the MI L remai ns i l l umi nated unti l the next key
cycl e. (On some vehi cl es, the MI L wi l l actual l y turn
OFF duri ng the thi rd key cycl e) Duri ng the key cycl e
for the thi rd good tri p, the Requested MI L state i s
OFF, whi l e the Actual MI L state i s ON. After the
next key cycl e, the MI L i s not i l l umi nated and both
MI L states read OFF.
Diagnostic Trouble Codes (DTCs)
Wi th OBD I I , di fferent DTC faul ts have di fferent
pri ori ti es accordi ng to regul ati ons. As a resul t, the
pri ori ti es determi ne MI L i l l umi nati on and DTC era-
sure. DTCs are entered accordi ng to i ndi vi dual pri or-
i ty. DTCs wi th a hi gher pri ori ty overwri te l ower
pri ori ty DTCs.
Priorities
• Pri ori ty 0 —Non-emi ssi ons rel ated troubl e codes
• Pri ori ty 1 — One tri p fai l ure of a two tri p faul t
for non-fuel system and non-mi sfi re.
• Pri ori ty 2 — One tri p fai l ure of a two tri p faul t
for fuel system (ri ch/l ean) or mi sfi re.
• Pri ori ty 3 — Two tri p fai l ure for a non-fuel sys-
tem and non-mi sfi re or matured one tri p comprehen-
si ve component faul t.
• Pri ori ty 4 — Two tri p fai l ure or matured faul t
for fuel system (ri ch/l ean) and mi sfi re or one tri p cat-
al yst damagi ng mi sfi re.
Non-emi ssi ons rel ated fai l ures have no pri ori ty.
One tri p fai l ures of two tri p faul ts have l ow pri ori ty.
Two tri p fai l ures or matured faul ts have hi gher pri -
ori ty. One and two tri p fai l ures of fuel system and
mi sfi re moni tor take precedence over non-fuel system
and non-mi sfi re fai l ures.
DTC Self Erasure
Wi th one tri p components or systems, the MI L i s
i l l umi nated upon test fai l ure and DTCs are stored.
Two tri p moni tors are components requi ri ng fai l ure
i n two consecuti ve tri ps for MI L i l l umi nati on. Upon
fai l ure of the fi rst test, the Task Manager enters a
maturi ng code. I f the component fai l s the test for a
second ti me the code matures and a DTC i s set.
After three good tri ps the MI L i s exti ngui shed and
the Task Manager automati cal l y swi tches the tri p
counter to a warm-up cycl e counter. DTCs are auto-
mati cal l y erased fol l owi ng 40 warm-up cycl es i f the
component does not fai l agai n.
For mi sfi re and fuel system moni tors, the compo-
nent must pass the test under a Si mi l ar Condi ti ons
Wi ndow i n order to record a good tri p. A Si mi l ar Con-
di ti ons Wi ndow i s when engi ne RPM i s wi thi n ±375
RPM and l oad i s wi thi n ±10% of when the faul t
occurred.
NOTE: It is important to understand that a compo-
nent does not have to fail under a similar window of
operation to mature. It must pass the test under a
Similar Conditions Window when it failed to record
a Good Trip for DTC erasure for misfire and fuel
system monitors.
DTCs can be erased anyti me wi th a DRB I I I . Eras-
i ng the DTC wi th the DRB I I I erases al l OBD I I
i nformati on. The DRB I I I automati cal l y di spl ays a
warni ng that erasi ng the DTC wi l l al so erase al l
OBD I I moni tor data. Thi s i ncl udes al l counter i nfor-
mati on for warm-up cycl es, tri ps and Freeze Frame.
Trip Indicator
The Trip i s essenti al for runni ng moni tors and
exti ngui shi ng the MI L. I n OBD I I terms, a tri p i s a
set of vehi cl e operati ng condi ti ons that must be met
for a speci fi c moni tor to run. Al l tri ps begi n wi th a
key cycl e.
Good Trip
The Good Tri p counters are as fol l ows:
• Speci fi c Good Tri p
• Fuel System Good Tri p
• Mi sfi re Good Tri p
• Al ternate Good Tri p (appears as a Gl obal Good
Tri p on DRB I I I )
• Comprehensi ve Components
• Major Moni tor
• Warm-Up Cycl es
Specific Good Trip
The term Good Tri p has di fferent meani ngs
dependi ng on the ci rcumstances:
• I f the MI L i s OFF, a tri p i s defi ned as when the
Oxygen Sensor Moni tor and the Catal yst Moni tor
have been compl eted i n the same dri ve cycl e.
TJ EMISSIONS CONTROL 25 - 7
EMISSIONS CONTROL (Continued)
• I f the MI L i s ON and a DTC was set by the Fuel
Moni tor or Mi sfi re Moni tor (both conti nuous moni -
tors), the vehi cl e must be operated i n the Si mi l ar
Condi ti on Wi ndow for a speci fi ed amount of ti me.
• I f the MI L i s ON and a DTC was set by a Task
Manager commanded once-per-tri p moni tor (such as
the Oxygen Sensor Moni tor, Catal yst Moni tor, Purge
Fl ow Moni tor, Leak Detecti on Pump Moni tor, EGR
Moni tor or Oxygen Sensor Heater Moni tor), a good
tri p i s when the moni tor i s passed on the next start-
up.
• I f the MI L i s ON and any other emi ssi ons DTC
was set (not an OBD I I moni tor), a good tri p occurs
when the Oxygen Sensor Moni tor and Catal yst Mon-
i tor have been compl eted, or two mi nutes of engi ne
run ti me i f the Oxygen Sensor Moni tor and Catal yst
Moni tor have been stopped from runni ng.
Fuel System Good Trip
To count a good tri p (three requi red) and turn off
the MI L, the fol l owi ng condi ti ons must occur:
• Engi ne i n cl osed l oop
• Operati ng i n Si mi l ar Condi ti ons Wi ndow
• Short Term mul ti pl i ed by Long Term l ess than
threshol d
• Less than threshol d for a predetermi ned ti me
I f al l of the previ ous cri teri a are met, the PCM wi l l
count a good tri p (three requi red) and turn off the
MI L.
Misfire Good Trip
I f the fol l owi ng condi ti ons are met the PCM wi l l
count one good tri p (three requi red) i n order to turn
off the MI L:
• Operati ng i n Si mi l ar Condi ti on Wi ndow
• 1000 engi ne revol uti ons wi th no mi sfi re
Warm-Up Cycles
Once the MI L has been exti ngui shed by the Good
Tri p Counter, the PCM automati cal l y swi tches to a
Warm-Up Cycl e Counter that can be vi ewed on the
DRB I I I . Warm-Up Cycl es are used to erase DTCs
and Freeze Frames. Forty Warm-Up cycl es must
occur i n order for the PCM to sel f-erase a DTC and
Freeze Frame. A Warm-Up Cycl e i s defi ned as fol -
l ows:
• Engi ne cool ant temperature must start bel ow
and ri se above 160° F
• Engi ne cool ant temperature must ri se by 40° F
• No further faul ts occur
Freeze Frame Data Storage
Once a fai l ure occurs, the Task Manager records
several engi ne operati ng condi ti ons and stores i t i n a
Freeze Frame. The Freeze Frame i s consi dered one
frame of i nformati on taken by an on-board data
recorder. When a faul t occurs, the PCM stores the
i nput data from vari ous sensors so that techni ci ans
can determi ne under what vehi cl e operati ng condi -
ti ons the fai l ure occurred.
The data stored i n Freeze Frame i s usual l y
recorded when a system fai l s the fi rst ti me for two
tri p faul ts. Freeze Frame data wi l l onl y be overwri t-
ten by a di fferent faul t wi th a hi gher pri ori ty.
CAUTION: Erasing DTCs, either with the DRB III or
by disconnecting the battery, also clears all Freeze
Frame data.
Similar Conditions Window
The Si mi l ar Condi ti ons Wi ndow di spl ays i nforma-
ti on about engi ne operati on duri ng a moni tor. Abso-
l ute MAP (engi ne l oad) and Engi ne RPM are stored
i n thi s wi ndow when a fai l ure occurs. There are two
di fferent Si mi l ar condi ti ons Wi ndows: Fuel System
and Mi sfi re.
FUEL SYSTEM
• Fuel System Similar Conditions Window —
An i ndi cator that ’Absol ute MAP When Fuel Sys Fai l ’
and ’RPM When Fuel Sys Fai l ed’ are al l i n the same
range when the fai l ure occurred. I ndi cated by swi tch-
i ng from ’NO’ to ’YES’.
• Absolute MAP When Fuel Sys Fail — The
stored MAP readi ng at the ti me of fai l ure. I nforms
the user at what engi ne l oad the fai l ure occurred.
• Absolute MAP — A l i ve readi ng of engi ne l oad
to ai d the user i n accessi ng the Si mi l ar Condi ti ons
Wi ndow.
• RPM When Fuel Sys Fail — The stored RPM
readi ng at the ti me of fai l ure. I nforms the user at
what engi ne RPM the fai l ure occurred.
• Engine RPM — A l i ve readi ng of engi ne RPM
to ai d the user i n accessi ng the Si mi l ar Condi ti ons
Wi ndow.
• Adaptive Memory Factor — The PCM uti l i zes
both Short Term Compensati on and Long Term Adap-
ti ve to cal cul ate the Adapti ve Memory Factor for
total fuel correcti on.
• Upstream O2S Volts — A l i ve readi ng of the
Oxygen Sensor to i ndi cate i ts performance. For
exampl e, stuck l ean, stuck ri ch, etc.
• SCW Time in Window (Similar Conditions
Window Time in Window) — A ti mer used by the
PCM that i ndi cates that, after al l Si mi l ar Condi ti ons
have been met, i f there has been enough good engi ne
runni ng ti me i n the SCW wi thout fai l ure detected.
Thi s ti mer i s used to i ncrement a Good Tri p.
• Fuel System Good Trip Counter — A Tri p
Counter used to turn OFF the MI L for Fuel System
DTCs. To i ncrement a Fuel System Good Tri p, the
engi ne must be i n the Si mi l ar Condi ti ons Wi ndow,
Adapti ve Memory Factor must be l ess than cal i -
brated threshol d and the Adapti ve Memory Factor
25 - 8 EMISSIONS CONTROL TJ
EMISSIONS CONTROL (Continued)
must stay bel ow that threshol d for a cal i brated
amount of ti me.
• Test Done This Trip — I ndi cates that the
moni tor has al ready been run and compl eted duri ng
the current tri p.
MISFIRE
• Same Misfire Warm-Up State — I ndi cates i f
the mi sfi re occurred when the engi ne was warmed up
(above 160° F).
• In Similar Misfire Window — An i ndi cator
that ’Absol ute MAP When Mi sfi re Occurred’ and
’RPM When Mi sfi re Occurred’ are al l i n the same
range when the fai l ure occurred. I ndi cated by swi tch-
i ng from ’NO’ to ’YES’.
• Absolute MAP When Misfire Occurred —
The stored MAP readi ng at the ti me of fai l ure.
I nforms the user at what engi ne l oad the fai l ure
occurred.
• Absolute MAP — A l i ve readi ng of engi ne l oad
to ai d the user i n accessi ng the Si mi l ar Condi ti ons
Wi ndow.
• RPM When Misfire Occurred — The stored
RPM readi ng at the ti me of fai l ure. I nforms the user
at what engi ne RPM the fai l ure occurred.
• Engine RPM — A l i ve readi ng of engi ne RPM
to ai d the user i n accessi ng the Si mi l ar Condi ti ons
Wi ndow.
• Adaptive Memory Factor — The PCM uti l i zes
both Short Term Compensati on and Long Term Adap-
ti ve to cal cul ate the Adapti ve Memory Factor for
total fuel correcti on.
• 200 Rev Counter — Counts 0–100 720 degree
cycl es.
• SCWCat 200 Rev Counter — Counts when i n
si mi l ar condi ti ons.
• SCW FTP 1000 Rev Counter — Counts 0–4
when i n si mi l ar condi ti ons.
• Misfire Good Trip Counter — Counts up to
three to turn OFF the MI L.
• Misfire Data— Data col l ected duri ng test.
• Test Done This Trip— I ndi cates YES when the
test i s done.
TJ EMISSIONS CONTROL 25 - 9
EMISSIONS CONTROL (Continued)
EVAPORATIVE EMISSIONS
TABLE OF CONTENTS
page page
EVAPORATIVE EMISSIONS
DESCRIPTION - EVAPORATION CONTROL
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SPECIFICATIONS
TORQUE - EMISSIONS . . . . . . . . . . . . . . . . . 11
CCV SYSTEM
DESCRIPTION - CCV SYSTEM . . . . . . . . . . . . . 11
OPERATION - CCV SYSTEM . . . . . . . . . . . . . . 11
DIAGNOSIS AND TESTING - CCV SYSTEM . . . 11
PCV VALVE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 12
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
EVAP/PURGE SOLENOID
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 13
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14
FUEL FILLER CAP
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 14
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
LEAK DETECTION PUMP
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 14
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 19
ORVR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 19
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
VACUUM LINES
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 20
VAPOR CANISTER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 20
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 20
EVAPORATIVE EMISSIONS
DESCRIPTION - EVAPORATION CONTROL
SYSTEM
The evaporati on control system prevents the emi s-
si on of fuel tank vapors i nto the atmosphere. When
fuel evaporates i n the fuel tank, the vapors pass
through vent hoses or tubes to a charcoal fi l l ed evap-
orati ve cani ster. The cani ster temporari l y hol ds the
vapors. The Powertrai n Control Modul e (PCM) al l ows
i ntake mani fol d vacuum to draw vapors i nto the com-
busti on chambers duri ng certai n operati ng condi -
ti ons.
Al l engi nes use a duty-cycl e purge system. The
PCM control s vapor fl ow by operati ng the duty-cycl e
EVAP purge sol enoi d. Refer to Duty-Cycl e EVAP
Cani ster Purge Sol enoi d.
An ORVR system i s used. Thi s system i s part of
the EVAP Control System. Refer to On-Board Refuel -
i ng Vapor Recovery (ORVR) for i nformati on.
When equi pped wi th certai n emi ssi ons packages, a
Leak Detecti on Pump (LDP) wi l l be used as part of
the evaporati ve system for OBD I I requi rements.
Al so refer to Leak Detecti on Pump.
NOTE: The evaporative system uses specially man-
ufactured lines/hoses. If replacement becomes nec-
essary, only use fuel resistant hose.
25 - 10 EVAPORATIVE EMISSIONS TJ
SPECIFICATIONS
TORQUE - EMISSIONS
DESCRIPTION N-m Ft. Lbs. In. Lbs.
EVAP Canister Mounting Nuts 9 - 80
Leak Detection Pump Filter Mounting Bolt 7 - 65
LDP Pump Mounting Bolts 1 - 11
EVAP Canister/LDP Mounting Bracket-to-Body Nuts - - 250
EVAP Canister/LDP Mounting Bracket-to-Body Bolts - - 212
CCV SYSTEM
DESCRIPTION - CCV SYSTEM
The 4.0L 6-cyl i nder engi ne i s equi pped wi th a
Cl osed Crankcase Venti l ati on (CCV) system and a
fi xed ori fi ce val ve (Fi g. 1). The 2.4L 4-cyl i nder uses a
PCV val ve. Refer to PCV Val ve for 2.4L i nformati on.
OPERATION - CCV SYSTEM
The CCV system performs the same functi on as a
conventi onal PCV system, but does not use a vacuum
control l ed val ve.
On 4.0L 6-cyl i nder engi nes, a mol ded vacuum tube
connects mani fol d vacuum to the top of the cyl i nder
head (val ve) cover. The vacuum fi tti ng contai ns a
fi xed ori fi ce of a cal i brated si ze. I t meters the
amount of crankcase vapors drawn out of the engi ne.
When the engi ne i s operati ng, fresh ai r enters the
engi ne and mi xes wi th crankcase vapors. Mani fol d
vacuum draws the vapor/ai r mi xture through the
fi xed ori fi ce and i nto the i ntake mani fol d. The vapors
are then consumed duri ng combusti on.
DIAGNOSIS AND TESTING - CCV SYSTEM
TESTING/CLEANING
The Crankcase Venti l ati on (CCV) system performs
the same functi on as a conventi onal PCV system, but
does not use a vacuum control l ed val ve. A vacuum
fi tti ng contai ni ng a fi xed ori fi ce of a cal i brated si ze i s
used. I t meters the amount of crankcase vapors
drawn out of the engi ne.
(1) Check each CCV system tube (l i ne) for l eaks,
cracks, ki nks or bends. Repl ace as necessary
(2) Di sconnect each CCV tube.
(3) Remove fi xed ori fi ce fi tti ng from val ve cover.
(4) Bl ow compressed ai r through each tube, and
the fi xed ori fi ce fi tti ng. Check for bl ockage or restri c-
ti ons. I f cl eani ng i s necessary, spray a soapy-type al l -
purpose cl eaner i nto each component and bl ow out.
After restri cti on i s cl eared, ri nse out component wi th
cl ear water. Bl ow water from component and i nstal l
to vehi cl e. To prevent damage to plastic compo-
nents, never spray carburetor-type cleaner into
any of the plastic tubes or the fixed orifice fit-
ting. Never attempt to clean the fixed orifice
fitting with a metal object as calibration could
be affected. If fixed fitting cannot be cleared,
replace it.
Fig. 1 CRANKCASE VENTILATION (CCV) FITTING -
4.0L
1 - AIR CLEANER ASSEMBLY
2 - AIR INTAKE TUBE
3 - FIXED ORIFICE FITTING
4 - VACUUM LINE
5 - AIR INLET FITTING
TJ EVAPORATIVE EMISSIONS 25 - 11
EVAPORATIVE EMISSIONS (Continued)
PCV VALVE
DESCRIPTION
2. 4L
The 2.4L 4-cyl i nder engi ne i s equi pped wi th a
cl osed crankcase venti l ati on system and a Posi ti ve
Crankcase Venti l ati on (PCV) val ve.
Thi s system consi sts of:
• a PCV val ve attached to the l eft/front si de of the
val ve cover (Fi g. 2). I t i s secured wi th 1 bol t. An
o-ri ng i s used to seal val ve to val ve cover (Fi g. 3).
Another type of threaded PCV val ve may be used
(Fi g. 4).
• the ai r cl eaner housi ng
• tubes and hoses to connect the system compo-
nents.
Fig. 2 PCV VALVE LOCATION - 2.4L
1 - PCV VALVE
2 - HOSE
3 - MOUNTING BOLT
4 - VALVE COVER (LEFT SIDE)
Fig. 3 PCV VALVE AND O-RING - 2.4L
1 - PCV VALVE
2 - O-RING
3 - MOUNTING BOLT
Fig. 4 PCV VALVE - 2.4L - THREADED
1 - PCV VALVE (THREADED)
2 - VALVE COVER (LEFT SIDE)
25 - 12 EVAPORATIVE EMISSIONS TJ
OPERATION
2. 4L
The PCV system operates by engi ne i ntake mani -
fol d vacuum. Fi l tered ai r i s routed i nto the crankcase
through the ai r cl eaner hose and crankcase breath-
er(s) (i f used). The metered ai r, al ong wi th crankcase
vapors, are drawn through the PCV val ve and i nto a
passage i n the i ntake mani fol d. The PCV system
manages crankcase pressure and meters bl ow-by
gases to the i ntake system, reduci ng engi ne sl udge
formati on.
The PCV val ve contai ns a spri ng l oaded pl unger.
Thi s pl unger meters the amount of crankcase vapors
routed i nto the combusti on chamber based on i ntake
mani fol d vacuum.
TYPICAL PCV val ves are shown i n (Fi g. 5), (Fi g.
6) and (Fi g. 7).
When the engi ne i s not operati ng, or duri ng an
engi ne pop-back, the spri ng forces the pl unger back
agai nst the seat (Fi g. 5). Thi s wi l l prevent vapors
from fl owi ng through the val ve.
Duri ng peri ods of hi gh mani fol d vacuum, such as
i dl e or crui si ng speeds, vacuum i s suffi ci ent to com-
pl etel y compress spri ng. I t wi l l then pul l the pl unger
to the top of the val ve (Fi g. 6). I n thi s posi ti on there
i s mi ni mal vapor fl ow through the val ve.
Duri ng peri ods of moderate mani fol d vacuum, the
pl unger i s onl y pul l ed part way back from i nl et. Thi s
resul ts i n maxi mum vapor fl ow through the val ve
(Fi g. 7).
REMOVAL
2. 4L
The PCV val ve i s attached to the l eft/front si de of
the val ve cover (Fi g. 2). I t i s secured wi th 1 bol t. An
o-ri ng i s used to seal val ve to val ve cover (Fi g. 3).
Another type of threaded PCV val ve may be used
(Fi g. 4).
(1) Remove hose from val ve. Check condi ti on of
hose.
(2) Bol ted PCV Val ve:
(a) Remove 1 bol t.
(b) Remove PCV val ve from val ve cover.
(c) Check condi ti on of val ve o-ri ng.
(3) Threaded PCV Val ve:
(a) Unscrew val ve from val ve cover.
EVAP/PURGE SOLENOID
DESCRIPTION
The duty cycl e EVAP cani ster purge sol enoi d (DCP)
regul ates the rate of vapor fl ow from the EVAP can-
i ster to the i ntake mani fol d. The Powertrai n Control
Modul e (PCM) operates the sol enoi d.
OPERATION
Duri ng the col d start warm-up peri od and the hot
start ti me del ay, the PCM does not energi ze the sol e-
noi d. When de-energi zed, no vapors are purged. The
PCM de-energi zes the sol enoi d duri ng open l oop oper-
ati on.
The engi ne enters cl osed l oop operati on after i t
reaches a speci fi ed temperature and the ti me del ay
ends. Duri ng cl osed l oop operati on, the PCM cycl es
(energi zes and de-energi zes) the sol enoi d 5 or 10
ti mes per second, dependi ng upon operati ng condi -
ti ons. The PCM vari es the vapor fl ow rate by chang-
i ng sol enoi d pul se wi dth. Pul se wi dth i s the amount
of ti me that the sol enoi d i s energi zed. The PCM
adjusts sol enoi d pul se wi dth based on engi ne operat-
i ng condi ti on.
Fig. 5 ENGINE OFF OR ENGINE BACKFIRE - NO
VAPOR FLOW
Fig. 6 HIGH INTAKE MANIFOLD VACUUM - MINIMAL
VAPOR FLOW
Fig. 7 MODERATE INTAKE MANIFOLD VACUUM -
MAXIMUM VAPOR FLOW
TJ EVAPORATIVE EMISSIONS 25 - 13
PCV VALVE (Continued)
REMOVAL
The duty cycl e EVAP cani ster purge sol enoi d i s
l ocated i n the engi ne compartment near the front of
the brake master cyl i nder (Fi g. 8). I t i s attached to a
sl i p-on type bracket.
The EVAP System Test Port i s l ocated near the
EVAP/Purge Sol enoi d (Fi g. 8).
(1) Di sconnect el ectri cal wi ri ng connector at sol e-
noi d.
(2) Di sconnect vacuum l i nes/hoses at sol enoi d.
(3) Li ft sol enoi d and rubber sol enoi d support from
mounti ng bracket.
INSTALLATION
(1) I nstal l purge sol enoi d and rubber support to i ts
mounti ng bracket.
(2) Connect vacuum harness and wi ri ng connector.
FUEL FILLER CAP
DESCRIPTION
The pl asti c fuel tank fi l l er tube cap i s threaded
onto the end of the fuel fi l l tube. Certai n model s are
equi pped wi th a 1/4 turn cap.
OPERATION
The l oss of any fuel or vapor out of fuel fi l l er tube
i s prevented by the use of a pressure-vacuum fuel fi l l
cap. Rel i ef val ves i nsi de the cap wi l l rel ease fuel tank
pressure at predetermi ned pressures. Fuel tank vac-
uum wi l l al so be rel eased at predetermi ned val ues.
Thi s cap must be repl aced by a si mi l ar uni t i f
repl acement i s necessary. Thi s i s i n order for the sys-
tem to remai n effecti ve.
CAUTION: Remove fill cap before servicing any fuel
system component to relieve tank pressure. If
equipped with a California emissions package and a
Leak Detection Pump (LDP), the cap must be tight-
ened securely. If cap is left loose, a Diagnostic
Trouble Code (DTC) may be set.
REMOVAL
I f repl acement of the 1/4 turn fuel tank fi l l er tube
cap i s necessary, i t must be repl aced wi th an i denti -
cal cap to be sure of correct system operati on.
CAUTION: Remove the fuel tank filler tube cap to
relieve fuel tank pressure. The cap must be
removed prior to disconnecting any fuel system
component or before draining the fuel tank.
LEAK DETECTION PUMP
DESCRIPTION
The Leak Detecti on Pump (LDP) i s attached to a
bracket l ocated to the rear of the ri ght / rear ti re
under the pl asti c wheel house l i ner.
Vehi cl es equi pped wi th JTEC engi ne control mod-
ul es use a l eak detecti on pump. Vehi cl es equi pped
wi th NGC engi ne control modul es use an NVLD
pump. Refer to Natural Vacuum - Leak Detecti on
(NVLD) for addi ti onal i nformati on.
The evaporati ve emi ssi on system i s desi gned to
prevent the escape of fuel vapors from the fuel sys-
tem (Fi g. 9). Leaks i n the system, even smal l ones,
can al l ow fuel vapors to escape i nto the atmosphere.
Government regul ati ons requi re onboard testi ng to
make sure that the evaporati ve (EVAP) system i s
functi oni ng properl y. The l eak detecti on system tests
for EVAP system l eaks and bl ockage. I t al so performs
sel f-di agnosti cs. Duri ng sel f-di agnosti cs, the Power-
trai n Control Modul e (PCM) fi rst checks the Leak
Detecti on Pump (LDP) for el ectri cal and mechani cal
faul ts. I f the fi rst checks pass, the PCM then uses
the LDP to seal the vent val ve and pump ai r i nto the
system to pressuri ze i t. I f a l eak i s present, the PCM
wi l l conti nue pumpi ng the LDP to repl ace the ai r
that l eaks out. The PCM determi nes the si ze of the
l eak based on how fast/l ong i t must pump the LDP
as i t tri es to mai ntai n pressure i n the system.
Fig. 8 EVAP/PURGE SOLENOID
1 - EVAP SYSTEM TEST PORT
2 - EVAP/PURGE SOLENOID
3 - FRONT OF BRAKE MASTER CYLINDER
4 - SOLENOID MOUNTING BRACKET
25 - 14 EVAPORATIVE EMISSIONS TJ
EVAP/PURGE SOLENOID (Continued)
EVAP LEAK DETECTION SYSTEM COMPONENTS
Servi ce Port: Used wi th speci al tool s l i ke the Mi l l er
Evaporati ve Emi ssi ons Leak Detector (EELD) to test
for l eaks i n the system.
EVAP Purge Sol enoi d: The PCM uses the EVAP
purge sol enoi d to control purgi ng of excess fuel
vapors stored i n the EVAP cani ster. I t remai ns cl osed
duri ng l eak testi ng to prevent l oss of pressure.
EVAP Cani ster: The EVAP cani ster stores fuel
vapors from the fuel tank for purgi ng.
EVAP Purge Ori fi ce: Li mi ts purge vol ume.
EVAP System Ai r Fi l ter: Provi des ai r to the LDP
for pressuri zi ng the system. I t fi l ters out di rt whi l e
al l owi ng a vent to atmosphere for the EVAP system.
OPERATION
The mai n purpose of the LDP i s to pressuri ze the fuel
system for l eak checki ng. I t cl oses the EVAP system
vent to atmospheri c pressure so the system can be pres-
suri zed for l eak testi ng. The di aphragm i s powered by
engi ne vacuum. I t pumps ai r i nto the EVAP system to
devel op a pressure of about 7.5Љ H2O (1/4) psi . A reed
swi tch i n the LDP al l ows the PCM to moni tor the posi -
ti on of the LDP di aphragm. The PCM uses the reed
swi tch i nput to moni tor how fast the LDP i s pumpi ng
ai r i nto the EVAP system. Thi s al l ows detecti on of l eaks
and bl ockage. The LDP assembl y consi sts of several
parts (Fi g. 10). The sol enoi d i s control l ed by the PCM,
and i t connects the upper pump cavi ty to ei ther engi ne
vacuum or atmospheri c pressure. A vent val ve cl oses the
EVAP system to atmosphere, seal i ng the system duri ng
l eak testi ng. The pump secti on of the LDP consi sts of a
di aphragm that moves up and down to bri ng ai r i n
through the ai r fi l ter and i nl et check val ve, and pump i t
out through an outl et check val ve i nto the EVAP sys-
tem. The di aphragm i s pul l ed up by engi ne vacuum,
and pushed down by spri ng pressure, as the LDP sol e-
noi d turns on and off. The LDP al so has a magneti c
reed swi tch to si gnal di aphragm posi ti on to the PCM.
When the di aphragm i s down, the swi tch i s cl osed,
whi ch sends a 12 V (system vol tage) si gnal to the PCM.
When the di aphragm i s up, the swi tch i s open, and
there i s no vol tage sent to the PCM. Thi s al l ows the
PCM to moni tor LDP pumpi ng acti on as i t turns the
LDP sol enoi d on and off.
Fig. 9 SYSTEM COMPONENTS
1 - Throttle Body
2 - Service Vacuum Supply Tee (SVST)
3 - LDP Solenoid
4 - EVAP System Air Filter
5 - LDP Vent Valve
6 - EVAP Purge Orifice
7 - EVAP Purge Solenoid
8 - Service Port
9 - To Fuel Tank
10 - EVAP Canister
11 - LDP
12 - Intake Air Plenum
Fig. 10 EVAP LEAK DETECTION SYSTEM
COMPONENTS
1 - Reed Switch
2 - Solenoid
3 - Spring
4 - Pump Cavity
5 - Diaphragm
6 - Inlet Check Valve
7 - Vent Valve
8 - From Air Filter
9 - To Canister
10 - Outlet Check Valve
11 - Engine Vacuum
TJ EVAPORATIVE EMISSIONS 25 - 15
LEAK DETECTION PUMP (Continued)
LDP AT REST (NOT POWERED)
When the LDP i s at rest (no el ectri cal /vacuum) the
di aphragm i s al l owed to drop down i f the i nternal
(EVAP system) pressure i s not greater than the
return spri ng. The LDP sol enoi d bl ocks the engi ne
vacuum port and opens the atmospheri c pressure
port connected through the EVAP system ai r fi l ter.
The vent val ve i s hel d open by the di aphragm. Thi s
al l ows the cani ster to see atmospheri c pressure (Fi g.
11).
DIAPHRAGM UPWARD MOVEMENT
When the PCM energi zes the LDP sol enoi d, the
sol enoi d bl ocks the atmospheri c port l eadi ng through
the EVAP ai r fi l ter and at the same ti me opens the
engi ne vacuum port to the pump cavi ty above the
di aphragm. The di aphragm moves upward when vac-
uum above the di aphragm exceeds spri ng force. Thi s
upward movement cl oses the vent val ve. I t al so
causes l ow pressure bel ow the di aphragm, unseati ng
the i nl et check val ve and al l owi ng ai r i n from the
EVAP ai r fi l ter. When the di aphragm compl etes i ts
upward movement, the LDP reed swi tch turns from
cl osed to open (Fi g. 12).
Fig. 11 LDP AT REST
1 - Diaphragm
2 - Inlet Check Valve (Closed)
3 - Vent Valve (Open)
4 - From Air Filter
5 - To Canister
6 - Outlet Check Valve (Closed)
7 - Engine Vacuum (Closed)
Fig. 12 DIAPHRAGM UPWARD MOVEMENT
1 - Diaphragm
2 - Inlet Check Valve (Open)
3 - Vent Valve (Closed)
4 - From Air Filter
5 - To Canister
6 - Outlet Check Valve (Closed)
7 - Engine Vacuum (Open)
25 - 16 EVAPORATIVE EMISSIONS TJ
LEAK DETECTION PUMP (Continued)
DIAPHRAGM DOWNWARD MOVEMENT
Based on reed swi tch i nput, the PCM de-energi zes the
LDP sol enoi d, causi ng i t to bl ock the vacuum port, and
open the atmospheri c port. Thi s connects the upper
pump cavi ty to atmosphere through the EVAP ai r fi l ter.
The spri ng i s now abl e to push the di aphragm down.
The downward movement of the di aphragm cl oses the
i nl et check val ve and opens the outl et check val ve
pumpi ng ai r i nto the evaporati ve system. The LDP reed
swi tch turns from open to cl osed, al l owi ng the PCM to
moni tor LDP pumpi ng (di aphragm up/down) acti vi ty
(Fi g. 13). Duri ng the pumpi ng mode, the di aphragm wi l l
not move down far enough to open the vent val ve. The
pumpi ng cycl e i s repeated as the sol enoi d i s turned on
and off. When the evaporati ve system begi ns to pressur-
i ze, the pressure on the bottom of the di aphragm wi l l
begi n to oppose the spri ng pressure, sl owi ng the pump-
i ng acti on. The PCM watches the ti me from when the
sol enoi d i s de-energi zed, unti l the di aphragm drops
down far enough for the reed swi tch to change from
opened to cl osed. I f the reed swi tch changes too qui ckl y,
a l eak may be i ndi cated. The l onger i t takes the reed
swi tch to change state, the ti ghter the evaporati ve sys-
tem i s seal ed. I f the system pressuri zes too qui ckl y, a
restri cti on somewhere i n the EVAP system may be i ndi -
cated.
PUMPING ACTION
Acti on : Duri ng porti ons of thi s test, the PCM uses
the reed swi tch to moni tor di aphragm movement.
The sol enoi d i s onl y turned on by the PCM after the
reed swi tch changes from open to cl osed, i ndi cati ng
that the di aphragm has moved down. At other ti mes
duri ng the test, the PCM wi l l rapi dl y cycl e the LDP
sol enoi d on and off to qui ckl y pressuri ze the system.
Duri ng rapi d cycl i ng, the di aphragm wi l l not move
enough to change the reed swi tch state. I n the state
of rapi d cycl i ng, the PCM wi l l use a fi xed ti me i nter-
val to cycl e the sol enoi d. I f the system does not pass
the EVAP Leak Detecti on Test, the fol l owi ng DTCs
may be set:
• P0442 - EVAP LEAK MONI TOR 0.040Љ LEAK
DETECTED
• P0455 - EVAP LEAK MONI TOR LARGE LEAK
DETECTED
• P0456 - EVAP LEAK MONI TOR 0.020Љ LEAK
DETECTED
• P1486 - EVAP LEAK MON PI NCHED HOSE
FOUND
• P1494 - LEAK DETECTI ON PUMP SW OR
MECH FAULT
• P1495 - LEAK DETECTI ON PUMP SOLENOI D
CI RCUI T
REMOVAL
The Leak Detecti on Pump (LDP), LDP Fi l ter, and
EVAP cani ster are attached to a common support
bracket. Thi s support assembl y i s l ocated to the rear
of the ri ght / rear ti re under the pl asti c wheel house
l i ner (Fi g. 14). The LDP fi l ter i s al so l ocated near the
EVAP cani ster (Fi g. 15). The LDP and LDP fi l ter are
repl aced (servi ced) as one uni t.
Fig. 14 EVAP CANISTER / LDP LOCATION
1 - RIGHT / REAR FENDER (WHEELHOUSE)
2 - VERTICAL SUPPORT BRACKET
3 - EVAP CANISTER
Fig. 13 DIAPHRAGM DOWNWARD MOVEMENT
1 - Diaphragm
2 - Inlet Check Valve (Closed)
3 - Vent Valve (Closed)
4 - From Air Filter
5 - To Canister
6 - Outlet Check Valve (Open)
7 - Engine Vacuum (Closed)
TJ EVAPORATIVE EMISSIONS 25 - 17
LEAK DETECTION PUMP (Continued)
(1) Remove ri ght/rear ti re/wheel .
(2) Remove wheel house l i ner at ri ght/rear wheel .
(3) Remove verti cal support bracket (Fi g. 14) to
gai n access to 2 ORVR vapor l i nes.
(4) Two vapor l i nes connect the fuel tank to the
EVAP cani ster and Leak Detecti on Pump (LDP). Thi s
connecti on i s made near the ri ght/rear corner of the
fuel tank. Careful l y di sconnect these 2 vapor l i nes
(Fi g. 15) near top of fl ow management val ve. Be very
careful not to bend or ki nk the vapor l i nes. I f l i nes
l eak, a Di agnosti c Troubl e Code (DTC) wi l l be set.
(5) Remove common support bracket assembl y
(Fi g. 16) contai ni ng LDP pump, LDP fi l ter and EVAP
cani ster from vehi cl e. Whi l e l oweri ng thi s assembl y,
di sconnect LDP el ectri cal connector (Fi g. 16) at LDP
pump. Do not allow the assembly to hang from
the wire harness.
(6) Careful l y separate hose at bottom of LDP fi l ter.
(7) Careful l y remove vapor/vacuum l i nes at LDP.
(8) I f necessary, remove LDP fi l ter mounti ng bol t
and remove fi l ter.
(9) Remove EVAP cani ster from common support
bracket by removi ng 4 nuts (Fi g. 16).
(10) Remove 3 LDP mounti ng bol ts (Fi g. 17) and
remove LDP from support bracket.
Fig. 15 DISCONNECTING ORVR VAPOR LINES
1 - EVAP CANISTER
2 - LDP FILTER
3 - LDP
4 - FLOW MANAGEMENT VALVE
5 - FUEL TANK
6 - VAPOR LINES (2)
Fig. 16 COMMON SUPPORT BRACKET ASSEMBLY
1 - LDP FILTER
2 - COMMON SUPPORT BRACKET
3 - EVAP CANISTER NUTS (4)
4 - EVAP CANISTER
5 - LDP
6 - LDP ELEC. CONNECT.
Fig. 17 LDP MOUNTING BOLTS
1 - COMMON SUPPORT BRACKET
2 - LDP MOUNTING BOLTS (3)
25 - 18 EVAPORATIVE EMISSIONS TJ
LEAK DETECTION PUMP (Continued)
INSTALLATION
The Leak Detecti on Pump (LDP), LDP Fi l ter, and
EVAP cani ster are attached to a common support
bracket. Thi s support assembl y i s l ocated to the rear
of the ri ght / rear ti re under the pl asti c wheel house
l i ner (Fi g. 14). The LDP fi l ter i s al so l ocated near the
EVAP cani ster (Fi g. 15). The LDP and LDP fi l ter are
repl aced (servi ced) as one uni t.
(1) I nstal l LDP and 3 mounti ng bol ts to common
support bracket. Ti ghten bol ts to 1 N·m (11 i n. l bs.)
torque.
(2) I f necessary, i nstal l LDP fi l ter to common sup-
port bracket. Ti ghten bol t to 7 N·m (65 i n. l bs.)
torque.
(3) I nstal l EVAP cani ster to common support
bracket and i nstal l 4 mounti ng nuts (Fi g. 16).
(4) Careful l y i nstal l vapor/vacuum l i nes to LDP,
LDP fi l ter and EVAP cani ster. The vapor/vacuum
lines and hoses must be firmly connected.
Check the vapor/vacuum lines at the LDP, LDP
filter and EVAP canister purge solenoid for
damage or leaks. If a leak is present, a Diagnos-
tic Trouble Code (DTC) will be set.
(5) Rai se assembl y i nto posi ti on whi l e connecti ng
el ectri cal connector to LDP. Do not al l ow thi s assem-
bl y to hang from the wi re harness. Whi l e assembl y i s
sti l l bei ng supported, connect 2 vapor l i nes to fuel
tank. Thi s connecti on i s made near the ri ght/rear cor-
ner of the fuel tank. Careful l y connect these 2 vapor
l i nes (Fi g. 15) near top of fl ow management val ve.
Be very careful not to bend or kink the vapor
lines. If lines leak, a Diagnostic Trouble Code
(DTC) will be set.
(6) Posi ti on common support bracket assembl y to
body. I nstal l and ti ghten bol ts.
(7) I nstal l verti cal support bracket (Fi g. 14).
(8) I nstal l wheel house l i ner at ri ght/rear wheel .
(9) I nstal l ri ght/rear ti re/wheel .
ORVR
DESCRIPTION
The ORVR (On-Board Refuel i ng Vapor Recovery)
system consi sts of a uni que fuel tank, fl ow manage-
ment val ve, fl ui d control val ve, one-way check val ve
and EVAP (vapor) cani ster (Fi g. 18), or (Fi g. 19).
Fig. 18 FUEL TANK/FUEL PUMP MODULE (TOP VIEW)
1 - VAPOR LINES (2) 8 - CHECK VALVE
2 - FUEL SUPPLY LINE 9 - FUEL MANAGEMENT VALVE
3 - ELECTRICAL CONNECTOR 10 - SKID PLATE
4 - MODULE LOCKNUT 11 - CHECK VALVE
5 - FUEL PUMP MODULE ASSEMBLY 12 - CLAMPS (2)
6 - FUEL FILTER/FUEL PRESSURE REGULATOR 13 - VENT LINE
7 - FUEL TANK STRAPS (2) 14 - FUEL FILL TUBE
TJ EVAPORATIVE EMISSIONS 25 - 19
LEAK DETECTION PUMP (Continued)
OPERATION
The ORVR (On-Board Refuel i ng Vapor Recovery)
system i s used to remove excess fuel tank vapors.
Thi s i s done whi l e the vehi cl e i s bei ng refuel ed.
Fuel fl owi ng i nto the fuel fi l l er tube (approx. 1” I .D.)
creates an aspi rati on effect drawi ng ai r i nto the fuel fi l l
tube. Duri ng refuel i ng, the fuel tank i s vented to the
EVAP cani ster to capture escapi ng vapors. Wi th ai r
fl owi ng i nto the fi l l er tube, there are no fuel vapors
escapi ng to the atmosphere. Once the refuel i ng vapors
are captured by the EVAP cani ster, the vehi cl e’s com-
puter control l ed purge system draws vapor out of the
cani ster for the engi ne to burn. The vapor fl ow i s
metered by the purge sol enoi d so that there i s no, or
mi ni mal i mpact on dri veabi l i ty or tai l pi pe emi ssi ons.
As fuel starts to fl ow through the fuel fi l l tube, i t
opens the normal l y cl osed check val ve and enters the
fuel tank. Vapor or ai r i s expel l ed from the tank
through the control val ve and on to the vapor cani ster.
Vapor i s absorbed i n the EVAP cani ster unti l vapor fl ow
i n the l i nes stops. Thi s stoppage occurs fol l owi ng fuel
shut-off, or by havi ng the fuel l evel i n the tank ri se hi gh
enough to cl ose the control val ve. Thi s control val ve con-
tai ns a fl oat that ri ses to seal the l arge di ameter vent
path to the EVAP cani ster. At thi s poi nt i n the refuel i ng
process, fuel tank pressure i ncreases, the check val ve
cl oses (preventi ng l i qui d fuel from spi ti ng back at the
operator), and fuel then ri ses up the fuel fi l l er tube to
shut off the di spensi ng nozzl e.
VACUUM LINES
DESCRIPTION
A vacuum schemati c for emi ssi on rel ated i tems can
be found on the VECI l abel . Refer to Vehi cl e Emi s-
si on Control I nformati on (VECI ) Label for l abel l oca-
ti on.
VAPOR CANISTER
DESCRIPTION
The EVAP (vapor) cani ster, Leak Detecti on Pump
(LDP) and LDP Fi l ter are attached to a common sup-
port bracket. Thi s support assembl y i s l ocated to the
rear of the ri ght / rear ti re under the pl asti c wheel -
house l i ner (Fi g. 14).
OPERATION
A mai ntenance free, EVAP cani ster i s used on al l
vehi cl es. The EVAP cani ster i s fi l l ed wi th granul es of
an acti vated carbon mi xture. Fuel vapors enteri ng
the EVAP cani ster are absorbed by the charcoal gran-
ul es.
Fuel tank pressure vents i nto the EVAP cani ster.
Fuel vapors are temporari l y hel d i n the cani ster unti l
they can be drawn i nto the i ntake mani fol d. The duty
cycl e EVAP cani ster purge sol enoi d al l ows the EVAP
cani ster to be purged at predetermi ned ti mes and at
certai n engi ne operati ng condi ti ons.
The EVAP cani ster i s al so to be consi dered as part
of the ORVR system.
REMOVAL
The Leak Detecti on Pump (LDP), LDP Fi l ter, and
EVAP cani ster are attached to a common support
bracket. Thi s support assembl y i s l ocated to the rear
of the ri ght / rear ti re under the pl asti c wheel house
l i ner (Fi g. 14).
For EVAP cani ster removal procedures, refer to
Leak Detecti on Pump Removal /I nstal l ati on.
INSTALLATION
The Leak Detecti on Pump (LDP), LDP Fi l ter, and
EVAP cani ster are attached to a common support
bracket. Thi s support assembl y i s l ocated to the rear
of the ri ght / rear ti re under the pl asti c wheel house
l i ner (Fi g. 14).
For EVAP cani ster i nstal l ati on procedures, refer to
Leak Detecti on Pump Removal /I nstal l ati on.
Fig. 19 ORVR VAPOR LINES
1 - EVAP CANISTER
2 - LDP FILTER
3 - LDP
4 - FLOW MANAGEMENT VALVE
5 - FUEL TANK
6 - VAPOR LINES (2)
25 - 20 EVAPORATIVE EMISSIONS TJ
ORVR (Continued)
INDEX
A-PILLAR TRIM . . . . . . . . . . . . . . . . . . . . . . 23-58
A/C COMPRESSOR CLUTCH RELAY . . . . . . 24-14
A/C COMPRESSOR CLUTCH/COIL . . . . . . . . 24-10
A/C COMPRESSOR . . . . . . . . . . . . . . . . . . . 24-53
A/C CONDENSER . . . . . . . . . . . . . . . . . . . . . 24-56
A/C DISCHARGE LINE . . . . . . . . . . . . . . . . . 24-58
A/C EVAPORATOR . . . . . . . . . . . . . . . . . . . . 24-59
A/C HEATER CONTROL . . . . . . . . . . . . . . . . 24-15
A/C HIGH PRESSURE SWITCH . . . . . . . . . . 24-21
A/C LOW PRESSURE SWITCH . . . . . . . . . . . 24-22
A/C ORIFICE TUBE . . . . . . . . . . . . . . . . . . . . 24-60
ABS INDICATOR . . . . . . . . . . . . . . . . . . . . . . 8J -20
ACCELERATOR PEDAL . . . . . . . . . . . . . . . . . 14-22
ACCESSORY DRIVE . . . . . . . . . . . . . . . . . . . . 7-14
ACCESSORY SWITCH BEZEL . . . . . . . . . . . . 23-36
ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . 21-138
ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . 24-61
ADAPTER HOUSING SEAL . . . . . . . . . . . . . 21-138
ADD-A-TRUNK . . . . . . . . . . . . . . . . . . . . . . . 23-51
AIR CLEANER ELEMENT - 2.4L . . . . . . . . . . . 9-20
AIR CLEANER ELEMENT . . . . . . . . . . . . . . . . 9-84
AIR CLEANER HOUSING . . . . . . . . . . . 9-20, 9-84
AIR OUTLETS . . . . . . . . . . . . . . . . . . . . . . . 24-33
AIRBAG CONTROL MODULE . . . . . . . . . . . . . 8O-8
AIRBAG INDICATOR . . . . . . . . . . . . . . . . . . . 8J -21
AMPLIFIED SUBWOOFER . . . . . . . . . . . . . . . 8A-3
ANTENNA BODY & CABLE . . . . . . . . . . . . . . 8A-4
AUDIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-1
AUTO SHUT DOWN RELAY . . . . . . . . . . . . . . 8I-4
AUTOMATIC DAY / NIGHT MIRROR . . . . . . . 8N-1
AUTOMATIC TRANSMISSION - 42RLE . . . . 21-72
AXLE BEARINGS . . . . . . . . . . . . . . . 3-101, 3-135
AXLE LOCK SWITCH . . . . . . . . . . . . . . . . . . 23-37
AXLE SHAFT SEALS . . . . . . . . . 3-33, 3-67, 3-100
AXLE SHAFTS . . . . . . . . 3-32, 3-66, 3-100, 3-134
BALANCE SHAFT CARRIER . . . . . . . . . . . . . . 9-65
BALANCE SHAFT CHAIN . . . . . . . . . . . . . . . . 9-66
BALANCE SHAFTS AND CARRIER
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 9-61
BASE TRIM . . . . . . . . . . . . . . . . . . . . . . . . . 23-39
BASECOAT/CLEARCOAT FINISH . . . . . . . . . . 23-62
BATTERY CABLES . . . . . . . . . . . . . . . . . . . . 8F-16
BATTERY HOLDDOWN . . . . . . . . . . . . . . . . . 8F-14
BATTERY SYSTEM . . . . . . . . . . . . . . . . . . . . . 8F-1
BATTERY TEMPERATURE SENSOR . . . . . . . 8F-23
BATTERY TRAY . . . . . . . . . . . . . . . . . . . . . . 8F-19
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F-7
BEARINGS . . . . . . . . . . . . . . . . . . . . . . . . . 21-139
BELT TENSIONERS . . . . . . . . . . . . . . . . . . . . 7-14
BLEND DOOR ACTUATOR . . . . . . . . . . . . . . 24-23
BLEND DOOR . . . . . . . . . . . . . . . . . . . . . . . 24-34
BLOWER MOTOR RELAY . . . . . . . . . . . . . . . 24-24
BLOWER MOTOR RESISTOR BLOCK . . . . . . 24-25
BLOWER MOTOR SWITCH . . . . . . . . . . . . . 24-26
BLOWER MOTOR . . . . . . . . . . . . . . . . . . . . 24-34
BODY CODE PLATE . . . . . . . . . . . . . . . . . . Intro.-3
BODY DECALS . . . . . . . . . . . . . . . . . . . . . . . 23-26
BODY SIDE GUARD . . . . . . . . . . . . . . . . . . . 23-32
BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-1
BRAKE LAMP SWITCH . . . . . . . . . . . . . . . . . 8L-8
BRAKE LINES . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
BRAKE PADS/SHOES . . . . . . . . . . . . . . . . . . . 5-16
BRAKE TRANSMISSION SHIFT
INTERLOCK MECHANISM . . . . . . . . . . . . . 21-139
BRAKE/PARK BRAKE INDICATOR . . . . . . . . 8J -22
BRAKES - ABS . . . . . . . . . . . . . . . . . . . . . . . . 5-39
BRAKES - BASE . . . . . . . . . . . . . . . . . . . . . . . . 5-2
CAMSHAFT & BEARINGS (IN BLOCK) . . . . . . 9-96
CAMSHAFT OIL SEAL(S) . . . . . . . . . . . . . . . . 9-24
CAMSHAFT POSITION SENSOR - 2.4L . . . . . . 8I-5
CAMSHAFT POSITION SENSOR - 4.0L . . . . . . 8I-7
CAMSHAFT(S) . . . . . . . . . . . . . . . . . . . . . . . . 9-25
CARGO AREA CARPET . . . . . . . . . . . . . . . . 23-52
CATALYTIC CONVERTER . . . . . . . . . . . . . . . . 11-4
CCV SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 25-11
CENTER BEZEL . . . . . . . . . . . . . . . . . . . . . . 23-40
CENTER CARPET . . . . . . . . . . . . . . . . . . . . . 23-52
CENTER CONSOLE CUP HOLDER . . . . . . . . 23-56
CENTER CONSOLE . . . . . . . . . . . . . . . . . . . 23-55
CENTER HIGH MOUNTED STOP LAMP
UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-9
CENTER HIGH MOUNTED STOP LAMP . . . . 8L-10
CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . 8F-21
CHECK GAUGES INDICATOR . . . . . . . . . . . . 8J -24
CHILD RESTRAINT ANCHOR . . . . . . . . . . . . 8O-12
CHIME WARNING SYSTEM . . . . . . . . . . . . . . 8B-1
CIGAR LIGHTER OUTLET . . . . . . . . . . . . 8W-97-2
CLOCKSPRING . . . . . . . . . . . . . . . . . . . . . . 8O-14
CLUSTER BEZEL . . . . . . . . . . . . . . . . . . . . . 23-41
CLUTCH DISC . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
CLUTCH PEDAL POSITION SWITCH . . . . . . . 6-10
CLUTCH PEDAL . . . . . . . . . . . . . . . . . . . . . . . 6-10
CLUTCH RELEASE BEARING . . . . . . . . . . . . . . 6-7
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
COIL RAIL - 4.0L . . . . . . . . . . . . . . . . . . . . . 8I-10
COLLAPSIBLE SPACER . . . . . . . . . . . 3-37, 3-103
COLUMN . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-6
COMBINATION FLASHER . . . . . . . . . . . . . . . 8L-10
COMBINATION VALVE . . . . . . . . . . . . . . . . . . 5-27
COMMUNICATION . . . . . . . . . . . . . . . . . . . . . 8E-1
CONNECTING ROD BEARINGS . . . . . . . 9-34, 9-98
CONNECTOR . . . . . . . . . . . . . . . . . . . . . 8W-01-11
CONNECTOR/GROUND/SPLICE
LOCATION . . . . . . . . . . . . . . . . . . . . . . . . 8W-91-1
CONSOLE LOCK CYLINDER . . . . . . . . . . . . . 23-57
CONTROLLER ANTILOCK BRAKE . . . . . . . . . 8E-2
COOLANT RECOVERY CONTAINER . . . . . . . . 7-24
COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
COWL GRILLE AND SCREEN . . . . . . . . . . . . 23-27
CRANKSHAFT MAIN BEARINGS . . . . . 9-38, 9-101
CRANKSHAFT OIL SEAL - FRONT . . . 9-39, 9-106
CRANKSHAFT OIL SEAL - REAR . . . . 9-41, 9-106
CRANKSHAFT POSITION SENSOR . . . . . . . . . 14-23
CRANKSHAFT . . . . . . . . . . . . . . . . . . . 9-34, 9-101
CRUISE INDICATOR . . . . . . . . . . . . . . . . . . . 8J -25
CYLINDER HEAD COVER . . . . . . . . . . . . . . . . 9-27
CYLINDER HEAD COVER(S) . . . . . . . . . . . . . 9-88
CYLINDER HEAD . . . . . . . . . . . . . . . . . 9-21, 9-85
DAMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-18
DATA LINK CONNECTOR . . . . . . . . . . . . . . . . 8E-3
DAYTIME RUNNING LAMP MODULE . . . . . . 8L-12
DEFROSTER DUCT . . . . . . . . . . . . . . . . . . . 24-38
DIFFERENTIAL - TRAC-LOK . . . . . . . . . . . . . 3-108
DIFFERENTIAL - TRU-LOK PUMP . . . 3-77, 3-152
DIFFERENTIAL - TRU-LOK . . . . . . . . . 3-71, 3-146
DIFFERENTIAL -TRAC-LOK . . . . . . . . . . . . . 3-141
DIFFERENTIAL CASE BEARINGS . . . . 3-43, 3-112,
3-154
DIFFERENTIAL COVER . . 3-38, 3-70, 3-105, 3-138
DIFFERENTIAL . . . . . . . . . . . . 3-39, 3-105, 3-139
DIODE . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-01-14
DISC BRAKE CALIPERS . . . . . . . . . . . . . . . . . 5-10
DOME LAMP UNIT . . . . . . . . . . . . . . . . . . . 8L-32
DOME LAMP . . . . . . . . . . . . . . . . . . . . . . . . 8L-33
DOOR AJ AR SWITCH . . . . . . . . . . . . . . . . . 8L-33
DOOR GLASS . . . . . . . . . . . . . . . . . . . . . . . 23-17
DOOR OPENING FRAME . . . . . . . . . . . . . . . 23-67
DOOR . . . . . . . . . . . . . . . . . . . . . . . . 23-17, 23-23
DOUBLE CARDAN UNIVERSAL J OINTS . . . . . 3-11
DRAG LINK . . . . . . . . . . . . . . . . . . . . . . . . . 19-19
DRIVE BELTS - 2.4L . . . . . . . . . . . . . . . . . . . 7-16
DRIVER AIRBAG . . . . . . . . . . . . . . . . . . . . . 8O-19
DRIVING CLUTCHES . . . . . . . . . . . . . . . . . 21-142
DRUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
EMERGENCY TOW HOOKS . . . . . . . . . . . . . . 0-24
EMISSIONS CONTROL . . . . . . . . . . . . . . . . . . 25-1
ENGINE 2.4L . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
ENGINE 4.0L . . . . . . . . . . . . . . . . . . . . . . . . . 9-68
ENGINE BLOCK HEATER . . . . . . . . . . . . . . . . 7-25
ENGINE BLOCK . . . . . . . . . . . . . . . . . . 9-32, 9-95
ENGINE COOLANT TEMPERATURE
SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
ENGINE COOLANT THERMOSTAT . . . . . . . . . 7-28
ENGINE MOUNTING . . . . . . . . . . . . . . . . . . . 9-46
ENGINE OIL PRESSURE SENSOR . . . . . . . . 9-123
ENGINE TEMPERATURE GAUGE . . . . . . . . . 8J -25
EVAP/PURGE SOLENOID . . . . . . . . . . . . . . . 25-13
EVAPORATIVE EMISSIONS . . . . . . . . . . . . . 25-10
EXHAUST MANIFOLD . . . . . . . . . . . . . 9-55, 9-128
EXHAUST PIPE . . . . . . . . . . . . . . . . . . . . . . . 11-6
EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . 11-1
EXHAUSTER . . . . . . . . . . . . . . . . . . . . . . . . 23-32
EXTERIOR HANDLE . . . . . . . . . . . . . 23-19, 23-24
FAN DRIVE VISCOUS CLUTCH . . . . . . . . . . . 7-30
FASTENER IDENTIFICATION . . . . . . . . . . . Intro.-6
FASTENER USAGE . . . . . . . . . . . . . . . . . . . Intro.-9
FINESSE SANDING, BUFFING &
POLISHING . . . . . . . . . . . . . . . . . . . . . . . . . 23-62
FLOOR DISTRIBUTION DUCT . . . . . . . . . . . 24-39
FLOW MANAGEMENT VALVE . . . . . . . . . . . . 14-20
FLUID AND FILTER . . . . . . . . . . . . . . . . . . 21-142
FLUID CAPACITIES . . . . . . . . . . . . . . . . . . . . . 0-6
FLUID RESERVOIR . . . . . . . . . . . . . . . . . . . . 5-22
FLUID TYPES . . . . . . . . . . . . . . . . . . . . . . . . . . 0-2
FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
FOG LAMP - REAR . . . . . . . . . . . . . . . . . . . 8L-18
FOG LAMP INDICATOR . . . . . . . . . . . . . . . . 8J -26
FOG LAMP RELAY . . . . . . . . . . . . . . . . . . . . 8L-16
FOG LAMP UNIT - REAR . . . . . . . . . . . . . . . 8L-17
FOG LAMP UNIT . . . . . . . . . . . . . . . . . . . . . 8L-13
FOG LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-15
FRAME & BUMPERS . . . . . . . . . . . . . . . . . . . 13-1
FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-3
FRONT AXLE - 181FBI . . . . . . . . . . . . . . . . . . 3-15
FRONT AXLE - 216FBI . . . . . . . . . . . . . . . . . . 3-49
FRONT BUMPER . . . . . . . . . . . . . . . . . . . . . . 13-2
FRONT CARPET . . . . . . . . . . . . . . . . . . . . . . 23-52
FRONT CHECK VALVE . . . . . . . . . . . . . . . . . . 8R-8
FRONT EXTENSION . . . . . . . . . . . . . . . . . . . . 13-2
FRONT LOCK INDICATOR . . . . . . . . . . . . . . 8J -27
FRONT MOUNT . . . . . . . . . . . . . . . . . 9-46, 9-115
FRONT OUTPUT SHAFT SEAL . . . 21-223, 21-261
FRONT PARK/TURN SIGNAL LAMP UNIT . . 8L-19
FRONT PARK/TURN SIGNAL LAMP . . . . . . . 8L-19
FRONT SEAT BACK COVER . . . . . . . . . . . . . 23-69
FRONT SEAT BACK DUMP CABLE . . . . . . . . 23-72
FRONT SEAT BACK RECLINER CABLE . . . . . 23-70
FRONT SEAT BACK RECLINER/COVER . . . . 23-70
FRONT SEAT BACK . . . . . . . . . . . . . . . . . . . 23-69
FRONT SEAT BELT & RETRACTOR . . . . . . . 8O-24
FRONT SEAT BELT BUCKLE . . . . . . . . . . . . 8O-26
FRONT SEAT CUSHION COVER . . . . . . . . . . 23-70
FRONT SEAT FOLDING RELEASE CABLE . . . 23-71
FRONT SEAT TRACK ADJ USTER . . . . . . . . . 23-72
FRONT SEAT . . . . . . . . . . . . . . . . . . . . . . . . 23-68
FRONT TOW HOOK . . . . . . . . . . . . . . . . . . . 13-10
FRONT WASHER HOSES/TUBES . . . . . . . . . 8R-10
FRONT WASHER NOZZLE . . . . . . . . . . . . . . 8R-10
FRONT WASHER PUMP MOTOR . . . . . . . . . 8R-11
FRONT WHEEL SPEED SENSOR . . . . . . . . . . 5-41
FRONT WIPER ARM . . . . . . . . . . . . . . . . . . 8R-13
FRONT WIPER BLADE . . . . . . . . . . . . . . . . . 8R-14
FRONT WIPER MODULE . . . . . . . . . . . . . . . 8R-15
FRONT WIPERS/WASHERS . . . . . . . . . . . . . . 8R-1
FUEL DELIVERY . . . . . . . . . . . . . . . . . . . . . . . 14-1
FUEL FILLER CAP . . . . . . . . . . . . . . . . . . . . 25-14
FUEL FILTER/PRESSURE REGULATOR . . . . . 14-5
FUEL GAUGE . . . . . . . . . . . . . . . . . . . . . . . . 8J -29
FUEL INJ ECTION . . . . . . . . . . . . . . . . . . . . . 14-21
FUEL INJ ECTOR . . . . . . . . . . . . . . . . . . . . . . 14-26
FUEL LEVEL SENDING UNIT / SENSOR . . . . 14-6
FUEL LINES . . . . . . . . . . . . . . . . . . . . . . . . . . 14-7
FUEL PUMP MODULE . . . . . . . . . . . . . . . . . . 14-8
FUEL PUMP RELAY . . . . . . . . . . . . . . . . . . . 14-27
FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . 14-8
FUEL RAIL - 4.0L ENGINE . . . . . . . . . . . . . . 14-12
FUEL RAIL/FUEL DAMPER - 2.4L . . . . . . . . 14-10
FUEL TANK SKID PLATE . . . . . . . . . . . . . . . 13-10
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . 14-13
FULL DOOR INNER BELT
WEATHERSTRIP . . . . . . . . . . . . . . . . . . . . . 23-82
FULL DOOR OUTER BELT SEAL . . . . . . . . . 23-82
FULL DOOR WEATHERSTRIP . . . . . . . . . . . 23-83
FUSE BLOCK . . . . . . . . . . . . . . . . . . . . . . 8W-97-3
G-SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42
GAP AND FLUSH . . . . . . . . . . . . . . . . . . . . . 23-86
GEARSHIFT CABLE . . . . . . . . . . . . . . . . . . 21-145
GENERATOR DECOUPLER PULLEY . . . . . . . 8F-26
GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . 8F-24
GLASS RUN CHANNEL . . . . . . . . . . . . . . . . 23-20
GLOVE BOX CHECK STRAP . . . . . . . . . . . . . 23-44
GLOVE BOX LATCH STRIKER . . . . . . . . . . . 23-44
GLOVE BOX . . . . . . . . . . . . . . . . . . . . . . . . . 23-42
GRAB HANDLE BEZEL . . . . . . . . . . . . . . . . . 23-46
GRAB HANDLE . . . . . . . . . . . . . . . . . . . . . . 23-45
HALF DOOR WEATHERSTRIP . . . . . . . . . . . 23-83
HARD TOP . . . . . . . . . . . . . . . . . . . . . . . . . . 23-64
HARD/SOFT TOP LATCH . . . . . . . . . . . . . . . 23-67
HCU (HYDRAULIC CONTROL UNIT) . . . . . . . 5-43
HEADLAMP LEVELING MOTOR . . . . . . . . . . 8L-21
HEADLAMP LEVELING SWITCH . . . . . . . . . 8L-21
HEADLAMP . . . . . . . . . . . . . . . . . . . . . . . . . 8L-19
HEAT SHIELDS . . . . . . . . . . . . . . . . . . . . . . . 11-8
HEATED GLASS . . . . . . . . . . . . . . . . . . . . . . . 8G-1
HEATED MIRRORS . . . . . . . . . . . . . . . . . . . . 8G-7
HEATER CORE . . . . . . . . . . . . . . . . . . . . . . . 24-62
HEATING & AIR CONDITIONING . . . . . . . . . . 24-1
HIGH BEAM INDICATOR . . . . . . . . . . . . . . . 8J -30
HINGE . . . . . . . . . . . . . . . . . . 23-20, 23-24, 23-34
HOISTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-21
HOLDING CLUTCHES . . . . . . . . . . . . . . . . . 21-146
HOOD SAFETY LATCH . . . . . . . . . . . . . . . . . 23-35
HOOD TO COWL WEATHERSTRIP . . . . . . . . 23-82
TJ INDEX 1
Description Group-Page Description Group-Page Description Group-Page
HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-34
HORN SWITCH . . . . . . . . . . . . . . . . . . . . . . . 8H-2
HORN SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 8H-1
HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H-1
HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-24
HUB / BEARING . . . . . . . . . . . . . . . . . . . . . . . . 2-8
HVAC HOUSING . . . . . . . . . . . . . . . . . . . . . . 24-40
HYDRAULIC LIFTERS . . . . . . . . . . . . . 9-30, 9-107
IDLE AIR CONTROL MOTOR . . . . . . . . . . . . 14-28
IGNITION COIL - 2.4L . . . . . . . . . . . . . . . . . 8I-12
IGNITION CONTROL . . . . . . . . . . . . . . . . . . . . 8I-1
IGNITION SWITCH . . . . . . . . . . . . . . . . . . . . . 19-9
INLET FILTER . . . . . . . . . . . . . . . . . . . . . . . . 14-16
INPUT CLUTCH ASSEMBLY . . . . . . . . . . . . 21-146
INPUT SPEED SENSOR . . . . . . . . . . . . . . . 21-163
INSIDE HANDLE ACTUATOR . . . . . . 23-21, 23-24
INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . 8J -2
INSTRUMENT PANEL ASSEMBLY . . . . . . . . 23-47
INSTRUMENT PANEL DEMISTER DUCTS . . 24-42
INSTRUMENT PANEL DUCTS . . . . . . . . . . . 24-43
INTAKE AIR TEMPERATURE SENSOR . . . . . 14-29
INTAKE MANIFOLD . . . . . . . . . . . . . . . 9-54, 9-126
INTAKE/EXHAUST VALVES & SEATS . . 9-29, 9-89
INTERNATIONAL SYMBOLS . . . . . . . . . . . . . . . 0-1
INTERNATIONAL SYMBOLS . . . . . . . . . . . Intro.-5
IOD FUSE . . . . . . . . . . . . . . . . . . . . . . . . 8W-97-5
J OUNCE BUMPER . . . . . . . . . . . . . . . . 2-10, 2-17
J UMP STARTING . . . . . . . . . . . . . . . . . . . . . . 0-23
KEY CYLINDER . . . . . . . . . . . . . . . . . . . . . . 19-11
KEY-IN IGNITION SWITCH . . . . . . . . . . . . . . 19-10
KNUCKLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
LAMPS/LIGHTING - EXTERIOR . . . . . . . . . . . 8L-2
LAMPS/LIGHTING - INTERIOR . . . . . . . . . . 8L-32
LATCH STRIKER . . . . . . . . . . . . . . . . 23-22, 23-25
LATCH . . . . . . . . . . . . . . . . . . . . . . . 23-21, 23-24
LEAK DETECTION PUMP . . . . . . . . . . . . . . . 25-14
LEFT FRONT FENDER . . . . . . . . . . . . . . . . . 23-28
LEFT MULTI-FUNCTION SWITCH . . . . . . . . . 8L-23
LICENSE PLATE BRACKET . . . . . . . . . . . . . . 23-33
LIFTGATE GLASS HINGE . . . . . . . . . . . . . . . 23-13
LIFTGATE GLASS SUPPORT CYLINDER . . . 23-15
LIFTGATE GLASS WEATHERSTRIP . . . . . . . 23-14
LIFTGATE GLASS . . . . . . . . . . . . . . . . . . . . . 23-14
LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-17
LIQUID LINE . . . . . . . . . . . . . . . . . . . . . . . . 24-63
LOCK CYLINDER . . . . . . . . . . . . . . . 23-22, 23-25
LOW FUEL INDICATOR . . . . . . . . . . . . . . . . 8J -31
LOWER BALL J OINT . . . . . . . . . . . . . . . . . . . 2-10
LOWER CONTROL ARM . . . . . . . . . . . . 2-11, 2-17
LUBRICATION . . . . . . . . . . . . . . . . . . . 9-49, 9-117
MAINTENANCE SCHEDULES . . . . . . . . . . . . . . 0-7
MALFUNCTION INDICATOR LAMP (MIL) . . . 8J -32
MANUAL - NV1500 . . . . . . . . . . . . . . . . . . . . 21-1
MANUAL - NV3550 . . . . . . . . . . . . . . . . . . . 21-32
MAP SENSOR . . . . . . . . . . . . . . . . . . . . . . . 14-31
MASTER CYLINDER . . . . . . . . . . . . . . . . . . . 5-23
MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . 6-9
METRIC SYSTEM . . . . . . . . . . . . . . . . . . Intro.-10
MICRO-RELAY . . . . . . . . . . . . . . . . . . . . . 8W-97-6
MODE DOOR ACTUATOR . . . . . . . . . . . . . . . 24-27
MODE DOOR . . . . . . . . . . . . . . . . . . . . . . . . 24-44
MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-9
O2 HEATER RELAY . . . . . . . . . . . . . . . . . . . 14-33
O2 SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . 14-33
ODOMETER . . . . . . . . . . . . . . . . . . . . . . . . . 8J -33
OIL FILTER . . . . . . . . . . . . . . . . . . . . . 9-50, 9-121
OIL PAN . . . . . . . . . . . . . . . . . . . . . . . 9-50, 9-121
OIL PRESSURE GAUGE . . . . . . . . . . . . . . . . 8J -34
OIL PRESSURE SENSOR/SWITCH . . . . . . . . . 9-51
OIL PUMP . . . . . . . . . . . . . . . . . . . . . 9-51, 9-123
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . 21-164
OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-49, 9-120
OPENING DIMENSIONS . . . . . . . . . . . . . . . . 23-89
ORVR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-19
OUTPUT SPEED SENSOR . . . . . . . . . . . . . 21-166
OVERDRIVE SWITCH . . . . . . . . . . . . . . . . . 21-167
PAINT CODE . . . . . . . . . . . . . . . . . . . . . . . . 23-61
PAINT TOUCH-UP . . . . . . . . . . . . . . . . . . . . 23-62
PAINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-61
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . 5-33
PARTS & LUBRICANT
RECOMMENDATION . . . . . . . . . . . . . . . . . . . . 0-1
PASSENGER AIRBAG DOOR . . . . . . . . . . . . 8O-29
PASSENGER AIRBAG ON/OFF SWITCH . . . . 8O-31
PASSENGER AIRBAG . . . . . . . . . . . . . . . . . 8O-27
PCV VALVE . . . . . . . . . . . . . . . . . . . . . . . . . 25-12
PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
PILOT BEARING . . . . . . . . . . . . . . . . . . . . . . . 6-8
PINION GEAR/RING GEAR . . . . 3-44, 3-79, 3-113
PINION GEAR/RING GEAR/TONE RING . . . . 3-155
PINION SEAL . . . . . . . . . 3-35, 3-69, 3-101, 3-136
PISTON & CONNECTING ROD . . . . . . 9-42, 9-109
PISTON RINGS . . . . . . . . . . . . . . . . . . 9-44, 9-112
PITMAN ARM . . . . . . . . . . . . . . . . . . . . . . . 19-19
PLANETARY GEARTRAIN . . . . . . . . . . . . . . 21-167
PLUMBING . . . . . . . . . . . . . . . . . . . . . . . . . 24-48
POSITION SENSOR . . . . . . . . . . . . . . . . . . 21-263
POWER BRAKE BOOSTER . . . . . . . . . . . . . . . 5-26
POWER DISTRIBUTION CENTER
SUPPORT BRACKET . . . . . . . . . . . . . . . 8W-97-12
POWER DISTRIBUTION CENTER . . . . . . . 8W-97-7
POWER DISTRIBUTION . . . . . . . . . . . . . . 8W-97-1
POWER OUTLET . . . . . . . . . . . . . . . . . . 8W-97-12
POWER STEERING PRESSURE SWITCH . . . 19-24
POWERTRAIN CONTROL MODULE . . . . . . . . 8E-3
PROPELLER SHAFT - FRONT . . . . . . . . . . . . . 3-7
PROPELLER SHAFT - REAR RUBICON . . . . . . 3-8
PROPELLER SHAFT - REAR . . . . . . . . . . . . . . 3-7
PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . . . 3-1
PULLEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-25
PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-20
QUARTER GLASS . . . . . . . . . . . . . . . . . . . . 23-77
QUICK CONNECT FITTING . . . . . . . . . . . . . . . 14-17
RADIATOR FAN RELAY . . . . . . . . . . . . . . . . . 7-43
RADIATOR FAN . . . . . . . . . . . . . . . . . . . . . . . 7-42
RADIATOR GRILLE PANEL . . . . . . . . . . . . . 23-29
RADIATOR PRESSURE CAP . . . . . . . . . . . . . . 7-40
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33
RADIO NOISE SUPPRESSION
COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . 8A-7
RADIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-6
REAR AXLE - 194RBI . . . . . . . . . . . . . . . . . . 3-84
REAR AXLE - 216RBI . . . . . . . . . . . . . . . . . 3-118
REAR BUMPER . . . . . . . . . . . . . . . . . . . . . . . 13-2
REAR CHECK VALVE . . . . . . . . . . . . . . . . . . 8R-30
REAR EXTENSION SEAL . . . . . . . . . . . . . . 21-261
REAR EXTENSION . . . . . . . . . . . . . . . . . . . . . 13-2
REAR HEADER TRIM . . . . . . . . . . . . . . . . . . 23-58
REAR LOCK INDICATOR . . . . . . . . . . . . . . . 8J -35
REAR MOUNT . . . . . . . . . . . . . . . . . . 9-47, 9-116
REAR OUTPUT SHAFT SEAL . . . . . . . . . . . 21-224
REAR SEAT BACK COVER . . . . . . . . . . . . . . 23-74
REAR SEAT BACK HINGE . . . . . . . . . . . . . . 23-74
REAR SEAT BACK . . . . . . . . . . . . . . . . . . . . 23-74
REAR SEAT BELT & RETRACTOR . . . . . . . . 8O-33
REAR SEAT BELT BUCKLE . . . . . . . . . . . . . 8O-34
REAR SEAT CUSHION COVER . . . . . . . . . . . 23-75
REAR SEAT RELEASE CABLE . . . . . . . . . . . 23-76
REAR SEAT STRIKERS . . . . . . . . . . . . . . . . 23-76
REAR SEAT . . . . . . . . . . . . . . . . . . . . . . . . . 23-73
REAR TOW HOOK . . . . . . . . . . . . . . . . . . . . 13-11
REAR VIEW MIRROR SUPPORT
BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-53
REAR VIEW MIRROR . . . . . . . . . . . . . . . . . 23-53
REAR WASHER HOSES/TUBES . . . . . . . . . . 8R-31
REAR WASHER NOZZLE . . . . . . . . . . . . . . . 8R-32
REAR WASHER PUMP MOTOR . . . . . . . . . . 8R-33
REAR WHEEL SPEED SENSOR . . . . . . . . . . . 5-42
REAR WINDOW DEFOGGER GRID . . . . . . . . 8G-6
REAR WINDOW DEFOGGER RELAY . . . . . . . 8G-3
REAR WINDOW DEFOGGER SWITCH . . . . . . 8G-4
REAR WIPER ARM . . . . . . . . . . . . . . . . . . . 8R-34
REAR WIPER BLADE . . . . . . . . . . . . . . . . . . 8R-36
REAR WIPER MOTOR TRIM COVER . . . . . . 8R-39
REAR WIPER MOTOR . . . . . . . . . . . . . . . . . 8R-37
REAR WIPER/WASHER SWITCH
ILLUMINATION LAMP . . . . . . . . . . . . . . . . . 8L-35
REAR WIPER/WASHER SWITCH . . . . . . . . . 8R-40
REAR WIPERS/WASHERS . . . . . . . . . . . . . . 8R-24
REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
RECIRCULATION AIR DOOR . . . . . . . . . . . . 24-46
RECIRCULATION DOOR ACTUATOR . . . . . . 24-29
REFRIGERANT LINE COUPLER . . . . . . . . . . 24-64
REFRIGERANT OIL . . . . . . . . . . . . . . . . . . . 24-66
REFRIGERANT . . . . . . . . . . . . . . . . . . . . . . . 24-64
RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-97-13
REMOVEABLE TOP . . . . . . . . . . . . . . . . . . . 23-63
REPEATER LAMP . . . . . . . . . . . . . . . . . . . . . 8L-28
RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . 19-26
RESTRAINTS . . . . . . . . . . . . . . . . . . . . . . . . . 8O-1
RIGHT FRONT FENDER . . . . . . . . . . . . . . . . 23-27
RIGHT MULTI-FUNCTION SWITCH . . . . . . . 8R-18
ROCKER ARM / ADJ USTER ASSEMBLY . . . . 9-91
ROCKER ARMS . . . . . . . . . . . . . . . . . . . . . . . 9-31
ROTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
SEAL - OIL PUMP . . . . . . . . . . . . . . . . . . . 21-168
SEALER LOCATIONS . . . . . . . . . . . . . . . . . . 23-94
SEAT BELT SWITCH . . . . . . . . . . . . . . . . . . 8O-35
SEAT BELT TURNING LOOP ADJ USTER . . . 8O-36
SEATBELT INDICATOR . . . . . . . . . . . . . . . . . 8J -36
SENTRY KEY IMMOBILIZER MODULE . . . . . . 8E-8
SERVICE PORT VALVE CORE . . . . . . . . . . . . 24-66
SERVO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8P-4
SHIFT BEZEL - AUTOMATIC
TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . 23-54
SHIFT BOOT . . . . . . . . . . . . . . . . . . . . . . . . 23-55
SHIFT INDICATOR (TRANSFER CASE) . . . . . 8J -37
SHIFT LEVER . . . . . . . . . . . . . . . . 21-227, 21-264
SHIFT MECHANISM . . . . . . . . . . . . . . . . . . 21-168
SHOCK . . . . . . . . . . . . . . . . . . . . . . . . . 2-12, 2-18
SHOES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34
SIDE MARKER LAMP UNIT . . . . . . . . . . . . . 8L-28
SIDE MARKER LAMP . . . . . . . . . . . . . . . . . 8L-28
SIDE STEP . . . . . . . . . . . . . . . . . . . . . . . . . . 23-32
SIDE VIEW MIRROR . . . . . . . . . . . . . . . . . . 23-30
SINGLE CARDAN UNIVERSAL J OINT . . 3-34, 3-68
SINGLE CARDAN UNIVERSAL J OINTS . . . . . . 3-9
SKIS INDICATOR . . . . . . . . . . . . . . . . . . . . . 8J -39
SKIS INDICATOR . . . . . . . . . . . . . . . . . . . . . . 8Q-5
SOFT TOP FABRIC . . . . . . . . . . . . . . . . . . . . 23-67
SOFT TOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-65
SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . 21-169
SOLENOID/PRESSURE SWITCH ASSY . . . 21-170
SPARE TIRE CARRIER . . . . . . . . . . . . . . . . . 22-11
SPARE TIRE . . . . . . . . . . . . . . . . . . . . . . . . . 22-10
SPARK PLUG CABLE . . . . . . . . . . . . . . . . . . 8I-17
SPARK PLUG . . . . . . . . . . . . . . . . . . . . . . . . 8I-13
SPEAKER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-8
SPEED CONTROL . . . . . . . . . . . . . . . . . . . . . 8P-1
SPEEDOMETER DRIVE ADAPTER . . . . . . . 21-228
SPEEDOMETER . . . . . . . . . . . . . . . . . . . . . . 8J -40
SPORT BAR - SPEAKER POD . . . . . . . . . . . 23-60
SPORT BAR . . . . . . . . . . . . . . . . . . . . . . . . . 23-57
SPRING . . . . . . . . . . . . . . . . . . . . . . . . 2-13, 2-18
STABILIZER BAR . . . . . . . . . . . . . . . . . 2-14, 2-19
STARTER MOTOR RELAY . . . . . . . . . . . . . . 8F-40
STARTER MOTOR . . . . . . . . . . . . . . . . . . . . 8F-37
STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . 8F-31
STATIONARY GLASS . . . . . . . . . . . . . . . . . . 23-77
STEERING COLUMN OPENING COVER . . . . 23-49
STEERING WHEEL . . . . . . . . . . . . . . . . . . . . 19-11
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-1
STRUCTURAL ADHESIVE LOCATIONS . . . . 23-111
STRUCTURAL COLLAR . . . . . . . . . . . . . . . . . 9-46
STRUCTURAL SUPPORT . . . . . . . . . . . . . . . 9-114
STUDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-13
SUCTION LINE . . . . . . . . . . . . . . . . . . . . . . . 24-67
SUNVISOR . . . . . . . . . . . . . . . . . . . . . . . . . . 23-54
SUPPORT PLATE . . . . . . . . . . . . . . . . . . . . . . 5-32
SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8P-5
TACHOMETER . . . . . . . . . . . . . . . . . . . . . . . 8J -41
TAIL LAMP UNIT . . . . . . . . . . . . . . . . . . . . . 8L-29
TAIL LAMP . . . . . . . . . . . . . . . . . . . . . . . . . 8L-30
TAILGATE HINGE . . . . . . . . . . . . . . . . . . . . . 23-12
TAILGATE LATCH STRIKER . . . . . . . . . . . . . 23-13
TAILGATE LATCH . . . . . . . . . . . . . . . . . . . . . 23-13
TAILGATE LOCK CYLINDER . . . . . . . . . . . . . 23-14
TAILGATE OUTSIDE HANDLE . . . . . . . . . . . . 23-12
TAILGATE WEATHERSTRIP AND
CHANNEL. . . . . . . . . . . . . . . . . . . . . . . . . . . 23-84
TAILGATE . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-15
TAILPIPE . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-11
TERMINAL . . . . . . . . . . . . . . . . . . . . . . . 8W-01-14
THROTTLE BODY . . . . . . . . . . . . . . . . . . . . . 14-36
THROTTLE CONTROL CABLE . . . . . . . . . . . 14-37
THROTTLE POSITION SENSOR . . . . . . . . . . 14-40
TIE ROD END . . . . . . . . . . . . . . . . . . . . . . . . 19-19
TIMING BELT / CHAIN COVER(S) . . . . . . . . 9-124
TIMING BELT AND SPROCKET(S) . . . . . . . . . 9-57
TIMING BELT COVER(S) . . . . . . . . . . . . . . . . 9-56
TIMING BELT TENSIONER & PULLEY . . . . . . 9-61
TIMING BELT/CHAIN AND SPROCKETS . . . . 9-125
TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-5
TIRES/WHEELS . . . . . . . . . . . . . . . . . . . . . . . 22-1
TOP COVER . . . . . . . . . . . . . . . . . . . . . . . . . 23-50
TORQUE CONVERTER . . . . . . . . . . . . . . . . 21-172
TORQUE REFERENCES . . . . . . . . . . . . . . Intro.-12
TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-22
TRACK BAR . . . . . . . . . . . . . . . . . . . . . 2-14, 2-20
TRANSFER CASE - NV231 . . . . . . . . . . . . . 21-196
TRANSFER CASE - NV241 . . . . . . . . . . . . . 21-231
TRANSFER CASE SKID PLATE . . . . . . . . . . . . 13-9
TRANSMISSION CONTROL MODULE . . . . . 8E-13
2 INDEX TJ
Description Group-Page Description Group-Page Description Group-Page
TRANSMISSION CONTROL RELAY . . . . . . 21-178
TRANSMISSION COOLER . . . . . . . . . . . . . . . 7-44
TRANSMISSION RANGE SENSOR . . . . . . . 21-178
TRANSMISSION SKID PLATE . . . . . . . . . . . 13-11
TRANSMISSION TEMPERATURE SENSOR . 21-179
TRANSPONDER KEY . . . . . . . . . . . . . . . . . . . 8Q-6
TRIM PANEL . . . . . . . . . . . . . . . . . . 23-22, 23-25
TURN SIGNAL CANCEL CAM . . . . . . . . . . . . 8L-30
TURN SIGNAL INDICATOR . . . . . . . . . . . . . . 8J -41
UNDERHOOD LAMP UNIT . . . . . . . . . . . . . . 8L-30
UNDERHOOD LAMP . . . . . . . . . . . . . . . . . . 8L-31
UPPER BALL J OINT . . . . . . . . . . . . . . . . . . . 2-15
UPPER CONTROL ARM . . . . . . . . . . . . 2-15, 2-20
UPSHIFT INDICATOR . . . . . . . . . . . . . . . . . . 8J -42
VACUUM CHECK VALVE . . . . . . . . . . . . . . . 24-31
VACUUM LINES . . . . . . . . . . . . . . . . . . . . . . 25-20
VACUUM RESERVOIR . . . . . . . . . . . . . . . . . 24-32
VACUUM RESERVOIR . . . . . . . . . . . . . . . . . . 8P-7
VALVE BODY . . . . . . . . . . . . . . . . . . . . . . . 21-180
VALVE SPRINGS . . . . . . . . . . . . . . . . . 9-29, 9-93
VALVE STEM SEALS . . . . . . . . . . . . . . . . . . . 9-93
VALVE TIMING . . . . . . . . . . . . . . . . . . . . . . . 9-124
VAPOR CANISTER . . . . . . . . . . . . . . . . . . . . 25-20
VEHICLE CERTIFICATION LABEL . . . . . . . . Intro.-2
VEHICLE EMISSION CONTROL
INFORMATION (VECI) LABEL . . . . . . . . . . Intro.-2
VEHICLE IDENTIFICATION NUMBER . . . . . Intro.-1
VEHICLE SPEED SENSOR . 21-69, 21-229, 21-265
VEHICLE THEFT SECURITY . . . . . . . . . . . . . . 8Q-1
VIBRATION DAMPER . . . . . . . . . . . . . 9-46, 9-114
VOLTAGE GAUGE . . . . . . . . . . . . . . . . . . . . . 8J -43
VOLTAGE REGULATOR . . . . . . . . . . . . . . . . . 8F-30
WASHER RESERVOIR . . . . . . . . . . . . . . . . . 8R-22
WATER PUMP - 2.4L . . . . . . . . . . . . . . . . . . . 7-36
WATER PUMP - 4.0L . . . . . . . . . . . . . . . . . . . 7-37
WELD LOCATIONS . . . . . . . . . . . . . . . . . . . 23-120
WHEEL ALIGNMENT . . . . . . . . . . . . . . . . . . . . 2-1
WHEEL CYLINDERS . . . . . . . . . . . . . . . . . . . 5-31
WHEEL OPENING FLARE MOLDING . . . . . . 23-31
WHEELHOUSE CARPET . . . . . . . . . . . . . . . . 23-52
WHEELHOUSE SPLASH SHIELD . . . . . . . . . 23-30
WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-11
WINDOW REGULATOR . . . . . . . . . . . . . . . . 23-18
WINDOW . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-23
WINDSHIELD FRAME WEATHERSTRIP . . . . 23-84
WINDSHIELD FRAME . . . . . . . . . . . . . . . . . 23-80
WINDSHIELD HEADER . . . . . . . . . . . . . . . . 23-59
WINDSHIELD HINGE . . . . . . . . . . . . . . . . . . 23-80
WINDSHIELD . . . . . . . . . . . . . . . . . . . . . . . . 23-78
WIRING DIAGRAM INFORMATION . . . . . 8W-01-1
TJ INDEX 3
Description Group-Page Description Group-Page Description Group-Page
TABLE OF CONTENTS
1.0 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.1 SYSTEM COVERAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.2 SIX-STEP TROUBLE SHOOTING PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . .1
2.0 IDENTIFICATION OF SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
3.0 SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION . . . . . . . . . . . . . . . . . . . . . .1
3.1 GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
3.2 FUNCTION OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
3.2.1 FUEL CONTROL (GAS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
3.2.2 ON-BOARD DIAGNOSTICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
3.2.3 OTHER CONTROLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
3.2.4 NON-MONITORED CIRCUITS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
3.2.5 SKIS OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
3.2.6 SKIM ON-BOARD DIAGNOSTICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
3.2.7 SKIS OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
3.2.8 PROGRAMMING THE POWERTRAIN CONTROL MODULE. . . . . . . .11
3.2.9 PROGRAMMING THE SENTRY KEY IMMOBILIZER MODULE . . . . .11
3.2.10 PROGRAMMING THE IGNITION KEYS TO THE SENTRY KEY
IMMOBILIZER MODULE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
3.3 DIAGNOSTIC TROUBLE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
3.3.1 HARD CODE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
3.3.2 INTERMITTENT CODE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
3.3.3 STARTS SINCE SET COUNTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
3.3.4 NO START INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
3.4 USING THE DRBIIIா . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
3.5 DRBIIIா ERROR MESSAGES AND BLANK SCREEN . . . . . . . . . . . . . . . . . . . . .13
3.5.1 DRBIIIா DOES NOT POWER UP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
3.5.2 DISPLAY IS NOT VISIBLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
4.0 DISCLAIMERS, SAFETY, WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
4.1 DISCLAIMERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
4.2 SAFETY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
4.2.1 TECHNICIAN SAFETY INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . .14
4.2.2 VEHICLE PREPARATION FOR TESTING. . . . . . . . . . . . . . . . . . . . . . .14
4.2.3 SERVICING SUB-ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
4.2.4 DRBIIIா SAFETY INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
4.3 WARNINGS AND CAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
4.3.1 ROAD TEST WARNINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
4.3.2 VEHICLE DAMAGE CAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
5.0 REQUIRED TOOLS AND EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
6.0 ACRONYMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
7.0 DIAGNOSTIC INFORMATION AND PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . .19
i
TABLE OF CONTENTS - Continued
COMMUNICATION
*NO RESPONSE FROM PCM (PCI BUS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
*NO RESPONSE FROM PCM (SCI ONLY). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
*NO RESPONSE FROM SENTRY KEY IMMOBILIZER MODULE . . . . . . . . . . . . . . . .24
*PCI BUS COMMUNICATION FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
DRIVEABILITY - GAS
INTERMITTENT CONDITION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
P0031-O2 SENSOR 1/1 HEATER CIRCUIT LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
P0032-O2 SENSOR 1/1 HEATER CIRCUIT HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
P0037-O2 SENSOR 1/2 HEATER CIRCUIT LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
P0038-O2 SENSOR 1/2 HEATER CIRCUIT HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
P0051-O2 SENSOR 2/1 HEATER CIRCUIT LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
P0052-O2 SENSOR 2/1 HEATER CIRCUIT HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
P0071-AMBIENT/BATTERY TEMP SENSOR PERFORMANCE . . . . . . . . . . . . . . . . . .32
P0107-MAP SENSOR VOLTAGE TOO LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
P0108-MAP SENSOR VOLTAGE TOO HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
P0111-INTAKE AIR TEMP PERFORMANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
P0112-INTAKE AIR TEMP SENSOR VOLTAGE TOO LOW. . . . . . . . . . . . . . . . . . . . . .41
P0113-INTAKE AIR TEMP SENSOR VOLTAGE TOO HIGH . . . . . . . . . . . . . . . . . . . . .43
P0117-ENGINE COOLANT TEMP SENSOR VOLTAGE TOO LOW . . . . . . . . . . . . . . .45
P0118-ENGINE COOLANT TEMP SENSOR VOLTAGE TOO HIGH . . . . . . . . . . . . . . .47
P0121-TP SENSOR VOLTAGE DOES NOT AGREE WITH MAP SENSOR . . . . . . . . .49
P0122-THROTTLE POSITION SENSOR VOLTAGE TOO LOW . . . . . . . . . . . . . . . . . .54
P0123-THROTTLE POSITION SENSOR VOLTAGE TOO HIGH . . . . . . . . . . . . . . . . . .57
P0125-CLOSED LOOP TEMP NOT REACHED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
P0131-O2 SENSOR 1/1 CIRCUIT VOLTAGE LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
P0137-O2 SENSOR 1/2 CIRCUIT VOLTAGE LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
P0151-O2 SENSOR 2/1 CIRCUIT VOLTAGE LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
P0157-O2 SENSOR 2/2 CIRCUIT VOLTAGE LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
P0132-O2 SENSOR 1/1 CIRCUIT VOLTAGE HIGH. . . . . . . . . . . . . . . . . . . . . . . . . . . .65
P0138-O2 SENSOR 1/2 CIRCUIT VOLTAGE HIGH. . . . . . . . . . . . . . . . . . . . . . . . . . . .65
P0152-O2 SENSOR 2/1 CIRCUIT VOLTAGE HIGH. . . . . . . . . . . . . . . . . . . . . . . . . . . .65
P0158-O2 SENSOR 2/2 CIRCUIT VOLTAGE HIGH. . . . . . . . . . . . . . . . . . . . . . . . . . . .65
P0133-O2 SENSOR 1/1 SLOW RESPONSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
P0139-O2 SENSOR 1/2 SLOW RESPONSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
P0153-O2 SENSOR 2/1 SLOW RESPONSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
P0159-O2 SENSOR 2/2 SLOW RESPONSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
P0135-O2 SENSOR 1/1 HEATER FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
P0141-O2 SENSOR 1/2 HEATER FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
P0155-O2 SENSOR 2/1 HEATER FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
P0161-O2 SENSOR 2/2 HEATER FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
P0136-O2 SENSOR 1/2 HEATER CIRCUIT MALFUNCTION . . . . . . . . . . . . . . . . . . . .74
P0171-1/1 FUEL SYSTEM LEAN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
P0174-2/1 FUEL SYSTEM LEAN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
P0172-1/1 FUEL SYSTEM RICH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
P0175-2/1 FUEL SYSTEM RICH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
P0201-INJECTOR #1 CONTROL CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
P0202-INJECTOR #2 CONTROL CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
P0203-INJECTOR #3 CONTROL CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
P0204-INJECTOR #4 CONTROL CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
P0205-INJECTOR #5 CONTROL CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
P0206-INJECTOR #6 CONTROL CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
ii
TABLE OF CONTENTS - Continued
P0300-MULTIPLE CYLINDER MIS-FIRE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
P0301-CYLINDER #1 MISFIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
P0302-CYLINDER #2 MISFIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
P0303-CYLINDER #3 MISFIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
P0304-CYLINDER #4 MISFIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
P0305-CYLINDER #5 MISFIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
P0306-CYLINDER #6 MISFIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
P0320-NO CRANK REFERENCE SIGNAL AT PCM. . . . . . . . . . . . . . . . . . . . . . . . . . . .97
P0340-NO CAM REFERENCE SIGNAL AT PCM . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
P0351-IGNITION COIL # 1 PRIMARY CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105
P0352-IGNITION COIL # 2 PRIMARY CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105
P0353-IGNITION COIL # 3 PRIMARY CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105
P0420-1/1 CATALYTIC CONVERTER EFFICIENCY. . . . . . . . . . . . . . . . . . . . . . . . . . .108
P0432-2/1 CATALYTIC CONVERTER EFFICIENCY. . . . . . . . . . . . . . . . . . . . . . . . . . .108
P0441-EVAP PURGE FLOW MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110
P0442-EVAP LEAK MONITOR MEDIUM (0.040) LEAK DETECTED. . . . . . . . . . . . . .112
P0455-EVAP LEAK MONITOR LARGE LEAK DETECTED . . . . . . . . . . . . . . . . . . . . .112
P0456-EVAP LEAK MONITOR SMALL (0.020) LEAK DETECTED . . . . . . . . . . . . . . .112
P0443-EVAP PURGE SOLENOID CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
P0460-FUEL LEVEL UNIT NO CHANGE OVER MILES. . . . . . . . . . . . . . . . . . . . . . . .118
P0461-FUEL LEVEL UNIT NO CHANGE OVER TIME. . . . . . . . . . . . . . . . . . . . . . . . .118
P0462-FUEL LEVEL SENDING UNIT VOLTAGE TOO LOW . . . . . . . . . . . . . . . . . . . .119
P0463-FUEL LEVEL SENDING UNIT VOLTAGE TOO HIGH. . . . . . . . . . . . . . . . . . . .121
P0500-NO VEHICLE SPEED SIGNAL CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
P0505-IDLE AIR CONTROL MOTOR CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126
P0523-OIL PRESSURE VOLTAGE TOO HIGH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128
P0551-POWER STEERING SWITCH FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130
P0601-PCM INTERNAL CONTROLLER FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . .132
P0622-GENERATOR FIELD NOT SWITCHING PROPERLY. . . . . . . . . . . . . . . . . . . .133
P0645-A/C CLUTCH RELAY CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135
P0700-EATX CONTROLLER DTC PRESENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137
P1195-1/1 O2 SENSOR SLOW DURING CATALYST MONITOR . . . . . . . . . . . . . . . .138
P1196-2/1 O2 SENSOR SLOW DURING CATALYST MONITOR . . . . . . . . . . . . . . . .138
P1281-ENGINE IS COLD TOO LONG. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140
P1282-FUEL PUMP/SYSTEM RELAY CONTROL CIRCUIT . . . . . . . . . . . . . . . . . . . .141
P1294-TARGET IDLE NOT REACHED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143
P1296-NO 5-VOLTS TO MAP SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145
P1297-NO CHANGE IN MAP FROM START TO RUN. . . . . . . . . . . . . . . . . . . . . . . . .147
P1388-AUTO SHUTDOWN RELAY CONTROL CIRCUIT. . . . . . . . . . . . . . . . . . . . . . .150
P1389-NO ASD RELAY OUTPUT VOLTAGE AT PCM . . . . . . . . . . . . . . . . . . . . . . . . .152
P1391-INTERMITTENT LOSS OF CMP OR CKP. . . . . . . . . . . . . . . . . . . . . . . . . . . . .154
P1398-MIS-FIRE ADAPTIVE NUMERATOR AT LIMIT . . . . . . . . . . . . . . . . . . . . . . . . .158
P1486-EVAP LEAK MONITOR PINCHED HOSE FOUND . . . . . . . . . . . . . . . . . . . . . .160
P1489-HIGH SPEED FAN RELAY CONTROL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . .162
P1490-LOW SPEED FAN RELAY CONTROL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . .164
P1491-COOLING FAN RELAY CONTROL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . .166
P1492-BATTERY TEMPERATURE SENSOR VOLTAGE TOO HIGH . . . . . . . . . . . . .168
P1493-BATTERY TEMPERATURE SENSOR VOLTAGE TOO LOW. . . . . . . . . . . . . .170
P1494-LEAK DETECTION PUMP SW OR MECHANICAL FAULT. . . . . . . . . . . . . . . .172
P1495-LEAK DETECTION PUMP SOLENOID CIRCUIT . . . . . . . . . . . . . . . . . . . . . . .174
P1594-CHARGING SYSTEM VOLTAGE TOO HIGH . . . . . . . . . . . . . . . . . . . . . . . . . .176
P1595-SPEED CONTROL SOLENOID CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . .178
P1683-SPD CTRL PWR RELAY; OR S/C 12V DRIVER CKT . . . . . . . . . . . . . . . . . . .178
iii
TABLE OF CONTENTS - Continued
P1596-SPEED CONTROL SWITCH ALWAYS HIGH . . . . . . . . . . . . . . . . . . . . . . . . . .182
P1597-SPEED CONTROL SWITCH ALWAYS LOW. . . . . . . . . . . . . . . . . . . . . . . . . . .185
P1682-CHARGING SYSTEM VOLTAGE TOO LOW. . . . . . . . . . . . . . . . . . . . . . . . . . .187
P1685 WRONG OR INVALID KEY MSG RECEIVED FROM SKIM. . . . . . . . . . . . . . .190
P1686 NO SKIM BUS MESSAGE RECEIVED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .192
P1687-NO CLUSTER BUS MESSAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .193
P1692-CLUSTER SOFTWARE MISMATCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .194
P1696-PCM FAILURE EEPROM WRITE DENIED . . . . . . . . . . . . . . . . . . . . . . . . . . . .195
P1698-NO BUS MESSAGE FROM TRANS CONTROL MODULE . . . . . . . . . . . . . . .196
P1899-P/N SWITCH PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .198
*BRAKE SWITCH SENSE STATUS DOES NOT CHANGE ON DRBIIIா. . . . . . . . . . .200
*CHECKING A/C SYSTEM OPERATION WITH NO DTCS . . . . . . . . . . . . . . . . . . . . .203
*CHECKING EVAPORATIVE EMISSION OPERATION WITH NO DTCS . . . . . . . . . .206
*CHECKING HARD TO FILL WITH FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .208
*CHECKING THE PCM POWER AND GROUNDS. . . . . . . . . . . . . . . . . . . . . . . . . . . .209
STARTING
*CHECKING FUEL DELIVERY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .210
*CHECKING HARD START (FUEL DELIVERY SYSTEM) . . . . . . . . . . . . . . . . . . . . . .213
*ENGINE CRANKS DOES NOT START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .215
*FUEL PRESSURE LEAK DOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .218
*NO CRANK CONDITION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .219
*NO RESPONSE FROM PCM WITH A NO START CONDITION . . . . . . . . . . . . . . . .222
*START AND STALL CONDITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .225
VERIFICATION TESTS
VERIFICATION TESTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .227
8.0 COMPONENT LOCATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .233
8.1 CONTROL MODULES AND PDC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .233
8.2 DATA LINK CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .233
8.3 SENSORS AND SOLENOIDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .234
8.4 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .237
8.5 SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .238
9.0 CONNECTOR PINOUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .239
A/C COMPRESSOR CLUTCH - BLACK 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .239
A/C HIGH PRESSURE SWITCH (4.0L) - BLACK 2 WAY. . . . . . . . . . . . . . . . . . . . . . .239
A/C LOW PRESSURE SWITCH (2.4L) - GREEN 2 WAY. . . . . . . . . . . . . . . . . . . . . . .239
A/C LOW PRESSURE SWITCH (4.0L) - GREEN 2 WAY. . . . . . . . . . . . . . . . . . . . . . .239
A/C PRESSURE TRANSDUCER (2.4L) - 4 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . .240
BATTERY TEMPERATURE SENSOR - BLACK 2 WAY . . . . . . . . . . . . . . . . . . . . . . . .240
BRAKE LAMP SWITCH - GRAY 6 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .240
BRAKE TRANSMISSION SHIFT INTERLOCK SOLENOID - WHITE 2 WAY . . . . . . .240
CAMSHAFT POSITION SENSOR (2.4L) - BLACK 3 WAY. . . . . . . . . . . . . . . . . . . . . .240
CAMSHAFT POSITION SENSOR (4.0L) - 3 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . .241
CLOCKSPRING C1 - 4 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .241
CLUTCH PEDAL POSITION SWITCH (M/T) - BLACK 2 WAY. . . . . . . . . . . . . . . . . . .241
CRANKSHAFT POSITION SENSOR (2.4L/4.0L A/T) - BLACK 3 WAY . . . . . . . . . . . .241
CRANKSHAFT POSITION SENSOR (4.0L M/T) - 3 WAY . . . . . . . . . . . . . . . . . . . . . .241
DATA LINK CONNECTOR - BLACK 16 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .242
ENGINE COOLANT TEMPERATURE SENSOR - BLACK 2 WAY. . . . . . . . . . . . . . . .242
iv
TABLE OF CONTENTS - Continued
ENGINE OIL PRESSURE SWITCH - BLACK 2 WAY. . . . . . . . . . . . . . . . . . . . . . . . . .242
EVAP/PURGE SOLENOID - BLACK 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .242
FUEL INJECTOR NO. 1 (2.4L) - 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .243
FUEL INJECTOR NO. 1 (4.0L) - 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .243
FUEL INJECTOR NO. 2 (2.4L) - 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .243
FUEL INJECTOR NO. 2 (4.0L) - 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .243
FUEL INJECTOR NO. 3 (2.4L) - 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .243
FUEL INJECTOR NO. 3 (4.0L) - 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .243
FUEL INJECTOR NO. 4 (2.4L) - 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .244
FUEL INJECTOR NO. 4 (4.0L) - 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .244
FUEL INJECTOR NO. 5 (4.0L) - 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .244
FUEL INJECTOR NO. 6 (4.0L) - 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .244
FUEL PUMP MODULE - 4 WAY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .244
FUSES (FUSE/RELAY BLOCK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .246
GENERATOR - 3 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .246
GENERATOR - BLACK 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .247
IDLE AIR CONTROL MOTOR - BLACK 4 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .247
IGNITION COIL PACK (2.4L) - BLACK 3 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .247
IGNITION COIL PACK (4.0L) - BLACK 4 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .247
IGNITION SWITCH - 10 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .248
INTAKE AIR TEMPERATURE SENSOR - GRAY 2 WAY . . . . . . . . . . . . . . . . . . . . . . .248
LEAK DETECTION PUMP - BLACK 4 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .248
MANIFOLD ABSOLUTE PRESSURE SENSOR (2.4L) - BLACK 3 WAY. . . . . . . . . . .248
MANIFOLD ABSOLUTE PRESSURE SENSOR (4.0L) - 3 WAY . . . . . . . . . . . . . . . . .249
OVERDRIVE OFF SWITCH - 4 WAY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .249
OXYGEN SENSOR 1/1 UPSTREAM - 4 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .249
OXYGEN SENSOR 1/2 DOWNSTREAM - BLACK 4 WAY . . . . . . . . . . . . . . . . . . . . .249
OXYGEN SENSOR 2/1 UPSTREAM (EXCEPT EXPORT/JAPAN LOW
EMISSION VEHICLE) - 4 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250
OXYGEN SENSOR 2/2 DOWNSTREAM (EXCEPT EXPORT/JAPAN
LOW EMISSION VEHICLE) - 4 WAY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250
FUSES (PDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .252
A/C COMPRESSOR CLUTCH RELAY (IN PDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .252
AUTOMATIC SHUT DOWN RELAY (IN PDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .252
ENGINE STARTER MOTOR RELAY (IN PDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .253
FUEL PUMP RELAY (IN PDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .253
HIGH SPEED RADIATOR FAN RELAY (2.4L). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .253
LOW SPEED RADIATOR FAN RELAY (2.4L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .253
OXYGEN SENSOR DOWNSTREAM HEATER RELAY . . . . . . . . . . . . . . . . . . . . . . . .253
POWER STEERING PRESSURE SWITCH (2.4L) - BLACK 2 WAY . . . . . . . . . . . . . .254
POWERTRAIN CONTROL MODULE C1 - BLACK 32 WAY. . . . . . . . . . . . . . . . . . . . .254
POWERTRAIN CONTROL MODULE C2 - WHITE 32 WAY. . . . . . . . . . . . . . . . . . . . .255
POWERTRAIN CONTROL MODULE C3 - GRAY 32 WAY. . . . . . . . . . . . . . . . . . . . . .256
SENTRY KEY IMMOBILIZER MODULE - BLACK 6 WAY . . . . . . . . . . . . . . . . . . . . . .256
SPEED CONTROL SERVO - BLACK 4 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .257
THROTTLE POSITION SENSOR (2.4L) - WHITE/BLUE 3 WAY . . . . . . . . . . . . . . . . .257
THROTTLE POSITION SENSOR (4.0L) - 3 WAY. . . . . . . . . . . . . . . . . . . . . . . . . . . . .257
VEHICLE SPEED SENSOR - BLACK 3 WAY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .257
10.0 SCHEMATIC DIAGRAMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .259
11.0 CHARTS AND GRAPHS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .263
v
NOTES
vi
1.0 INTRODUCTION
The procedures contai ned i n thi s manual i ncl ude
speci fi cati ons, i nstructi ons, and graphi cs needed to
di agnose the PCM Powertrai n System. The di ag-
nosti cs i n thi s manual are based on the fai l ure
condi ti on or symptom bei ng present at the ti me of
di agnosi s.
Pl ease fol l ow the recommendati ons bel ow when
choosi ng your di agnosti c path.
1. Fi rst make sure the DRBI I I ௡ i s communi cati ng
wi th the appropri ate modul es; i .e., i f the
DRBI I I ௡ di spl ays a ‘‘No Response’’ condi ti on, you
must di agnose thi s fi rst before proceedi ng.
2. Read DTCs (di agnosti c troubl e codes) wi th the
DRBI I I ௡.
3. I f no DTCs are present, i denti fy the customer
compl ai nt.
4. Once the DTC or customer compl ai nt i s i denti -
fi ed, l ocate the matchi ng test i n the Tabl e of
Contents and begi n to di agnose the symptom.
Al l component l ocati on vi ews are i n Secti on 8.0.
Al l connector pi nouts are i n Secti on 9.0. Al l system
schemati c di agrams are i n Secti on 10.0. Al l charts
and graphs are i n Secti on 11.0.
An * pl aced before the symptom descri pti on i ndi -
cates a customer compl ai nt.
When repai rs are requi red, refer to the appropri -
ate servi ce manual for the proper removal and
repai r procedure.
Di agnosti c procedures change every year. New
di agnosti c systems may be added; current systems
may be enhanced. READ THI S MANUAL BEFORE
TRYI NG TO DI AGNOSE A VEHI CLE DTC. I t i s
recommended that you revi ew the enti re manual to
become fami l i ar wi th al l new and enhanced di ag-
nosti c procedures.
After usi ng thi s book, i f you have any comments
or recommendati ons, pl ease fi l l out the form at the
back of the book and mai l i t back to us.
1. 1 SYSTEM COVERAGE
Thi s di agnosti c procedure manual covers the
2004 Wrangl er (TJ) wi th 2.4L and 4.0L Engi nes.
1. 2 SIX-STEP TROUBLE SHOOTING
PROCEDURE
Di agnosi s of the Powertrai n Control Modul e
(PCM) i s done i n si x basi c steps:
• veri fi cati on of compl ai nt
• veri fi cati on of any rel ated symptoms
• symptom anal ysi s
• probl em i sol ati on
• repai r of i sol ated probl em
• veri fi cati on of proper operati on
2.0 IDENTIFICATION OF
SYSTEM
The Powertrai n Control Modul e (PCM) moni tors
and control s:
• fuel system
• i gni ti on system
• chargi ng system
• speed control system
• automati c transmi ssi on (‘‘42RLE’’ transmi ssi ons
onl y)
3.0 SYSTEM DESCRIPTION AND
FUNCTIONAL OPERATION
3. 1 GENERAL DESCRIPTION
The on-board OBDI I /EUROI I I di agnosti cs i ncor-
porated wi th the PCM control l er are i ntended to
assi st the fi el d techni ci an i n repai ri ng vehi cl e prob-
l ems by the qui ckest means.
3. 2 FUNCTION OPERATION
3. 2. 1 FUEL CONTROL (GAS)
The PCM control s the ai r/fuel rati o of the engi ne
by varyi ng fuel i njector on ti me. Mass ai r fl ow i s
cal cul ated by the speed densi ty method usi ng en-
gi ne speed and mani fol d absol ute pressure (I ATi s a
modi fi er i n Speed Densi ty).
Di fferent fuel cal cul ati on strategi es are used de-
pendi ng on the operati onal state of the engi ne.
Duri ng crank mode, a pri me shot fuel pul se i s
del i vered fol l owed by fuel pul ses determi ned by a
crank ti me strategy. Col d engi ne operati on i s deter-
mi ned vi a an open l oop strategy unti l the O2
sensors have reached operati ng temperature. At
thi s poi nt, the strategy enters a cl osed l oop mode
where fuel requi rements are based upon the state of
the O2 sensors, engi ne speed, MAP, throttl e posi -
ti on, ai r temperature, battery vol tage, and cool ant
temperature.
1
GENERAL INFORMATION
3. 2. 2 ON-BOARD DIAGNOSTICS
The PCM has been programmed to moni tor any
ci rcui t or system that has an effect on vehi cl e
emi ssi ons, or i s used by the PCM to determi ne the
proper functi onal i ty of these systems. Thi s moni tor-
i ng i s cal l ed ‘‘on-board di agnosi s.’’
Certai n cri teri a or, ‘‘armi ng condi ti ons’’, must be
met for a troubl e code to be entered i nto the PCM
memory. The cri teri a may be a range of: engi ne rpm,
engi ne temperature, and/or i nput vol tage to the
PCM. I f a probl em i s detected wi th a moni tored
ci rcui t, and al l of the cri teri a or armi ng condi ti ons
are met, a troubl e code wi l l be stored i n the PCM.
I t i s possi bl e that a troubl e code for a moni tored
ci rcui t may not be entered i nto the PCM memory
even though a mal functi on has occurred. Thi s may
happen because one of the troubl e code cri teri a
(armi ng condi ti ons) has not been met.
The PCM compares i nput si gnal vol tages from
each i nput devi ce wi th speci fi cati ons (the estab-
l i shed hi gh and l ow l i mi ts of the range) that are
preprogrammed for that devi ce. I f the i nput vol tage
i s not wi thi n speci fi cati ons and other troubl e code
cri teri a (armi ng condi ti ons) are met, a troubl e code
wi l l be stored i n the PCM memory.
The On Board Di agnosti cs have evol ved to the
second Generati on of Di agnosti cs referred to as
OBDI I /EUROI I I . These OBDI I /EUROI I I Di agnos-
ti cs control the functi ons necessary to meet the
requi rements of Cal i forni a OBDI I /EUROI I I and
Federal OBD regul ati ons. These requi rements
speci fy the i ncl usi on of a Mal functi on I ndi cator
Li ght (MI L) l ocated on the i nstrument panel for al l
1994 and subsequent model -year passenger cars,
l i ght duty trucks, and medi um-duty vehi cl es. The
purpose of the MI L i s to i nform the vehi cl e operator
i n the event of the mal functi on of any emi ssi on
systems and components whi ch can affect emi ssi ons
and whi ch provi de i nput to, or recei ve output from,
the PCM.
The fol l owi ng tabl e summari zes the vari ous
OBDI I EuroI I I moni tors operati on.
2
GENERAL INFORMATION
OBDII / EUROIII Monitor Operation
Comprehensive Major Monitors Major Monitors
Components Non Fuel Control Fuel Control
Monitor & Non Misfire & Misfire
Run constantly Run Once Per Trip Run constantly
Includes All Engine Hardware Monitors Entire Emission Monitors Entire System
•Sensors, Switches, System
Solenoids, etc.
Most are One Trip Faults –
Usually Turns On
Most are Two Trip Faults –
Turns On
Two Trip Faults –
Turns On
The MIL and Sets DTC After The MIL and Sets DTC After The MIL and Sets DTC After
One Failure Two Consecutive Failures Two Consecutive Failures
Priority 3 Priority 1 or 3 Priority 2 or 4
All Checked For Continuity Done Stop Testing = Yes
Fuel Control Monitor
Open Monitors Fuel Control
Short To Ground Oxygen Sensor Heater System For:
Short To Voltage Oxygen Sensor Response
Fuel System Lean
Fuel System Rich
Inputs Checked For
Requires 3 Consecutive
Rationality Catalytic Converter
Fuel System G ood Trips to
Efficiency Except EWMA
Extinguish The MIL
Outputs Checked For ¼ up to 6 tests per trip
Functionality and a one trip fault (SBEC)
and a two-trip fault on JTEC
EGR System
Misfire Monitor
Evaporative Emission Monitors For Engine Misfire
System at:
(Purge and Leak) 4 X 1000 RPM Counter
(4000 Revs)
Non-LDP (Type B)
or **200 X 3 (600) RPM Counter
LDP (Type A)
Requires 3 Consecutive Requires 3 Consecutive Requires 3 Consecutive
G lobal G ood Trips G lobal G ood Trips G lobal G ood Trips
to Extinguish the MIL* to Extinguish the MIL* To Extinguish the MIL
*40 Warm Up Cycles are required to erase **Type A misfire is a one
DTCs after the MIL has been extinguished.
trip failure on pre-1999,
2 Trip failure on 1999 and
later. The MIL will illuminate
at the first or second failure,
based on MY.
3
GENERAL INFORMATION
OBDII/EUROIII MONITOR RUN PROCESS, JTEC
The fol l owi ng procedure has been establ i shed to
assi st Chrysl er Deal er Techni ci ans i n the fi el d wi th
enabl i ng and runni ng OBD I I /EURO I I I Moni tors.
The order l i sted i n the fol l owi ng procedure i s i n-
tended to al l ow the techni ci an to effecti vel y com-
pl ete each moni tor and to set the CARB Readi ness
Status i n the l east ti me possi bl e.
NOTE:
A. Once the monitor run process has begun,
do not turn off the ignition. By turning the
ignition key off, monitor enabling conditions
will be lost.
B. By performing a Battery Disconnect, or
Selecting Erase DTCs, the CARB Readiness
and all additional OBD information will be
cleared.
Monitor Preliminary Checks:
1. Pl ug a DRB I I I ௡ i nto the vehi cl e’s DLC.
2. Turn the i gni ti on, KEY ON - ENGI NE OFF.
Watch for MI L l amp i l l umi nati on duri ng the
bul b check. MI L l amp must have i l l umi nated, i f
not, repai r MI L l amp.
3. On the DRB I I I ௡ Sel ect #1 DRB I I I Standal one.
4. Sel ect #1 1998-2002 Di agnosti cs
5. Sel ect #1 Engi ne.
6. Sel ect #2 DTCs and Rel ated Functi ons
7. Sel ect #1 Read DTCs
* Veri fy that No Emi ssi ons Rel ated DTCs are
Present.
* I f an Emi ssi ons DTC i s Present, the
OBD I I /EUROI I I Moni tors may not run and the
CARB Readi ness wi l l not update.
*The Emi ssi ons rel ated DTC, wi l l need to be
repai red, then cl eared. By cl eari ng DTCs, the OBD
Moni tors wi l l need to be run and compl eted to set
the CARB Readi ness Status.
8. Return to Engi ne Sel ect Functi on Menu and
Sel ect #9, OBD I I /EUROI I I Moni tors.
9. Sel ect #3 CARB Readi ness Status.
Do al l the CARB Readi ness Status Locati ons read
YES?
*YES, then al l moni tors have been compl eted and
thi s vehi cl e i s ready to be I /M or Emi ssi on Tested.
*NO, then the fol l owi ng procedure needs to be
fol l owed to run/compl ete al l avai l abl e moni tors.
NOTE:
A. Only the monitors, which are not YES in
the CARB Readiness Status, need to be
completed.
B. Specific criteria need to be met for each
monitor. Each monitor has a Pre-Test screen
to assist in running the monitor. For
additional information, refer to the Chrysler
Corporation Technical Training Workbook
titled On Board Diagnostics, part number
81-699-97094.
The most effi ci ent order to run the moni tors has
been outl i ned bel ow, i ncl udi ng suggesti ons to ai d
the process. The fi rst two moni tors have very si m-
i l ar enabl e cri teri a; i t i s possi bl e that the Evapora-
ti ve Leak Detecti on Moni tor wi l l run duri ng the O2
Sensor Heater Moni tor.
1. O2 Sensor Heater Monitor
Thi s moni tor requi res a col d start, usual l y an
overni ght soak or parked for at l east 8 hours
wi thout the engi ne runni ng. The engi ne cool ant
temperature must be wi thi n 10 degrees of
ambi ent/battery temperature, and the sensed
Ambi ent (outsi de) Temperature must be be-
tween approxi matel y 0° F and 100° F. For the
moni tor run condi ti ons, sel ect the O2S HEATER
MON PRE-TEST i n the DRB I I I ௡, OBD I I /
EUROI I I Moni tors Menu
2. EvaporativeLeak Detection Monitor (If the
vehicle is equipped with an LDP system)
Thi s moni tor requi res a col d start, usual l y an
overni ght soak or parked for at l east 8 hours
wi thout the engi ne runni ng. The engi ne cool ant
temperature must be wi thi n 10 degrees of
ambi ent/battery temperature, and the sensed
Ambi ent (outsi de) Temperature must be be-
tween approxi matel y 40° F and 90° F. For the
moni tor run condi ti ons sel ect the EVAP LDP
MON PRE-TEST i n the DRB I I I ௡,
OBD I I /EUROI I I Moni tors Menu.
3. Catalyst Monitor
The vehi cl e wi l l need to be dri ven at hi ghway
speed for a few mi nutes. I f the vehi cl e i s
equi pped wi th a manual transmi ssi on, usi ng 4th
gear may assi st i n meeti ng the moni tor runni ng
cri teri a. For the moni tor run condi ti ons, sel ect
the EWMA CAT MON PRE-TEST i n the
DRB I I I ௡, OBD I I /EUROI I I Moni tors Menu.
4
GENERAL INFORMATION
4. O2 Sensor Monitor
The vehi cl e wi l l need to be dri ven for a peri od of
ti me and brought to a stop for a short peri od of
ti me wi th the Automati c Transmi ssi on l eft i n
Dri ve. The O2S Moni tor wi l l not run i n Park or
Neutral on an Automati c Transmi ssi on equi pped
vehi cl e. For the moni tor run condi ti ons, sel ect
the O2S MON PRE-TEST i n the DRB I I I ௡,
OBD I I /EUROI I I Moni tors Menu.
5. Purge Monitor
Al l the Purge Free (PF) cel l s must update on the
ADAPTI VE MEMORY screen before the Purge
Fl ow Moni tor wi l l run. For the moni tor run
condi ti ons, sel ect the PURGE FLOW MON PRE-
TEST i n the DRB I I I ௡, OBD I I /EUROI I I Moni -
tors Menu. The Purge Fl ow Moni tor wi l l not run
i n Park or Neutral on an Automati c Transmi s-
si on equi pped vehi cl e. The Purge Fl ow Moni tor
wi l l attempt to run every other throttl e cl osure.
I f al l of the parameters are met and i t sti l l does
not run, wi th your foot fi rml y on the Servi ce
Brake, sl i ghtl y (1/4) open the Throttl e and
qui ckl y cl ose the Throttl e. Thi s wi l l al l ow the
Purge Free update to happen, and then the
Purge Fl ow Moni tor wi l l Run.
3. 2. 3 OTHER CONTROLS
CHARGING SYSTEM
The chargi ng system i s turned on when the
engi ne i s started and ASD rel ay energi zed. When
the ASD rel ay i s on, ASD output vol tage i s suppl i ed
to the ASD sense ci rcui t at the PCM. Thi s vol tage i s
connected i n some cases, through the PCM and
suppl i ed to one of the generator fi el d termi nal s
(Generator Source +). Al l others, the Generator fi el d
i s connected di rectl y to the ASD output vol tage. The
amount of current produced by the generator i s
control l ed by the El ectroni c Vol tage Regul ator
(EVR) ci rcui try, i n the PCM. Battery temperature i s
determi ned ei ther by I AT, Ambi ent or Battery tem-
perature sensor. Thi s temperature al ong wi th
sensed l i ne vol tage i s used by the PCM to vary
battery chargi ng. Thi s i s accompl i shed by cycl i ng
the path to ground to the other generator fi el d
termi nal (Generator fi el d dri ver).
SPEED CONTROL
The PCM control s vehi cl e speed by operati on of
the speed control servo vacuum and vent sol enoi ds.
Energi zi ng the vacuum sol enoi d appl i es vacuum to
the servo to i ncrease throttl e posi ti on. Operati on of
the vent sol enoi d sl owl y rel eases the vacuum al l ow-
i ng throttl e posi ti on to decrease. A speci al dump
sol enoi d al l ows i mmedi ate rel ease of throttl e posi -
ti on caused by braki ng, crui se control turn off,
shi fti ng i nto neutral , excessi ve RPM (ti res spi n-
ni ng) or i gni ti on key off.
FUEL VAPOR RECOVERY SYSTEM (DUTY
CYCLE PURGE CONTROL) GAS ENGINE
Duty Cycl e Purge i s a system that feeds fuel
gases from the purge cani ster and gasol i ne tank
i nto the throttl e body for mi xi ng wi th i ncomi ng ai r.
Meteri ng of the gases i s performed by duty cycl i ng
the purge sol enoi d by the PCM.
The system i s di sabl ed duri ng wi de-open throttl e
condi ti ons and whi l e the engi ne i s bel ow a speci fi ed
cool ant temperature. When engi ne temperature be-
comes greater than a cal i brated parameter, duty
cycl e purge i s del ayed for a cal i brated ti me. Once
purge del ay i s over, purge wi l l be ramped i n to
soften the effect of dumpi ng addi ti onal fuel i nto the
engi ne.
The PCM provi des a modul ated 5 Hz si gnal (at
cl osed throttl e) or 10 Hz si gnal (at open throttl e) to
control thi s system. Modul ati on of the si gnal i s
based upon a cal cul ated ai r fl ow (based upon known
fuel fl ow through the i njector at a gi ven pul se wi dth
and RPM) and i s adjusted to compensate for
changes i n fl ow due to varyi ng engi ne vacuum.
LEAK DETECTION PUMP
LEAK DETECTION PUMP OPERATION
The evaporati ve emi ssi on system i s desi gned to
prevent the escape of fuel vapors from the fuel
system. Leaks i n the system, even smal l ones, can
al l ow fuel vapors to escape i nto the atmosphere.
Government regul ati ons requi re onboard testi ng to
make sure that the evaporati ve (EVAP) system i s
functi oni ng properl y. The l eak detecti on system test
for EVAP system l eaks and bl ockage. I t al so per-
forms sel f-di agnosti cs. Duri ng sel f-di agnosti cs, the
Powertrai n Control Modul e (PCM) fi rst checks the
Leak Detecti on Pump (LDP) for el ectri cal and me-
chani cal faul ts. I f the fi rst checks pass, the PCM
then uses the LDP to seal the vent val ve and pump
ai r i nto the system to pressuri ze i t. I f a l eak i s
present, the PCM wi l l conti nue pumpi ng the LDP to
repl ace the ai r that l eaks out. The PCM determi nes
the si ze of the l eak based on how fast/l ong i t must
pump the LDP as i t tri es to mai ntai n pressure i n
the system.
EVAP LEAK DETECTION SYSTEM COMPONENTS
(FIGURE 1)
Service Port: Used wi th speci al tool s l i ke the
Mi l l er Evaporati ve Emi ssi ons Leak Detector
(EELD) to test for l eaks i n the system.
EVAP Purge Solenoid: The PCM uses the EVAP
purge sol enoi d to control purgi ng of excess fuel
5
GENERAL INFORMATION
vapors stored i n the EVAP cani ster. I t remai ns
cl osed duri ng l eak testi ng to prevent l oss of pres-
sure.
EVAP Canister: The EVAP cani ster stores fuel
vapors from the fuel tank for purgi ng.
EVAP Purge Orifice: Li mi ts purge vol ume.
EVAP SystemAir Filter: Provi des ai r to the LDP
for pressuri zi ng the system. I t fi l ters out di rt whi l e
al l owi ng a vent to atmosphere for the EVAP system.
LEAK DETECTION PUMP (LDP) COMPONENTS
The mai n purpose of the LDP i s to pressuri ze the
fuel system for l eak checki ng. I t cl oses the EVAP
system vent to atmospheri c pressure so the system
can be pressuri zed for l eak testi ng. The di aphragm
i s powered by engi ne vacuum. I t pumps ai r i nto the
EVAP system to devel op a pressure of about 7.5Љ HO
(1/4) psi . A reed swi tch i n the LDP al l ows the PCM
to moni tor the posi ti on of the LDP di aphragm. The
PCM uses the reed swi tch i nput to moni tor how fast
the LDP i s pumpi ng ai r i nto the EVAP system. Thi s
al l ows detecti on of l eaks and bl ockage.
The LDP assembl y consi sts of several parts (Fi g-
ure 2). The sol enoi d i s control l ed by the PCM, and i t
connects the upper pump cavi ty to ei ther engi ne
vacuum or atmospheri c pressure. A vent val ve
cl oses the EVAP system to atmosphere, seal i ng the
system duri ng l eak testi ng. The pump secti on of the
LDP consi sts of a di aphragm that moves up and
down to bri ng ai r i n through the ai r fi l ter and i nl et
check val ve, and pump i t out through an outl et
check val ve i nto the EVAP system.
The di aphragm i s pul l ed up by engi ne vacuum,
and pushed down by spri ng pressure, as the LDP
sol enoi d turns on and off. The LDP al so has a
magneti c reed swi tch to si gnal di aphragm posi ti on
to the PCM. When the di aphragm i s down, the
swi tch i s cl osed, whi ch sends a 12 V (system vol t-
age) si gnal to the PCM. When the di aphragm i s up,
the swi tch i s open, and there i s no vol tage sent to
the PCM. Thi s al l ows the PCM to moni tor LDP
pumpi ng acti on as i t turns the LDP sol enoi d on and
off.
LDP AT REST (NOT POWERED)
When the LDP i s at rest (no el ectri cal /vacuum)
the di aphragm i s al l owed to drop down i f the
i nternal (EVAP system) pressure i s not greater than
the return spri ng. The LDP sol enoi d bl ocks the
engi ne vacuum port and opens the atmospheri c
pressure port connected through the EVAP system
ai r fi l ter. The vent val ve i s hel d open by the di a-
phragm. Thi s al l ows the cani ster to see atmospheri c
pressure (Fi gure 3).
DIAPHRAGM UPWARD MOVEMENT
When the PCM energi zes the LDP sol enoi d, the
sol enoi d bl ocks the atmospheri c port l eadi ng
through the EVAP ai r fi l ter and at the same ti me
opens the engi ne vacuum port to the pump cavi ty
above the di aphragm. The di aphragm moves up-
ward when vacuum above the di aphragm exceeds
spri ng force. Thi s upward movement cl oses the vent
val ve. I t al so causes l ow pressure bel ow the di a-
6
GENERAL INFORMATION
phragm, unseati ng the i nl et check val ve and al l ow-
i ng ai r i n from the EVAP ai r fi l ter. When the
di aphragm compl etes i ts upward movement, the
LDP reed swi tch turns from cl osed to open (Fi gure
4).
DIAPHRAGM DOWNWARD MOVEMENT
Based on reed swi tch i nput, the PCM de-
energi zes the LDP sol enoi d, causi ng i t to bl ock the
vacuum port, and open the atmospheri c port. Thi s
connects the upper pump cavi ty to atmosphere
through the EVAP ai r fi l ter. The spri ng i s now abl e
to push the di aphragm down. The downward move-
ment of the di aphragm cl oses the i nl et check val ve
and opens the outl et check val ve pumpi ng ai r i nto
the evaporati ve system. The LDP reed swi tch turns
from open to cl osed, al l owi ng the PCM to moni tor
LDP pumpi ng (di aphragm up/down) acti vi ty (Fi g-
ure 5. Duri ng the pumpi ng mode, the di aphragm
wi l l not move down far enough to open the vent
val ve.
The pumpi ng cycl e i s repeated as the sol enoi d i s
turned on and off. When the evaporati ve system
begi ns to pressuri ze, the pressure on the bottom of
the di aphragm wi l l begi n to oppose the spri ng
pressure, sl owi ng the pumpi ng acti on. The PCM
watches the ti me from when the sol enoi d i s de-
energi zed, unti l the di aphragm drops down far
enough for the reed swi tch to change from opened to
cl osed. I f the reed swi tch changes too qui ckl y, a l eak
may be i ndi cated. The l onger i t takes the reed
swi tch to change state, the ti ghter the evaporati ve
system i s seal ed. I f the system pressuri zes too
qui ckl y, a restri cti on somwehere i n the EVAP sys-
tem may be i ndi cated.
PUMPING ACTION
Duri ng porti ons of thi s test, the PCM uses the
reed swi tch to moni tor di aphragm movement. The
sol enoi d i s onl y turned on by the PCM after the reed
swi tch changes from open to cl osed, i ndi cati ng that
the di aphragm has moved down. At other ti mes
duri ng the test, the PCM wi l l rapi dl y cycl e the LDP
sol enoi d on and off to qui ckl y pressuri ze the system.
Duri ng rapi d cycl i ng, the di aphragm wi l l not move
enough to change the reed swi tch state. I n the state
of rapi d cycl i ng, the PCM wi l l use a fi xed ti me
i nterval to cycl e the sol enoi d.
I f the system does not pass the EVAP Leak
Detecti on Test, the fol l owi ng DTCs may be set:
• P0442 – EVAP LEAK MONI TOR 0.040Љ LEAK
DETECTED
• P0455 – EVAP LEAK MONI TOR LARGE LEAK
DETECTED
• P0456 – EVAP LEAK MONI TOR 0.020Љ LEAK
DETECTED
• P1486 – EVAP LEAK MON PI NCHED HOSE
FOUND
• P1494 – LEAK DETECTI ON PUMP SW OR
MECH FAULT
• P1495 – LEAK DETECTI ON PUMP SOLENOI D
CI RCUI T
ENABLING CONDITIONS TO RUN EVAP LEAK
DETECTION TEST
1. Col d start: wi th ambi ent temperature (obtai ned
from model i ng the i nl et ai r temperature sensor
on passenger vehi cl es and the battery tempera-
ture sensor on Jeep & truck vehi cl es) between
4°C (40°F) and 32°C (90°F) for 0.040 l eak. Be-
tween 4°C (40°F) and 29°C (85°F) for 0.020 l eak.
2. Engi ne cool ant temperature wi thi n: -12° to -8°C
(10° to 18°F) of battery/ambi ent.
3. Battery vol tage between 10 and 15 vol ts.
7
GENERAL INFORMATION
NOTE: If battery voltage drops below 10 volts
for more than 5 seconds during engine
cranking, the EVAP leak detection test will
not run.
4. Low fuel warni ng l i ght off (fuel l evel must be
between 15% and 85%).
5. MAP sensor readi ng 22 i n Hg or above (Thi s i s
the mani fol d absol ute pressure, not vacuum).
6. No engi ne stal l duri ng test.
NOTE: The following values are approximate
and vehicle specific. Use the values seen in
pre test/monitor test screen on the DRBIIIா.
See TSB 25-002-98 for more detail.
A DTC wi l l not set i f a one-tri p faul t i s set or i f the
MI L i s i l l umi nated for any of the fol l owi ng:
• Purge Sol enoi d
• Al l engi ne Control l er Sel f Test Faul ts
• Al l Cam and/or Crank Sensor Faul ts
• MAP Sensor Faul ts
• Ambi ent/Battery Temperature Sensor El ectri cal
Faul ts
• Al l Cool ant Sensor Faul ts
• Al l TPS Faul ts
• LDP Pressure Swi tch Faul ts
• EGR Sol enoi d El ectri cal Faul ts
• Al l I njector Faul ts
• Baro Out Of Range
• Vehi cl e Speed Faul ts
• LDP Sol enoi d Ci rcui t
FIGURE 6 SECTION 1
When the i gni ti on key i s turned to “ON”, the LDP
di aphragm shoul d be i n the down posi ti on and the
LDP reed swi tch shoul d be cl osed. I f the EVAP
system has resi dual pressure, the LDP di aphragm
may be up. Thi s coul d resul t i n the LDP reed swi tch
bei ng open when the key i s turned to “ON” and a
P1494 faul t coul d be set because the PCM i s expect-
i ng the reed swi tch to be cl osed.
After the key i s turned “ON”, the PCM i mmedi -
atel y tests the LDP sol enoi d ci rcui t for el ectri cal
faul ts. I f a faul t i s detected, DTC P1495 wi l l set, the
MI L wi l l i l l umi nate, and the remai ni ng EVAP Leak
Detecti on Test i s cancel l ed.
NOTE: If battery temperature is not within
range, or if the engine coolant temperature is
not within a specified range of the battery
temperature, the PCM will not run tests for
DTC P1494, P1486, P0442, P0455 and P04441.
These temperature calibrations may be
different between models.
FIGURE 6 SECTION 2
I f DTCP1495 i s not set, the PCM wi l l check for
DTC P1494. I f the LDP reed swi tch was cl osed
when the key was turned to “ON”, the PCM ener-
gi zes the LDP sol enoi d for up to 8 seconds and
moni tors the LDP swi tch. As the LDP di aphragm i s
pul l ed up by engi ne vacuum, the LDP reed swi tch
shoul d change from cl osed to open. I f i t does not, the
PCM sets a temporary faul t (P1494) i n memory, and
wai ts unti l the next ti me the Enabl i ng Condi ti ons
are met to run the test agai n. I f thi s i s agai n
detected, P1494 i s stored and the MI L i s i l l umi -
nated. I f the probl em i s not detected duri ng the next
enabl i ng cycl e, the temporary faul t wi l l be cl eared.
However, i f the PCM detects the reed swi tch open
when the key i s turned to “ON”, the PCM must
determi ne i f thi s condi ti on i s due to resi dual pres-
sure i n the EVAP system, or an actual faul t. The
PCM stores i nformati on i n memory on EVAP sys-
tem purgi ng from previ ous engi ne run or dri ve
cycl es.
I f l i ttl e or no purgi ng took pl ace, resi dual pres-
sure coul d be hol di ng the LDP di aphragm up,
causi ng the LDP swi tch to be open. Si nce thi s i s not
a mal functi on, the PCM cancel s the EVAP Leak
Detecti on Test wi thout setti ng the temporary faul t.
I f there was suffi ci ent purgi ng duri ng the previ -
ous sycl e to el i mi nate EVAP system pressure, the
PCM judges that thi s i s a mal functi on and sets a
temporary faul t i n memory. The next ti me that the
Enabl i ng Condi ti ons are met, the test wi l l run
agai n. I f the faul t i s agai n detected, the MI L wi l l
i l l umi nate and DTC 1494 wi l l be stored. I f the faul t
i s not detected, the temporary faul t wi l l be cl eared.
FIGURE 6 SECTION 3
I f no faul t has been detected so far, the PCM
begi ns testi ng for possi bl e bl ockage i n the EVAP
system between the LDP and the fuel tank. Thi s i s
done by moni tori ng the ti me requi red for the LDP to
8
GENERAL INFORMATION
pump ai r i nto the EVAP system duri ng two to three
pump cycl es. I f no bl ockage i s present, the LDP
di aphragm i s abl e to qui ckl y pump ai r out of the
LDP each ti me the PCM turns off the LDP sol enoi d.
I f a bl ockage i s present, the PCM detects that the
LDP takes l onger to compl ete each pump cycl e. I f
the pump cycl es take l onger than expected (approx-
i matel y 6 to 10 seconds) the PCM wi l l suspect a
bl ockage. On the next dri ve when Enabl i ng Condi -
ti ons are met, the test wi l l run agai n. I f bl ockage i s
agai n detected, P1486 i s stored, and the MI L i s
i l l umi nated.
FIGURE 6 SECTION 4
After the LDP bl ockage tests are compl eted, the
PCM then tests for EVAP system l eakage. Fi rst, the
PCM commands the LDP to rapi dl y pump for 20 to
50 seconds (dependi ng on fuel l evel ) to bui l d pres-
sure i n the EVAP system. Thi s eval uates the system
to see i f i t can be suffi ci entl y pressuri zed. Thi s
eval uati on (rapi d pump cycl i ng) may occur several
ti mes pri or to l eak checki ng. The LDP reed swi tch
does not cl ose and open duri ng rapi d pumpi ng
because the di aphragm does not travel through i ts
ful l range duri ng thi s part of the test.
FIGURE 6 SECTION 5
Next, the PCM performs one or more tests cycl es
by moni tori ng the ti me requi red for the LDP reed
swi tch to cl ose (di aphragm to drop) after the LDP
sol enoi d i s turned off.
I f the swi tch does not cl ose, or cl oses after a l ong
del ay, i t means that the system does not have any
si gni fi cant l eakage and the EVAP Leak Detecti on
Test i s compl ete.
However, i f the LDP reed swi tch cl oses qui ckl y,
there may be a l eak or the fuel l evel may be l ow
enough that the LDP must pump more to fi ni sh
pressuri zi ng the EVAP system. I n thi s case, the
PCM wi l l rapi dl y pump the LDP agai n to bui l d
pressure i n the EVAP system, and fol l ow that by
moni tori ng the ti me needed for several LDP test
cycl es. Thi s process of rapi d pumpi ng fol l owed by
several LDP test cycl es may repeat several ti mes
before the PCM judges that a l eak i s present.
When l eaks are present, the LDP test cycl e ti me
wi l l be i nversel y proporti onal to the si ze of the l eak.
The l arger the l eak, the shorter the test cycl e ti me.
The smal l er the l eak, the l onger the test cycl e ti me.
DTC’s may be set when a l eak as smal l as 0.5 mm
(0.020Љ) di ameter i s present.
I f the system detects a l eak, a temporary faul t
wi l l be stored i n PCM memory. The ti me i t takes to
detect a .020, .040, or l arger l eak i s based on
cal i brati ons that vary from model to model . The
i mportant poi nt to remember i s i f a l eak i s agai n
detected on the next EVAP Leak Detecti on Test, the
MI L wi l l i l l umi nate and a DTC wi l l be stored based
on the si ze of l eak detected. I f no l eak i s detected
duri ng the next test, the temporary faul t wi l l be
cl eared.
DIAGNOSTIC TIPS
Duri ng di agnosi s, you can compare the LDP so-
l enoi d acti vi ty wi th the moni tor sequence i n Fi gure
6. I f the PCM detects a probl em that coul d set a
DTC, the testi ng i s hal ted and LDP sol enoi d acti v-
i ty wi l l stop. As each secti on of the test begi ns, i t
i ndi cates that the previ ous secti on passed success-
ful l y. By watchi ng to see whi ch tests compl ete, you
can see i f any condi ti ons are present that the PCM
consi ders abnormal .
For exampl e, i f the LDP sol enoi d i s energi zed for
the test cycl es to test for bl ockage (P1486), i t means
that the LDP has al ready passed i ts test for P1494.
Then, i f the PCM detects a possi bl e bl ockage, i t wi l l
set a temporary faul t wi thout turni ng on the MI L
and conti nue the l eak porti on of the test. However,
the PCM wi l l assume that the system i s al ready
pressuri zed and ski p the rapi d pump cycl es.
Al ways di agnose l eaks, i f possi bl e, before di scon-
necti ng connecti ons. Di sconnecti ng connecti ons
may mask a l eak condi ti on.
Keep i n mi nd that i f the purge sol enoi d seat i s
l eaki ng, i t coul d go undetected si nce the l eak woul d
end up i n the i ntake mani fol d. Di sconnect the purge
sol enoi d at the mani fol d when l eak checki ng. I n
addi ti on, a pi nched hose faul t (P1486) coul d set i f
the purge sol enoi d does not purge the fuel system
properl y (bl ocked seat). The purge sol enoi d must
vent the fuel system pri or to the LDP system test. I f
the purge sol enoi d cannot properl y vent the system
the LDP cannot properl y compl ete the test for
P1486 and thi s faul t can be set due to pressure
bei ng i n the EVAP system duri ng the test sequence.
Mul ti pl e actuati on’s of the DRBI I I ௡ Leak Detec-
ti on Pump (LDP) Moni tor Test can hi de a 0.020 l eak
because of excess vapor generati on. Addi ti onal l y,
any source for addi ti onal vapor generati on can hi de
a smal l l eak i n the EVAP system. Excess vapor
generati on can del ay the fal l of the LDP di aphragm
thus hi di ng the smal l l eak. An exampl e of thi s
condi ti on coul d be bri ngi ng a col d vehi cl e i nto a
warm shop for testi ng for hi gh ambi ent tempera-
tures.
Ful l y pl ugged and parti al l y pl ugged underhood
vacuum l i nes have been known to set MI L condi -
ti ons. P1494 and P0456 can be set for thi s reason.
Al ways, thoroughl y, check pl umbi ng for pi nches or
bl ockage before condemni ng components.
TEST EQUIPMENT
The Evaporati ve Emi ssi on Leak Detector (EELD)
Mi l l er Speci al Tool 8404 i s capabl e of vi sual l y de-
tecti ng l eaks i n the evaporati ve system and wi l l
take the pl ace of the Evap System Di agnosti c Ki t.
9
GENERAL INFORMATION
The EELD uti l i zes shop ai r and a smoke generator
to vi sual l y detect l eaks down to 0.020 or smal l er.
The food grade oi l used to make the smoke i ncl udes
an UV trace dye that wi l l l eave tel l tal e si gns of the
l eak under a bl ack l i ght. Thi s i s hel pful when
components have to be removed to determi ne the
exact l eak l ocati on. For detai l ed test i nstructi ons,
fol l ow the operators manual packaged wi th the
EELD.
IMPORTANT
Be sure that the PCM has the l atest software
update. Reprogram as i ndi cated by any appl i cabl e
Techni cal Servi ce Bul l eti n. After LDP repai rs are
compl eted, veri fy the repai r by runni ng the
DRBI I I ௡ Leak Detecti on Pump (LDP) Moni tor Test
as descri bed i n Techni cal Servi ce Bul l eti n 18-12-99.
3. 2. 4 NON-MONITORED CIRCUITS
The PCM does not moni tor the fol l owi ng ci rcui ts,
systems, and condi ti ons even though they coul d
have mal functi ons that resul t i n dri veabi l i ty prob-
l ems. A di agnosti c code may not be di spl ayed for the
fol l owi ng condi ti ons. However, probl ems wi th these
systems may cause a di agnosti c code to be di spl ayed
for other systems. For exampl e, a fuel pressure
probl em wi l l not regi ster a di agnosti c code di rectl y,
but coul d cause a ri ch or l ean condi ti on. Thi s coul d
cause an oxygen sensor, fuel system, or mi sfi re
moni tor troubl e code to be stored i n the PCM.
Engine Timing − The PCM cannot detect an
i ncorrectl y i ndexed ti mi ng chai n, camshaft
sprocket, or crankshaft sprocket. The PCM al so
cannot detect an i ncorrectl y i ndexed di stri butor or
Cam Sensor.(*)
Fuel Pressure − Fuel pressure i s control l ed by
the fuel pressure regul ator. The PCM cannot detect
a cl ogged fuel pump i nl et fi l ter, cl ogged i n-l i ne fi l ter,
or a pi nched fuel suppl y.(*)
Fuel Injectors − The PCM cannot detect a
cl ogged fuel i njector, a sti cki ng pi ntl e, or that an
i ncorrect i njector i s i nstal l ed.(*)
Fuel Requirements− Poor qual i ty gasol i ne can
cause probl ems such as hard starti ng, stal l i ng, and
stumbl e. Use of methanol -gasol i ne bl ends may re-
sul t i n starti ng and dri veabi l i ty probl ems. (See
i ndi vi dual symptoms and thei r defi ni ti ons i n Sec-
ti on 6.0 Gl ossary of Terms).
PCM Grounds − The PCM cannot detect a poor
system ground. However, a di agnosti c troubl e code
may be stored i n the PCM as a resul t of thi s
condi ti on.
Throttle Body Air Flow − The PCM cannot
detect a cl ogged or restri cted ai r cl eaner i nl et or
fi l ter el ement.(*)
Exhaust System − The PCM cannot detect a
pl ugged, restri cted, or l eaki ng exhaust system.(*)
Cylinder Compression − The PCM cannot de-
tect uneven, l ow, or hi gh engi ne cyl i nder compres-
si on.(*)
Excessive Oil Consumption − Al though the
PCM moni tors the exhaust oxygen content through
the oxygen sensor when the system i s i n a cl osed
l oop, i t cannot determi ne excessi ve oi l consumpti on.
NOTE: Any of these conditions could result
in a rich or lean condition causing an oxygen
sensor trouble code to be stored in the PCM,
or the vehicle may exhibit one or moer of the
driveability symptoms listed in the Table of
Contents.
3. 2. 5 SKIS OVERVIEW
The Sentry Key I mmobi l i zer System (SKI S) i s an
i mmobi l i zer system desi gned to prevent unautho-
ri zed vehi cl e operati on. The system consi sts of Sen-
try Key I mmobi l i zer Modul e (SKI M) sends a PCI
Bus message to the engi ne control l er i ndi cati ng
i gni ti on key status. Upon recei vi ng thi s message
the PCM wi l l termi nate engi ne operati on or al l ow
the engi ne to conti nue to operate.
3. 2. 6 SKIM ON-BOARD DIAGNOSTICS
The SKI M has been programmed to transmi t and
moni tor many di fferent coded messages as wel l as
PCI Bus messages. Thi s moni tori ng i s cal l ed “On-
Board Di agnosi s”.
Certai n cri teri a must be met for a di agnosti c
troubl e code to be entered i nto the SKI M memory.
The cri teri a may be a range of I nput vol tage, PCI
Bus message, or coded messages to the SKI M. I f al l
of the cri teri a for moni tori ng a ci rcui t or functi on
are met and a faul t i s sensed, a di agnosti c troubl e
code wi l l be stored i n the SKI M memory.
3. 2. 7 SKIS OPERATION
When i gni ti on power i s suppl i ed to the SKI M, the
SKI M performs an i nternal sel f-test. After the sel f-
test i s compl eted, the SKI M energi zes the antenna
(thi s acti vates the transponder chi p) and sends a
chal l enge to the transponder chi p. The transponder
chi p responds to the chal l enge by generati ng an
encrypted response message usi ng the fol l owi ng:
Secret Key - Thi s i s an el ectroni cal l y stored
val ue (i denti fi cati on number) that i s uni que to each
SKI S. The secret key i s stored i n the SKI M, PCM,
and al l i gni ti on key transponders.
Challenge - Thi s i s a random number that i s
generated by the SKI M at each i gni ti on key cycl e.
The secret key and chal l enge are the two vari abl es
used i n the al gori thm that produces the crypto
al gori thm to recei ve, decode and respond to the
message sent by the SKI M. After respondi ng to the
coded message, the transponder sends a transpon-
10
GENERAL INFORMATION
der I D message to the SKI M. The SKI M compares
the transponder I D to the avai l abl e val i d i gni ti on
key codes i n the SKI M memory (8 key maxi mum).
After val i dati ng the key, the SKI M sends a PCI Bus
message cal l ed a “Seed Request” to the engi ne
control l er then wai ts for a PCM response. I f the
PCM does not respond, the SKI M wi l l send the seed
request agai n. After three fai l ed attempts, the
SKI M wi l l stop sendi ng the seed request and store
a troubl e code. I f the PCM sends a seed response,
the SKI M sends a val i d/i nval i d key message to the
PCM. Thi s i s an encrypted message that i s gener-
ated usi ng the fol l owi ng:
VIN - Vehi cl e I denti fi cati on Number
Seed- Thi s i s a random number that i s generated
by the PCM at each i gni ti on key cycl e.
The VI N and seed are the two vari abl es used i n
the rol l i ng code al gori thm that encrypts the “val i d/
i nval i d key” message. The PCM uses the rol l i ng
code al gori thm to recei ve, decode and respond to the
val i d/i nval i d key message sent by the SKI M. After
sendi ng the val i d/i nval i d key message the SKI M
wai ts 3.5 seconds for a PCM status message from
the PCM. I f the PCM does not respond wi th a val i d
key message to the SKI M, a faul t i s detected and a
troubl e code i s stored. The SKI S i ncorporates a
warni ng l amp l ocated i n the i nstrument cl uster.
The l amp recei ves power and ground from the
i nstrument cl uster. The l amp i s actuated when the
SKI M sends a PCI Bus message to the i nstrument
cl uster requesti ng the l amp on. The SKI M wi l l
request warni ng l amp i l l umi nati on for:
– bul b checks at i gni ti on on
– to al ert the vehi cl e operator to a SKI S mal -
functi on
– customer key programmi ng mode
For al l faul ts except transponder faul ts and VI N
mi smatch, the l amp remai ns on steady. I n the event
of a transponder faul t the l i ght fl ashes at a rate of
1 Hz (once per second). I f a faul t i s present the l amp
wi l l remai n on or fl ashi ng for the compl ete i gni ti on
cycl e. I f a faul t i s stored i n SKI M memory whi ch
prevents the system from operati ng properl y, the
PCM wi l l al l ow the engi ne to start and run (for two
seconds) up to si x ti mes. After the si xth attempt the
PCM wi l l not al l ow engi ne to start.
3. 2. 8 PROGRAMMING THE POWERTRAIN
CONTROL MODULE
Important Notice: Before repl aci ng the PCM
for a fai l ed dri ver, control ci rcui t or ground ci rcui t,
be sure to check the rel ated component/ci rcui t i n-
tegri ty for fai l ures not detected due to a doubl e faul t
i n the ci rcui t. Most PCM dri ver/control ci rcui t fai l -
ures are caused by i nternal fai l ure to components
(i .e. rel ay and sol enoi ds) and short ci rcui ts (i .e.
12-vol t pul l -ups, dri vers and ground sensors). These
fai l ures are di ffi cul t to detect when a doubl e faul t
has occurred and onl y one DTC has set.
NOTE: If the PCM and the SKIM are
replaced at the same time, program the VIN
into the PCM first. All vehicle keys will then
need to be replaced and programmed to the
new SKIM.
The SKI S “Secret Key” i s an I D code that i s
uni que to each SKI S. Thi s code i s programmed and
stored i n the SKI M, PCM and transponder chi p
(i gni ti on key). When repl aci ng the PCM i t i s neces-
sary to program the secret key i nto the PCM.
1. Turn the i gni ti on on (transmi ssi on i n park/
neutral ).
2. Use the DRBI I I ௡ and sel ect “THEFT ALARM”,
“SKI M” then “MI SCELLANEOUS”.
3. Sel ect “PCM REPLACED”.
4. Enter secured access mode by enteri ng the vehi -
cl e four-di gi t PI N.
NOTE: If three attempts are made to enter
the secure access mode using an incorrect
PIN, secured access mode will be locked out
for one hour. To exit ths lockout mode, turn
the ignition to the RUN position for one hour
then enter the correct PIN. (Ensure all
accessories are turned off. Also, monitor the
battery state and connect a battery charger if
necessary).
5. Press “ENTER” to transfer the secret key (the
SKI M wi l l send the secret key to the PCM).
3. 2. 9 PROGRAMMING THE SENTRY KEY
IMMOBILIZER MODULE
NOTE: If the PCM and the SKIM are
replaced at the same time, program the VIN
into the PCM first. All vehicle keys will then
need to be replaced and programmed to the
new SKIM.
1. Turn the i gni ti on on (transmi ssi on i n park/
neutral ).
2. Use the DRBI I I ௡ and sel ect “THEFT ALARM”,
“SKI M”, then “MI SCELLANEOUS”.
3. Sel ect “SKI M MODULE REPLACEMENT
(GASOLI NE)”.
4. Program the vehi cl e four-di gi t PI N i nto the
SKI M.
5. Sel ect “COUNTRY CODE” and enter the correct
country.
11
GENERAL INFORMATION
NOTE: Be sure to enter the correct country
code. If the incorrect country code is
programmed into SKIM, the SKIM must be
replaced.
6. Sel ect “UPDATE VI N” (the SKI M wi l l l earn the
VI N from the PCM).
7. Press “ENTER” to transfer the VI N (the PCM
wi l l send the VI N to the SKI M).
8. The DRBI I I ௡ wi l l ask i f you want to transfer the
secret key from the PCM. Thi s wi l l ensure the
current vehi cl e i gni ti on keys wi l l sti l l operate
the SKI S system.
3. 2. 10 PROGRAMMING THE IGNITION
KEYS TO THE SENTRY KEY
IMMOBILIZER MODULE
1. Turn the i gnti on on (transmi ssi on i n park/
neutral ).
2. Use the DRBI I I ௡ and sel ect “THEFT ALARM”,
“SKI M” then “MI SCELLANEOUS”.
3. Sl ect “PROGRAM I GNI TI ON KEYS”.
4. Enter secured access mode by enteri ng the vehi -
cl e four-di gi t PI N.
NOTE: A maximum of eight keys can be
learned to each SKIM. Once a key is learned
to a SKIM, the key cannot be transferred to
another vehicle.
I f i gni ti on key programmi ng i s unsuccessful , the
DRB I I I ௡ wi l l di spl ay one of the fol l owi ng messages:
ProgramNot Attempted- The DRBI I I ௡ attempts
to read the programmed key status and there are no
keys programmed i n the SKI M memory.
Programming Key Failed - (Possi bl e Used Key
From Wrong Vehi cl e) - SKI M i s unabl e to program
key due to one of the fol l owi ng:
– faul ty i gni ti on key transponder
– i gni ti on key i s programmed to another vehi cl e.
8 Keys Already Learned, Programming Not
Done - SKI M transponder I D memory i s ful l .
– Obtai n i gni ti on keys to be programmed from
customer (8 keys maxi mum).
– Usi ng the DRBI I I ௡, erase al l i gni ti on keys by
sel ecti ng “MI SCELLANEOUS” and “ERASE
ALL CURRENT I GN. KEYS”.
– Program al l i gni ti on keys.
Learned Key In Ignition - I gni ti on key tran-
sponder I D i s currentl y programmed i n SKI M mem-
ory.
3. 3 DIAGNOSTIC TROUBLE CODES
Each di agnosti c troubl e code i s di agnosed by
fol l owi ng a speci fi c testi ng procedure. The di agnos-
ti c test procedures contai n step-by-step i nstructi ons
for determi ni ng the cause of troubl e codes as wel l as
no troubl e code probl ems. I t i s not necessary to
perform al l of the tests i n thi s book to di agnose an
i ndi vi dual code.
Al ways begi n by readi ng the di agnosti c troubl e
codes usi ng the DRBI I I ௡.
3. 3. 1 HARD CODE
A di agnosti c troubl e code that comes back wi thi n
one cycl e of the i gni ti on key i s a “hard” code. Thi s
means that the defect i s present when the PCM
checks that ci rcui t or functi on. Procedures i n thi s
manual veri fy i f the troubl e code i s a hard code at
the begi nni ng of each test. When i t i s not a hard
code, an “i ntermi ttent” test must be performed.
Codes that are for OBDI I /EUROI I I moni tors wi l l
not set wi th just the i gni ti on key on. Compari ng
these to non-emi ssi on codes, they wi l l seem l i ke an
i ntermi ttent. These codes requi re a set of parame-
ters to be performed (The DRBI I I ௡ pre-test screens
wi l l hel p wi th thi s for MONI TOR codes), thi s i s
cal l ed a “TRI P”. Al l OBDI I /EUROI I I DTCs wi l l set
after two or i n some cases one tri p fai l ures, and the
MI L wi l l be turned on. These codes requi re three
successful , no fai l ures, TRI PS to exti ngui sh the
MI L, fol l owed by 40 warm-up cycl es to erase the
code. For further expl anati on of TRI PS, Pre-test
screens, Warm-up cycl es, and the use of the
DRBI I I ௡, refer to the On Board Di agnosti c trai ni ng
bookl et #81-699-97094.
3. 3. 2 INTERMITTENT CODE
A di agnosti c troubl e code that i s not present every
ti me the PCM checks the ci rcui t i s an “i ntermi ttent”
code. Most i ntermi ttent codes are caused by wi ri ng
or connector probl ems. I ntermi ttents that come and
go l i ke thi s are the most di ffi cul t to di agnose; they
must be l ooked for under speci fi c condi ti ons that
cause them. The fol l owi ng procedures may assi st
you i n i denti fyi ng a possi bl e i ntermi ttent probl em:
• Vi sual l y i nspect rel ated wi re harness connectors.
Look for broken, bent, pushed out, or corroded
termi nal s.
• Vi sual l y i nspect the rel ated harnesses. Look for
chafed, pi erced, or parti al l y broken wi re.
• Refer to any S.T.A.R. Hotl i ne Newsl etters or
techni cal servi ce bul l eti ns that may appl y.
• Use the DRBI I I ௡ data recorder or co-pi l ot.
12
GENERAL INFORMATION
3. 3. 3 STARTS SINCE SET COUNTER
Thi s reset counter counts the number of ti mes the
vehi cl e has been started si nce codes were l ast set or
erased. Thi s counter wi l l count up to 255 start
counts.
The number of starts hel ps determi ne when the
troubl e code actual l y happened. Thi s i s recorded by
the PCM and can be vi ewed on the DRBI I I ௡ as
STARTS si nce set.
When there are no troubl e codes stored i n mem-
ory, the DRBI I I ௡ wi l l di spl ay “NO TROUBLE
CODES FOUND” and the reset counter wi l l show
“STARTS si nce set = XXX.”
OBDI I /EUROI I I vehi cl es wi l l al so di spl ay a DTC
Speci fi c or Gl obal “Good Tri p” counter whi ch wi l l
i ndi cate the number of “Good Tri ps” si nce the DTC
was set. After 3 consecuti ve “Good Tri ps,” the MI L i s
exti ngui shed and the good tri p counter i s repl aced
by a “Warm Up Cycl e” counter. 40 Warm-up Cycl es
wi l l erase the DTC and Freeze Frame i nformati on.
3. 3. 4 NO START INFORMATION
IMPORTANT NOTE:
I f the Powertrai n Control Modul e has been pro-
grammed, a DTC wi l l set i n the ABS and Ai r bag
modul es. I n addi ti on, i f the vehi cl e i s equi pped wi th
a Sentry Key I mmobi l i zer Modul e (SKI M), Secret
Key data must be updated to enabl e starti ng.
FOR ABS AND AIR BAG SYSTEMS:
1. Enter correct VI N and Mi l eage i n PCM.
2. Erase codes i n ABS and Ai r Bag modul es.
FOR SKIM THEFT ALARM:
1. Connect the DRBI I I ௡ to the data l i nk connector.
2. Go to Theft Al arm, SKI M, Mi sc. and pl ace the
SKI M i n secured access mode, by usi ng the
appropri ate PI N code for thi s vehi cl e.
3. Sel ect Update the Secret Key data, data wi l l be
transferred from the SKI M to the PCM (Thi s i s
requi red to al l ow the vehi cl e to start wi th the
new PCM).
4. I f three attempts are made to enter secured
access mode usi ng the i ncorrect PI N, secured
access mode wi l l be l ocked out for one hour. To
exi t thi s l ock out mode, l eave the i gni ti on key i n
the Run/Start posi ti on for one hour. Ensure al l
accessori es are turned off. Al so moni tor the bat-
tery state and connect a battery charger i f nec-
essary.
After readi ng Secti on 3.0 (System Descri pti on
and Functi onal Operati on), you shoul d have a bet-
ter understandi ng of the theory and operati on of the
on-board di agnosti cs, and how thi s rel ates to the
di agnosi s of a vehi cl e that may have a dri veabi l i ty-
rel ated symptom or compl ai nt.
3. 4 USING THE DRBIIIா
Refer to the DRBI I I ௡ user ’s gui de for i nstructi ons
and assi stance wi th readi ng troubl e codes, erasi ng
troubl e codes, and other DRBI I I ௡ functi ons.
3. 5 DRBIIIா ERROR MESSAGES AND
BLANK SCREEN
Under normal operati on, the DRBI I I ௡ wi l l di s-
pl ay one of onl y two error messages:
– User-Requested WARM Boot by pressi ng
MORE and NO at the same ti me.
ver: 2.29
date: 1 Oct 93
fi l e: key_i tf.cc
date: Jan 12 1994
l i ne: 544
err: 0x1
User-Requested WARM Boot
Press MORE to swi tch between thi s di spl ay
and the appl i cati on screen.
Press F4 when done noti ng i nformati on.
or
– User-Requested COLD Boot by pressi ng
MORE and YES at the same ti me.
ver: 2.29
date: 1 Oct 99
fi l e: key_hnd1.cc
date: Mar 8 2000
l i ne: 1297
err: 0x1
User-Requested COLD Boot
Press MORE to swi tch between thi s di spl ay
and the appl i cati on screen.
Press F4 when done noti ng i nformati on.
I f the DRBI I I ௡ shoul d di spl ay any other error
message, record the enti re di spl ay and cal l the Star
Center.
3. 5. 1 DRBIIIா DOES NOT POWER UP
I f the LED’s do not l i ght or no sound i s emi tted at
start up, check for l oose cabl e connecti ons or a bad
cabl e. Check the vehi cl e battery vol tage (data l i nk
connector cavi ty 16). Check for proper ground con-
necti on at DLC cavi ty. A mi ni mum of 11 vol ts i s
requi red to adequatel y power the DRBI I I ௡.
I f al l connecti ons are proper between the
DRBI I I ௡ and the vehi cl e or other devi ces, and the
vehi cl e battery i s ful l y charged, and i noperati ve
DRBI I I ௡
13
GENERAL INFORMATION
may be the resul t of faul ty cabl e or vehi cl e wi ri ng.
For a bl ank screen, refer to the appropri ate body
di agnosti cs manual .
3. 5. 2 DISPLAY IS NOT VISIBLE
Low temperatures wi l l affect the vi si bi l i ty of the
di spl ay. Adjust the contrast to compensate for thi s
condi ti on.
4.0 DISCLAIMERS, SAFETY,
WARNINGS
4. 1 DISCLAIMERS
Al l i nformati on, i l l ustrati ons, and speci fi cati ons
contai ned i n thi s manual are based on the l atest
i nformati on avai l abl e at the ti me of publ i cati on.
The ri ght i s reserved to make changes at any ti me
wi thout noti ce.
4. 2 SAFETY
4. 2. 1 TECHNICIAN SAFETY INFORMATION
WARNING: ENGINES PRODUCE CARBON
MONOXIDE THAT IS ODORLESS, CAUSES
SLOWER REACTION TIME, AND CAN LEAD
TO SERIOUS INJURY. WHEN THE ENGINE IS
OPERATING, KEEP SERVICE AREAS WELL
VENTILATED OR ATTACH THE VEHICLE
EXHAUST SYSTEM TO THE SHOP EXHAUST
REMOVAL SYSTEM.
Set the parki ng brake and bl ock the wheel s before
testi ng or repai ri ng the vehi cl e. I t i s especi al l y
i mportant to bl ock the wheel s on front-wheel dri ve
vehi cl es; the parki ng brake does not hol d the dri ve
wheel s.
When servi ci ng a vehi cl e, al ways wear eye pro-
tecti on, and remove any metal jewel ry such as
watchbands or bracel ets that mi ght make an i nad-
vertent el ectri cal contact.
When di agnosi ng a powertrai n system probl em,
i t i s i mportant to fol l ow approved procedures where
appl i cabl e. These procedures can be found i n ser-
vi ce manual procedures. Fol l owi ng these proce-
dures i s very i mportant to the safety of i ndi vi dual s
performi ng di agnosti c tests.
4. 2. 2 VEHICLE PREPARATION FOR
TESTING
Make sure the vehi cl e bei ng tested has a ful l y
charged battery. I f i t does not, fal se di agnosti c codes
or error messages may occur.
4. 2. 3 SERVICING SUB-ASSEMBLIES
Some components of the powertrai n system are
i ntended to be servi ced as an assembl y. Attempti ng
to remove or repai r certai n system sub-components
may resul t i n personal i njury and/or i mproper sys-
tem operati on. Onl y those components wi th ap-
proved repai r and i nstal l ati on procedures i n the
servi ce manual shoul d be servi ced.
4. 2. 4 DRBIIIா SAFETY INFORMATION
WARNING: EXCEEDING THE LIMITS OF THE
DRBIIIா MULTIMETER IS DANGEROUS. IT
CAN EXPOSE YOU TO SERIOUS INJURY.
CAREFULLY READ AND UNDERSTAND THE
CAUTIONS AND THE SPECIFICATION
LIMITS.
Fol l ow the vehi cl e manufacturer ’s servi ce speci fi -
cati ons at al l ti mes.
• Do not use the DRBI I I ௡ i f i t has been damaged.
• Do not use the test l eads i f the i nsul ati on i s
damaged or i f metal i s exposed.
• To avoi d el ectri cal shock, do not touch the test
l eads, ti ps, or the ci rcui t bei ng tested.
• Choose the proper range and functi on for the
measurement. Do not try vol tage or current mea-
surements that may exceed the rated capaci ty.
• Do not exceed the l i mi ts shown i n the tabl e bel ow:
FUNCTION INPUT LIMIT
Vol ts 0 - 500 peak vol ts AC
0 - 500 vol ts DC
Ohms (resi stance)* 0 - 1.12 megohms
Frequency Measured
Frequency Generated
0 - 10 kHz
14
GENERAL INFORMATION
FUNCTION INPUT LIMIT
Temperature -50 - 600°C
-58 - 1100°F
* Ohms cannot be measured i f vol tage i s present.
Ohms can be measured onl y i n a non-powered
ci rcui t.
• Vol tage between any termi nal and ground must
not exceed 500v DC or 500v peak AC.
• Use cauti on when measuri ng vol tage above 25v
DC or 25v AC.
• A 10A fuse or ci rcui t breaker must be used to
protect the ci rcui t bei ng tested.
• Use the l ow current shunt to measure ci rcui ts up
to 10A. Use the hi gh current cl amp to measure
ci rcui ts exceedi ng 10A.
• When testi ng for the presence of vol tage or cur-
rent, make sure the meter i s functi oni ng cor-
rectl y. Take a readi ng of a known vol tage or
current before accepti ng a zero readi ng.
• When measuri ng current, connect the meter i n
seri es wi th the l oad.
• Di sconnect the l i ve test l ead before di sconnecti ng
the common test l ead.
• When usi ng the meter functi on, keep the
DRBI I I ௡ away from spark pl ug or coi l wi res to
avoi d measuri ng error from outsi de i nterference.
4. 3 WARNINGS AND CAUTIONS
4. 3. 1 ROAD TEST WARNINGS
Some compl ai nts wi l l requi re a test dri ve as part
of the repai r veri fi cati on procedure. The purpose of
the test dri ve i s to try to dupl i cate the di agnosti c
code or symptom condi ti on.
CAUTION: Before road testing a vehicle, be
sure that all components are reassembled.
During the test drive, do not try to read the
DRBIIIா screen while in motion. Do not hang
the DRBIIIா from the rear view mirror or
operate it yourself. Have an assistant
available to operate the DRBIIIா.
4. 3. 2 VEHICLE DAMAGE CAUTIONS
Before di sconnecti ng any control modul e, make
sure the i gni ti on i s “off”. Fai l ure to do so coul d
damage the modul e.
When testi ng vol tage or conti nui ty at any control
modul e, use the termi nal si de (not the wi re end) of
the connector. Do not probe a wi re through the
i nsul ati on; thi s wi l l damage the i nsul ati on and wi re
and eventual l y cause i t to fai l because of corrosi on.
Be careful when performi ng el ectri cal tests so as
to prevent acci dental shorti ng of termi nal s. Such
mi stakes can damage fuses or components. Al so, a
second DTC coul d be set, maki ng di agnosi s of the
ori gi nal probl em more di ffi cul t.
5.0 REQUIRED TOOLS AND
EQUIPMENT
DRBI I I ௡ (di agnosti c read-out box) scan tool
Evaporati ve Emi ssi ons Leak Detector #8404
Fuel pressure ki t #8978
fuel fi l l er adapter #8382
fuel pressure adapter (C-6631) or #6539
fuel pressure ki t (C-4799-B) or #5069
fuel rel ease hose (C-4799-1)
Mi rco 420 battery system tester
mi n ai r fl ow fi tti ng #6714
jumper wi res
ohmmeter
osci l l oscope
vacuum gauge
vol tmeter
12-vol t test l i ght mi ni mum 25 ohms resi stance
wi th probe #6801
CAUTION: A 12-volt test light should not be
used for the following circuits, damage to the
powertrain controller will occur.
• 5-Vol t Suppl y
• 8 Vol t Suppl y
• J1850 PCI Bus
• CCD Bus
• CKP Sensor Si gnal
• CMP Sensor Si gnal
• Vehi cl e Speed Sensor Si gnal
• O2 Sensor Si gnal
6.0 ACRONYMS
A/C ai r condi ti oni ng
ABS anti -l ock brake system
ASD
Relay
auto shutdown rel ay
APPS accel erator pedal posi ti on sensor
Baro barometri c pressure
BCM body control modul e
BTS battery temperature sensor
CAA cl ean ai r act
15
GENERAL INFORMATION
CAB control l er anti l ock brakes
CARB Cal i forni a ai r resources board
CCD Bus Chrysl er col l i si on detecti on bus
CKP
Sensor
crank posi ti on sensor
CMP
Sensor
camshaft posi ti on sensor
CO carbon monoxi de
DCP
Solenoid
duty-cycl e purge sol enoi d
DLC data l i nk connector
DRBIII௡ di agnosti c readout box – 3rd gener-
ati on
DTC di agnosti c troubl e code
DVOM di gi tal vol t ohm meter
EATX II el ectroni c automati c transmi ssi on
control l er – 2nd Generati on
EC European communi ty
ECT
Sensor
engi ne cool ant temperature sensor
EE-
PROM
el ectri cal l y erasabl e programmabl e
read onl y memory
EGR
Valve
exhaust gas reci rcul ati on val ve
EMCC el ectroni c modul ated converter
cl utch
EMI el ectro-magneti c i nterference
EOBD European OBD (based upon Euro
Stage I I I )
EPA Envi ronmental Protecti on Agency
EPP engi ne posi ti on pul se
Eu European Uni on
EVAP evaporati ve emi ssi on system
EVR el ectroni c vol tage regul ator
EWMA exponenti al l y wei ghted movi ng
average
FTP federal test procedure
HC hydrocarbons
HO2S heated oxygen sensor
Genera-
tor
previ ousl y cal l ed “al ternator”
IAC
Motor
i dl e ai r control motor
IAT
Sensor
i ntake ai r temperature sensor
I/M i nspecti on and mai ntenance testi ng
J TEC Jeep/Truck engi ne control l er
LDP l eak detecti on pump
LSIACV l i near sol enoi d i dl e ai r control val ve
MAF mass ai r fl ow
MAP
Sensor
mani fol d absol ute pressure sensor
MDS
2
௡ Mopar di agnosti c system – 2nd gen-
erati on
MIL mal functi on i ndi cator l amp
MTV mani fol d tuni ng val ve
NGC next generati on control l er
NTC negati ve temperature coeffi ci ent
NVLD natural vacuum l eak detecti on
O
2
Sensor oxygen sensor
O2S oxygen sensor
OBD I on board di agnosti cs – 1st genera-
ti on
OBD II on-board di agnosti cs – 2nd genera-
ti on
ORVR on-board refuel i ng vapor recovery
PCI Bus programmabl e communi cati ons i n-
terface bus (J1850)
PCM powertrai n control modul e
PCV posi ti ve crankcase venti l ati on
PDC power di stri buti on center
PEP peri pheral expansi on port
P/N park/neutral
PPS proporti onal purge sol enoi d
PS power steeri ng
PSP power steeri ng pressure (swi tch)
PTC posi ti ve temperature coeffi ci ent
PWM pul se-wi dth modul ati on
RAM random access memory
RFI radi o frequency i nterference
16
GENERAL INFORMATION
RKE remote keyl ess entry
RPM revol uti ons per mi nute
SAE Soci ety of Automoti ve Engi neers
SBEC si ngl e board engi ne control l er
SCW Si mi l ar Condi ti ons Wi ndow
SKIM sentry key i mmobi l i zer modul e
SRV short runner val ve
TCC torque converter cl utch
TCM transmi ssi on control modul e
TDC top dead center
TPS throttl e posi ti on sensor
TRS transmi ssi on range sensor
VSS vehi cl e speed sensor
WOT wi de open throttl e
17
GENERAL INFORMATION
NOTES
18
7.0
DIAGNOSTIC INFORMATION AND
PROCEDURES
19
Symptom:
*NO RESPONSE FROM PCM (PCI BUS)
POSSIBLE CAUSES
PCM PCI NO RESPONSE
PCI BUS CI RCUI T OPEN
POWERTRAI N CONTROL MODULE
TEST ACTION APPLICABILITY
1 Turn the i gni ti on on.
NOTE:Assoon asoneor moremodulecommunicateswith theDRB, answer
the question.
Wi th the DRBI I I ௡, enter Body then El ectro/Mechani cal Cl uster (MI C).
Wi th the DRBI I I ௡, enter Passi ve Restrai nts then Ai rbag.
Were you abl e to establ i sh communi cati ons wi th any of the modul es?
Al l
Yes → Go To 2
No → Refer to symptom PCI Bus Communi cati on Fai l ure i n the Com-
muni cati ons category.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 1.
2 Wi th the DRBI I I ௡ read PCM Di agnosti c Troubl e Codes. Thi s i s to ensure power and
grounds to the PCM are operati onal .
NOTE: If the DRBIII௡ will not read PCM DTC’s, follow the NO RESPONSE
TO PCM (SCI only) symptompath.
NOTE: If the vehicle will not start and the DRBIII௡ displays a no response
message, refer to the appropriate symptom in the powertrain diagnostic
procedures.
Turn the i gni ti on off.
Di sconnect the PCM C3 harness connector.
Use Scope i nput cabl e CH7058, Cabl e to Probe adapter CH7062, and the red and
bl ack test probes.
Connect the scope i nput cabl e to the channel one connector on the DRBI I I ௡. Attach
the red and bl ack l eads and the cabl e to probe adapter to the scope i nput cabl e.
I nstal l DRBI I I ௡ SuperCard 2 CH8361 i nto DRBI I I ௡.
Wi th the DRBI I I ௡ sel ect Pep Modul e Tool s.
Sel ect l ab scope.
Sel ect Li ve Data.
Sel ect 12 vol t square wave.
Press F2 for Scope.
Press F2 and use the down arrow to set vol tage range to 20 vol ts. Press F2 agai n
when compl ete.
Connect the Bl ack l ead to the PCM ground. Connect the Red l ead to the PCI Bus
ci rcui t i n the PCM connector.
Turn the i gni ti on on.
Observe the vol tage di spl ay on the DRBI I I ௡ Lab Scope.
Does the vol tage pul se from 0 to approxi matel y 7.5 vol ts?
Al l
Yes → Repl ace and program the Powertrai n Control Modul e i n accor-
dance wi th the Servi ce I nformati on.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 1.
No → Repai r the PCI Bus ci rcui t for an open.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 1.
20
COMMUNICATION
Symptom:
*NO RESPONSE FROM PCM (SCI ONLY)
POSSIBLE CAUSES
CHECK PCM POWERS AND GROUNDS
CONTROLLER ANTI LOCK BRAKE
SCI TRANSMI T CI RCUI T SHORTED TO VOLTAGE
TRANSMI SSI ON CONTROL MODULE
SCI RECEI VE CI RCUI T SHORTED TO VOLTAGE
SCI CI RCUI TS SHORTED TOGETHER
SCI TRANSMI T CI RCUI T SHORTED TO GROUND
SCI RECEI VE CI RCUI T SHORTED TO GROUND
SCI RECEI VE CI RCUI T OPEN
SCI TRANSMI T CI RCUI T OPEN
POWERTRAI N CONTROL MODULE
TEST ACTION APPLICABILITY
1 Perform the symptom Checki ng PCM Power and Ground Ci rcui ts i n the Dri veabi l i ty
category.
NOTE: With the DRBIII௡ in the generic scan tool mode, attempt to commu-
nicate with the PCM.
NOTE: If the DRBIII௡ can communicate with the PCM in the generic scan
tool mode, it may not be necessary to performthis step.
Di d the vehi cl e pass thi s test?
Al l
Yes → Go To 2
No → Repai r as necessary.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 1.
2 Turn the i gni ti on off.
Di sconnect the PCM harness connectors.
Di sconnect the DRB from the DLC.
Measure the resi stance between ground and the SCI Transmi t ci rcui t.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 3
No → Go To 5
3 Turn the i gni ti on off.
Di sconnect the CAB harness connector (i f equi pped).
NOTE: If vehicle is not equipped with antilock brakes, answer yes to the
question.
Measure the resi stance between ground and the SCI Transmi t ci rcui t.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 4
No → Repl ace the Control l er Anti l ock Brake i n accordance wi th the
servi ce i nformati on.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 1.
21
COMMUNICATION
TEST ACTION APPLICABILITY
4 Turn the i gni ti on off.
Di sconnect the TCM harness connector (i f equi pped).
NOTE: If vehicle is not equipped with a TCM, answer yes to the question.
Measure the resi stance between ground and the SCI Transmi t ci rcui t.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Repai r the SCI Transmi t ci rcui t for a short to ground.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 1.
No → Repl ace the Transmi ssi on Control Modul e i n accordance wi th the
servi ce i nformati on.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 1.
5 Turn the i gni ti on off.
Di sconnect the DRB from the DLC.
Di sconnect the PCM harness connectors.
Di sconnect the TCM harness connector (i f equi pped).
Di sconnect the CAB harness connector (i f equi pped).
Turn the i gni ti on on.
Measure the vol tage of the SCI Transmi t ci rcui t at the DLC connector (cav 7).
I s the vol tage above 1.0 vol t?
Al l
Yes → Repai r the SCI Transmi t ci rcui t for a short to vol tage.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 1.
No → Go To 6
6 Turn the i gni ti on off.
Di sconnect the DRB from the DLC.
Di sconnect the PCM harness connectors.
Turn the i gni ti on on.
Measure the vol tage of the SCI Recei ve ci rcui t at the DLC connector (cav 6).
I s the vol tage above 1.0 vol t?
Al l
Yes → Repai r the SCI Recei ve ci rcui t for a short to vol tage.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 1.
No → Go To 7
7 Turn the i gni ti on off.
Di sconnect the DRB from the DLC.
Di sconnect the PCM harness connectors.
Measure the resi stance between the SCI Transmi t ci rcui t and the SCI Recei ve ci rcui t
at the PCM connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Repai r the short between the SCI Transmi t and the SCI Recei ve
ci rcui ts.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 1.
No → Go To 8
8 Turn the i gni ti on off.
Di sconnect the PCM harness connectors.
Di sconnect the DRB from the DLC.
Measure the resi stance between ground and the SCI Recei ve ci rcui t.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Repai r the SCI Recei ve ci rcui t for a short to ground.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 1.
No → Go To 9
22
COMMUNICATION
*NO RESPONSE FROM PCM (SCI ONLY) — Continued
TEST ACTION APPLICABILITY
9 Turn the i gni ti on off.
Di sconnect the PCM harness connectors.
Di sconnect the DRB from the DLC.
Measure the resi stance of the SCI Recei ve ci rcui t between the PCM connector and
the DLC.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 10
No → Repai r the SCI Recei ve ci rcui t for an open.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 1.
10 Turn the i gni ti on off.
Di sconnect the PCM harness connectors.
Di sconnect the DRB from the DLC.
Measure the resi stance of the SCI Transmi t ci rcui t between the PCM connector and
the DLC.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 11
No → Repai r the SCI Transmi t ci rcui t for an open.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 1.
11 I f there are no possi bl e causes remai ni ng, vi ew repai r. Al l
Repai r
Repl ace and program the Powertrai n Control Modul e i n accor-
dance wi th the Servi ce I nformati on.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 1.
23
COMMUNICATION
*NO RESPONSE FROM PCM (SCI ONLY) — Continued
Symptom:
*NO RESPONSE FROM SENTRY KEY IMMOBILIZER MODULE
POSSIBLE CAUSES
ATTEMPT TO COMMUNI CATE WI TH THE I NSTRUMENT CLUSTER
GROUND CI RCUI T OPEN
FUSED I GNI TI ON SWI TCH OUTPUT CI RCUI T OPEN
FUSED B(+) CI RCUI T OPEN
OPEN PCI BUS CI RCUI T
SENTRY KEY I MMOBI LI ZER MODULE
TEST ACTION APPLICABILITY
1 Turn the i gni ti on on.
Wi th the DRB, enter Body then El ectro/Mech Cl uster.
Was the DRB abl e to I /D or communi cate wi th the I nstrument Cl uster?
Al l
Yes → Go To 2
No → Refer to the symptom l i st for probl ems rel ated to no communi ca-
ti on wi th the I nstrument Cl uster.
Perform SKI S VERI FI CATI ON.
2 Turn the i gni ti on off.
Di sconnect the SKI M harness connector.
Usi ng a 12-vol t test l i ght connected to 12-vol ts, probe the ground ci rcui t.
I s the test l i ght i l l umi nated?
Al l
Yes → Go To 3
No → Repai r the ground ci rcui t for an open.
Perform SKI S VERI FI CATI ON.
3 Turn the i gni ti on off.
Di sconnect the SKI M harness connector.
Turn the i gni ti on on.
Usi ng a 12-vol t test l i ght connected to ground, probe the Fused I gni ti on Swi tch
Output ci rcui t.
I s the test l i ght i l l umi nated?
Al l
Yes → Go To 4
No → Repai r the Fused I gni ti on Swi tch Output ci rcui t for an open.
Perform SKI S VERI FI CATI ON.
4 Turn the i gni ti on off.
Di sconnect the SKI M harness connector.
Usi ng a 12-vol t test l i ght connected to ground, probe the Fused B(+) ci rcui t.
I s the test l i ght i l l umi nated?
Al l
Yes → Go To 5
No → Check the Fuse i n the Fuse Bl ock for an open. Refer to the wi ri ng
di agrams. I f OK, repai r the Fused B+ ci rcui t for an open.
Perform SKI S VERI FI CATI ON.
24
COMMUNICATION
TEST ACTION APPLICABILITY
5 Note: Ensure there is PCI Bus communication with other modules on the
vehicle before proceeding. If not, refer to the symptomlist fromthe menu
and repair as necessary.
Di sconnect the SKI M harness connector.
Use Scope i nput cabl e CH7058, Cabl e to Probe adapter CH7062, and the red and
bl ack test probes.
Connect the scope i nput cabl e to the channel one connector on the DRB. Attach the
red and bl ack l eads and the cabl e to probe adapter to the scope i nput cabl e.
Wi th the DRBI I I ௡ sel ect Pep Modul e Tool s.
Sel ect l ab scope.
Sel ect Li ve Data.
Sel ect 12 vol t square wave.
Press F2 for Scope.
Press F2 and use the down arrow to set vol tage range to 20 vol ts. Press F2 agai n
when compl ete.
Connect the Bl ack l ead to the chassi s ground. Connect the Red l ead to the PCI Bus
ci rcui t i n the SKI M connector.
Turn the i gni ti on on.
Observe the vol tage di spl ay on the DRB Lab Scope.
Does the vol tage pul se from 0 to approxi matel y 7.5 vol ts?
Al l
Yes → Go To 6
No → Repai r the PCI Bus ci rcui t for an open.
Perform SKI S VERI FI CATI ON.
6 I f there are no possi bl e causes remai ni ng, vi ew repai r. Al l
Repai r
Repl ace and program the Sentry Key I mmobi l i zer Modul e i n
accordance wi th the Servi ce I nformati on.
Perform SKI S VERI FI CATI ON.
25
COMMUNICATION
*NO RESPONSE FROM SENTRY KEY IMMOBILIZER MODULE —
Continued
Symptom:
*PCI BUS COMMUNICATION FAILURE
POSSIBLE CAUSES
WI RI NG HARNESS I NTERMI TTENT
OPEN PCI BUS CI RCUI T AT THE DATA LI NK CONNECTOR (DLC)
PCI BUS CI RCUI T SHORTED TO VOLTAGE
MODULE SHORT TO VOLTAGE
PCI BUS CI RCUI T SHORTED TO GROUND
MODULE SHORT TO GROUND
TEST ACTION APPLICABILITY
1 Note: Determinewhich modules this vehicleis equipped with beforebegin-
ning.
Note: When attempting to communicate with any of the modules on this
vehicle, the DRB will display 1 of 2 different communication errors: a NO
RESPONSE message or a BUS +/- SIGNALS OPEN message.
Turn the i gni ti on on.
Usi ng the DRB, attempt to communi cate wi th the fol l owi ng control modul es:
Ai rbag Control Modul e
SKI M (SENTRY KEY I MMOBI LI ZER)
MI C (I NSTRUMENT CLUSTER)
Was the DRBI I I ௡ abl e to communi cate wi th one or more Modul e(s)?
Al l
Yes → Go To 2
No → Go To 3
2 Turn the i gni ti on off.
Note: Visually inspect the related wiring harness. Look for any chafed,
pierced, pinched, or partially broken wires.
Note:Visuallyinspect therelatedwireharnessconnectors. Look for broken,
bent, pushed out, or corroded terminals.
Note: If the DRB can not communicate with a single module, refer to the
category list for the related symptom.
Were any probl ems found?
Al l
Yes → Repai r wi ri ng harness/connectors as necessary.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Test Compl ete.
3 Turn the i gni ti on off.
Di sconnect the PCM harness connector.
Di sconnect the DRB from the Data Li nk Connector (DLC).
Di sconnect the negati ve battery cabl e.
Measure the resi stance of the PCI Bus ci rcui t between the Data Li nk Connector
(DLC) and the PCM connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 4
No → Repai r the PCI Bus ci rcui t for an open.
Perform BODY VERI FI CATI ON TEST - VER 1.
26
COMMUNICATION
TEST ACTION APPLICABILITY
4 NOTE: Reconnect the PCM harness connector and the negative battery
cable.
Turn the i gni ti on on.
Measure the vol tage of the PCI Bus ci rcui t at the Data Li nk Connector (DLC).
I s the vol tage above 7.0 vol ts?
Al l
Yes → Go To 5
No → Go To 6
5 Turn the i gni ti on off.
Usi ng a vol tmeter, connect one end to the PCI Bus ci rcui t at the DLC, and the other
end to ground.
Note: When performingthenext stepturn theignition off (wait oneminute)
before disconnecting any module. When the module is disconnected turn
the ignition on to check for a short to voltage.
Turn the i gni ti on on.
Whi l e moni tori ng the vol tmeter, di sconnect each modul e the vehi cl e i s equi pped wi th
one at a ti me.
I s the vol tage steadi l y above 7.0 vol ts wi th al l the modul es di sconnected?
Al l
Yes → Repai r the PCI Bus ci rcui t for a short to vol tage.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Repl ace the modul e that when di sconnected the short to vol tage
was el i mi nated.
Perform BODY VERI FI CATI ON TEST - VER 1.
6 Turn the i gni ti on off.
Di sconnect the negati ve battery cabl e.
Usi ng a ohmmeter, connect one end to the PCI Bus ci rcui t at the DLC, and the other
end to ground.
Whi l e moni tori ng the ohmmeter, di sconnect each modul e the vehi cl e i s equi pped wi th
one at a ti me.
NOTE: Total bus resistance to ground thru all of the modules is typically
between 350to1000ohms. Themoremoduleson thebus, thelower thetotal
bus resistance will be.
I s the resi stance bel ow 150.0 ohms wi th al l the modul es di sconnected?
Al l
Yes → Repai r the PCI Bus ci rcui t for a short to ground.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Repl ace the modul e that when di sconnected the short to ground
was el i mi nated.
Perform BODY VERI FI CATI ON TEST - VER 1.
27
COMMUNICATION
*PCI BUS COMMUNICATION FAILURE — Continued
Symptom:
INTERMITTENT CONDITION
POSSIBLE CAUSES
I NTERMI TTENT CONDI TI ON
TEST ACTION APPLICABILITY
1 NOTE: The conditions that set the DTC are not present at this time. The
following list may help in identifying the intermittent condition.
WARNING: 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.
Refer to any Techni cal Servi ce Bul l eti ns (TSBs) that may appl y.
Revi ew the DRBI I I ௡ Freeze Frame i nformati on. I f possi bl e, try to dupl i cate the
condi ti ons under whi ch the DTC set.
Wi th the engi ne runni ng at normal operati ng temperature, moni tor the DRBI I I ௡
parameters rel ated to the DTC whi l e wi ggl i ng the wi re harness. Look for parameter
val ues to change and/or a DTC to set.
Turn the i gni ti on off.
Vi sual l y i nspect the rel ated wi re harness. Di sconnect al l the rel ated harness
connectors. Look for any chafed, pi erced, pi nched, parti al l y broken wi res and broken,
bent, pushed out, or corroded termi nal s.
Perform a vol tage drop test on the rel ated ci rcui ts between the suspected faul ty
component and the PCM.
I nspect and cl ean al l PCM, engi ne, and chassi s grounds.
I f numerous troubl e codes were set, use a wi re schemati c and l ook for any common
ground or suppl y ci rcui ts
For any Rel ay DTCs, actuate the Rel ay wi th the DRBI I I ௡ and wi ggl e the rel ated wi re
harness to try to i nterrupt the actuati on.
For i ntermi ttent Evaporati ve Emi ssi on troubl e codes perform a vi sual and physi cal
i nspecti on of the rel ated parts i ncl udi ng hoses and the Fuel Fi l l er cap.
For i ntermi ttent Mi sfi re DTC’s check for restri cti ons i n the I ntake and Exhaust
system, proper i nstal l ati on of Sensors, vacuum l eaks, and bi ndi ng components that
are run by the accessory dri ve bel t.
Use the DRBI I I ௡ to perform a System Test i f one appl i es to fai l i ng component.
A co-pi l ot, data recorder, and/or l ab scope shoul d be used to hel p di agnose i ntermi t-
tent condi ti ons.
Were any probl ems found duri ng the above i nspecti ons?
Al l
Yes → Repai r as necessary
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Test Compl ete.
28
DRIVEABILITY - GAS
SymptomList:
P0031-O2 SENSOR 1/1 HEATER CIRCUIT LOW
P0032-O2 SENSOR 1/1 HEATER CIRCUIT HIGH
P0037-O2 SENSOR 1/2 HEATER CIRCUIT LOW
P0038-O2 SENSOR 1/2 HEATER CIRCUIT HIGH
P0051-O2 SENSOR 2/1 HEATER CIRCUIT LOW
P0052-O2 SENSOR 2/1 HEATER CIRCUIT HIGH
Test Note: All symptomslistedabovearediagnosedusingthesametests.
The title for the tests will be P0031-O2SENSOR 1/1HEATER
CIRCUIT LOW.
When Monitored and Set Condition:
P0031-O2 SENSOR 1/1 HEATER CIRCUIT LOW
When Moni tored: Battery vol tage above 10.6 vol ts, ASD i s powered up, and O2 heater i s
on.
Set Condi ti on: Desi red state does not match Actual state.
P0032-O2 SENSOR 1/1 HEATER CIRCUIT HIGH
When Moni tored: Battery vol tage above 10.6 vol ts, ASD i s powered up, and O2 heater i s
off.
Set Condi ti on: Desi red state does not equal Actual state.
P0037-O2 SENSOR 1/2 HEATER CIRCUIT LOW
When Moni tored: Battery vol tage above 10.6 vol ts, ASD i s powered up, and O2 heater i s
on.
Set Condi ti on: Desi red state does not equal Actual state.
P0038-O2 SENSOR 1/2 HEATER CIRCUIT HIGH
When Moni tored: Battery vol tage above 10.6 vol ts, ASD i s powered up, and O2 heater i s
off.
Set Condi ti on: Desi red state does not equal Actual state.
P0051-O2 SENSOR 2/1 HEATER CIRCUIT LOW
When Moni tored: Battery vol tage above 10.6 vol ts, ASD i s powered up, and O2 heater i s
on.
Set Condi ti on: Desi red state does not equal Actual state.
P0052-O2 SENSOR 2/1 HEATER CIRCUIT HIGH
When Moni tored: Battery vol tage above 10.6 vol ts, ASD i s powered up, and O2 heater i s
off.
Set Condi ti on: Desi red state does not equal Actual state.
29
DRIVEABILITY - GAS
POSSIBLE CAUSES
O2 HEATER TEST
O2 SENSOR HEATER ELEMENT
(F142) FUSED ASD RELAY OUTPUT CI RCUI T
HEATER CONTROL CI RCUI T OPEN
HEATER CONTROL CI RCUI T SHORTED TO GROUND
PCM
TEST ACTION APPLICABILITY
1 Check for any rel ated TSBs.
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, read DTCs and record the rel ated Freeze Frame data.
NOTE: If P0136is set with the P0031or P0051, inspect the related fuse and
repair as necessary.
Wi th the DRBI I I ௡, actuate the O2 Heater test.
Moni tor the O2 Heater Vol tage for 5 mi nutes.
Di d the vol tage drop bel ow 0.5 of a vol t duri ng the Heater test?
Al l
Yes → Refer to the I NTERMI TTENT CONDI TI ON Symptom (Di agnos-
ti c Procedure).
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 2
NOTE: Stop the actuation before continuing.
2 Turn the i gni ti on off.
Di sconnect the O2 Sensor harness connector.
Measure the resi stance of the O2 Heater El ement at the O2 Sensor connector
(component si de).
I s the resi stance between 2.0 and 30 ohms?
Al l
Yes → Go To 3
No → Repl ace the O2 Sensor.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
3 I gni ti on on, engi ne not runni ng and the Sensor harness connector sti l l di sconnected.
Wi th the DRBI I I ௡, perform the O2 Heater Test.
Usi ng a 12-vol t test l i ght connected to ground, probe the (F142) Fused ASD Rel ay
Output at the O2 Sensor harness connector.
Di d the test l i ght i l l umi nate bri ghtl y?
Al l
Yes → Go To 4
No → Repai r the open or short to ground i n the (F142) Fused ASD Rel ay
Output ci rcui t. I nspect the rel ated fuse and repai r as necessary.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
30
DRIVEABILITY - GAS
P0031-O2 SENSOR 1/1 HEATER CIRCUIT LOW— Continued
TEST ACTION APPLICABILITY
4 Turn the i gni ti on off.
Di sconnect the PCM harness connectors.
Measure the resi stance of the O2 Heater Control ci rcui t (PWM) from the O2 Sensor
harness connector to the PCM harness connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 5
No → Repai r the open i n the O2 Heater Control (PWM) ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
5 Measure the resi stance between ground and the O2 Heater Control (PWM) ci rcui t at
the Sensor harness connector.
I s the resi stance bel ow 100 ohms?
Al l
Yes → Repai r the short to ground i n the Heater Control (PWM) ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 6
6 NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Usi ng the schemati cs as a gui de, i nspect the wi re harness and connectors. Pay
parti cul ar attenti on to al l Power and Ground ci rcui ts.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace and program the Powertrai n Control Modul e per Servi ce
I nformati on.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
31
DRIVEABILITY - GAS
P0031-O2 SENSOR 1/1 HEATER CIRCUIT LOW— Continued
Symptom:
P0071-AMBIENT/BATTERY TEMP SENSOR PERFORMANCE
When Monitored and Set Condition:
P0071-AMBIENT/BATTERY TEMP SENSOR PERFORMANCE
When Moni tored: Wi th the i gni ti on on and no Battery Temperature Sensor Open or Short
Faul ts present.
Set Condi ti on: After 5 warm cycl es have occurred (cool ant i ncreases at l east 22°C (40°F)
to a mi ni mum of 71°C (160°F) and the odometer mi l eage has i ncreased 196.6 mi l es and the
Battery Temperature has changed l ess than 4°C (7.2°F) change i n temperature. One tri p
faul t.
POSSIBLE CAUSES
GOOD TRI P EQUAL TO ZERO
(K118) BATTERY TEMP SI GNAL CI RCUI T SHORTED TO VOLTAGE
BATTERY TEMPERATURE SENSOR
RESI STANCE I N THE (K118) BATTERY TEMP SENSOR SI GNAL CI RCUI T
RESI STANCE I N THE (K4) SENSOR GROUND CI RCUI T
(K118) BATTERY TEMP SENSOR SI GNAL CI RCUI T SHORTED TO GROUND
PCM
TEST ACTION APPLICABILITY
1 I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, read DTCs and record the rel ated Freeze Frame data.
I s the Good Tri p Counter equal to zero?
Al l
Yes → Go To 2
No → Refer to the I NTERMI TTENT CONDI TI ON Symptom (Di agnos-
ti c Procedure).
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
2 Turn the i gni ti on off.
Di sconnect the Battery Temp Sensor harness connector.
I gni ti on on, engi ne not runni ng.
Measure the vol tage on the (K118) Battery Temp Si gnal ci rcui t at the Sensor
connector.
I s the vol tage above 5.2 vol ts?
Al l
Yes → Repai r the short to vol tage on the (K118) Batt Temp Si gnal
ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 3
32
DRIVEABILITY - GAS
TEST ACTION APPLICABILITY
3 Wi th the DRBI I I ௡, read the Battery Temp Sensor vol tage wi th the Batt Temp Sensor
sti l l di sconnected.
I s the vol tage above 4.6 vol ts?
Al l
Yes → Go To 4
No → Go To 7
4 Connect a jumper wi re between the (K118) Battery Temp Si gnal ci rcui t and the (K4)
Sensor ground ci rcui t at the Sensor harness connector.
Wi th the DRBI I I ௡, read the Battery Temp Sensor vol tage.
I s the vol tage bel ow 1.0 vol t?
Al l
Yes → Repl ace the Battery Temperature Sensor.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 5
5 Turn the i gni ti on off.
Connect the Battery Temp Sensor harness connector.
NOTE: Ensurethevoltmeter leads meet theterminals in theconnector and
that there is good terminal to wire connection.
NOTE: Ensure the voltmeter leads are connected for positive polarity.
Backprobe the (K118) Battery Temp Sensor Si gnal ci rcui t at the Sensor harness
connector and the PCM harness connector wi th both vol tmeter l eads.
Start the engi ne.
Al l ow the engi ne to i dl e.
I s the vol tage bel ow 0.10 of a vol t?
Al l
Yes → Go To 6
No → Repai r the excessi ve resi stance i n the (K118) Battery Temp
Sensor Si gnal ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
6 Turn the i gni ti on off.
NOTE: Ensurethevoltmeter leads meet theterminals in theconnector and
that there is good terminal to wire connection.
NOTE: Ensure the voltmeter leads are connected for positive polarity.
Backprobe the (K4) Sensor ground ci rcui t at the Battery Temperature Sensor
harness connector and the PCM harness connector usi ng both vol tmeter l eads.
Start the engi ne.
Al l ow the engi ne to i dl e.
I s the vol tage bel ow 0.10 of a vol t?
Al l
Yes → Go To 8
No → Repai r the excessi ve resi stance i n the (K4) Sensor ground ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
7 Turn the i gni ti on off.
Di sconnect the PCM harness connectors.
Measure the resi stance between ground and the (K118) Battery Temp Si gnal ci rcui t.
I s the resi stance bel ow 100 ohms?
Al l
Yes → Repai r the short to ground i n the (K118) Battery Temp Si gnal
ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 8
33
DRIVEABILITY - GAS
P0071-AMBIENT/BATTERY TEMP SENSOR PERFORMANCE — Continued
TEST ACTION APPLICABILITY
8 NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Usi ng the schemati cs as a gui de, i nspect the wi re harness and connectors. Pay
parti cul ar attenti on to al l Power and Ground ci rcui ts.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace and program the Powertrai n Control Modul e per Servi ce
I nformati on.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
34
DRIVEABILITY - GAS
P0071-AMBIENT/BATTERY TEMP SENSOR PERFORMANCE — Continued
Symptom:
P0107-MAP SENSOR VOLTAGE TOO LOW
When Monitored and Set Condition:
P0107-MAP SENSOR VOLTAGE TOO LOW
When Moni tored: Wi th the engi ne RPM above 416 but l ess than 1500, the TPS vol tage
l ess than 1.13 vol ts, and battery vol tage greater than 10.4 vol ts.
Set Condi ti on: The MAP Sensor si gnal vol tage i s bel ow 0.1 of a vol t for 2.0 seconds wi th
the engi ne runni ng.
POSSIBLE CAUSES
MAP SENSOR VOLTAGE BELOW 0.1 VOLT
(K7) 5-VOLT SUPPLY CI RCUI T OPEN
(K7) 5-VOLT SUPPLY CI RCUI T SHORTED TO GROUND
MAP SENSOR
(K1) MAP SENSOR SI GNAL CI RCUI T SHORTED TO GROUND
(K1) MAP SENSOR SI GNAL CI RCUI T SHORTED TO THE (K4) SENSOR GROUND CI RCUI T
PCM
TEST ACTION APPLICABILITY
1 Check for any rel ated TSBs.
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, read DTCs and record the rel ated Freeze Frame data.
Start the engi ne.
Wi th the DRBI I I ௡, read the MAP Sensor vol tage.
I s the vol tage bel ow 0.1 of a vol t?
Al l
Yes → Go To 2
No → Refer to the I NTERMI TTENT CONDI TI ON Symptom (Di agnos-
ti c Procedure).
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
2 Turn the i gni ti on off.
Di sconnect the MAP Sensor harness connector.
I gni ti on on, engi ne not runni ng.
Measure the vol tage of the (K7) 5-vol t Suppl y ci rcui t at the MAP Sensor harness
connector.
I s the vol tage between 4.5 and 5.2 vol ts?
Al l
Yes → Go To 3
No → Go To 6
35
DRIVEABILITY - GAS
TEST ACTION APPLICABILITY
3 Wi th the DRBI I I ௡, moni tor the MAP Sensor vol tage wi th the i gni ti on on and Map
Sensor sti l l di sconnected.
I s the vol tage above 1.2 vol ts?
Al l
Yes → Repl ace the MAP Sensor.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 4
4 Turn the i gni ti on off.
Di sconnect the PCM harness connectors.
Measure the resi stance between ground and the (K1) MAP Sensor Si gnal ci rcui t at
the MAP Sensor harness connector.
I s the resi stance bel ow 100 ohms?
Al l
Yes → Repai r the short to ground i n the (K1) MAP Sensor Si gnal ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 5
5 Measure the resi stance between the (K1) MAP Sensor Si gnal ci rcui t and the (K4)
Sensor ground ci rcui t at the MAP Sensor harness connector.
I s the resi stance bel ow 100 ohms?
Al l
Yes → Repai r the short between the (K4) Sensor ground and the (K1)
MAP Sensor Si gnal ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 8
6 Turn the i gni ti on off.
Di sconnect the PCM harness connectors.
Measure the resi stance i n the (K7) 5-vol t Suppl y ci rcui t from the MAP Sensor
harness connector to the PCM harness connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 7
No → Repai r the open i n the (K7) 5-vol t Suppl y ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
7 Measure the resi stance between ground and the (K7) 5-vol t Suppl y ci rcui t at the
MAP Sensor harness connector.
I s the resi stance bel ow 100 ohms?
Al l
Yes → Repai r the short to ground i n the (K7) 5-vol t Suppl y ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 8
8 NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Usi ng the schemati cs as a gui de, i nspect the wi re harness and connectors. Pay
parti cul ar attenti on to al l Power and Ground ci rcui ts.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace and program the Powertrai n Control Modul e per Servi ce
I nformati on.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
36
DRIVEABILITY - GAS
P0107-MAP SENSOR VOLTAGE TOO LOW— Continued
Symptom:
P0108-MAP SENSOR VOLTAGE TOO HIGH
When Monitored and Set Condition:
P0108-MAP SENSOR VOLTAGE TOO HIGH
When Moni tored: Wi th the engi ne RPM above 400, the TPS vol tage l ess than 1.13 vol ts,
and battery vol tage greater than 10.4 vol ts
Set Condi ti on: The MAP Sensor si gnal vol tage i s greater than 4.88 vol ts at start or wi th
the engi ne runni ng for 2.2 seconds.
POSSIBLE CAUSES
MAP SENSOR VOLTAGE ABOVE 4.6 VOLTS
MAP SENSOR
(K1) MAP SENSOR SI GNAL CI RCUI T SHORTED TO VOLTAGE
(K1) MAP SENSOR SI GNAL CI RCUI T OPEN
(K1) MAP SENSOR SI GNAL CI RCUI T SHORTED TO (K7) 5-VOLT SUPPLY CI RCUI T
(K4) SENSOR GROUND CI RCUI T OPEN
PCM
TEST ACTION APPLICABILITY
1 Check for any rel ated TSBs.
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, read DTCs and record the rel ated Freeze Frame data.
Start the engi ne.
Wi th the DRBI I I ௡, read the MAP Sensor vol tage.
I s the vol tage above 4.6 vol ts?
Al l
Yes → Go To 2
No → Refer to the I NTERMI TTENT CONDI TI ON Symptom (Di agnos-
ti c Procedure).
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
2 Turn the i gni ti on off.
Di sconnect the MAP Sensor harness connector.
Connect a jumper wi re between the (K1) MAP Sensor Si gnal ci rcui t and the (K4)
Sensor ground ci rcui t i n the Sensor harness connector.
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, moni tor the MAP Sensor vol tage.
I s the vol tage bel ow 1.0 vol t?
Al l
Yes → Repl ace the MAP Sensor.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 3
NOTE: Remove the jumper wire before continuing.
37
DRIVEABILITY - GAS
TEST ACTION APPLICABILITY
3 Turn the i gni ti on off.
Di sconnect the PCM harness connectors.
I gni ti on on, engi ne not runni ng.
Measure the vol tage on the (K1) MAP Sensor Si gnal ci rcui t at the MAP Sensor
harness connector.
I s the vol tage above 5.2 vol ts?
Al l
Yes → Repai r the short to vol tage i n the (K1) MAP Sensor Si gnal ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 4
4 Turn the i gni ti on off.
Measure the resi stance of the (K1) MAP Sensor Si gnal ci rcui t from the MAP Sensor
harness connector to the PCM harness connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 5
No → Repai r the open i n the (K1) MAP Sensor Si gnal ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
5 Measure the resi stance between the (K1) MAP Sensor Si gnal ci rcui t and the (K7)
5-vol t Suppl y ci rcui t at the MAP Sensor harness connector.
I s the resi stance bel ow 100 ohms?
Al l
Yes → Repai r the short between the (K7) 5-vol t Suppl y ci rcui t and the
(K1) MAP Sensor Si gnal ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 6
6 Measure the resi stance of the (K4) Sensor ground ci rcui t from the PCM harness
connector to the MAP Sensor harness connector.
I s the resi stance bel ow 100 ohms?
Al l
Yes → Go To 7
No → Repai r the open i n the (K4) Sensor ground ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
7 NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Usi ng the schemati cs as a gui de, i nspect the wi re harness and connectors. Pay
parti cul ar attenti on to al l Power and Ground ci rcui ts.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace and program the Powertrai n Control Modul e per Servi ce
I nformati on.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
38
DRIVEABILITY - GAS
P0108-MAP SENSOR VOLTAGE TOO HIGH — Continued
Symptom:
P0111-INTAKE AIR TEMP PERFORMANCE
When Monitored and Set Condition:
P0111-INTAKE AIR TEMP PERFORMANCE
When Moni tored: Wi th the i gni ti on on and no I ntake Ai r Temperature Sensor open/
shorted faul ts present.
Set Condi ti on: After 5 warm cycl es have occurred (cool ant i ncreases at l east 22°C (40°F)
to a mi ni mum of 71°C (160°F) and the odometer mi l eage has i ncreased 196.6 mi l es and the
I ntake Ai r Temperature has had l ess than 5°C (9°F) change i n temperature.
POSSIBLE CAUSES
GOOD TRI P EQUAL TO ZERO
I AT SENSOR VOLTAGE BELOW 1.0 VOLT
RESI STANCE I N THE (K21) I AT SENSOR SI GNAL CI RCUI T
RESI STANCE I N THE (K4) SENSOR GROUND CI RCUI T
PCM
TEST ACTION APPLICABILITY
1 Check for any rel ated TSBs.
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, read DTCs and record the rel ated Freeze Frame data.
I s the Good Tri p Counter equal to zero?
Al l
Yes → Go To 2
No → Refer to the I NTERMI TTENT CONDI TI ON Symptom (Di agnos-
ti c Procedure).
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
2 Turn the i gni ti on off.
Di sconnect the I ntake Ai r Temperature Sensor harness connector.
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, read the I AT Sensor vol tage.
I s the vol tage above 4.6 vol ts?
Al l
Yes → Go To 3
No → Go To 4
3 Connect a jumper wi re across the I AT Sensor harness connector.
Wi th the DRBI I I ௡, read the I AT Sensor vol tage.
I s the vol tage bel ow 1.0 vol t?
Al l
Yes → Repl ace the I ntake Ai r Temperature Sensor.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 4
NOTE: Removethejumper wireand connect theSensor harness connector
before continuing.
39
DRIVEABILITY - GAS
TEST ACTION APPLICABILITY
4 Turn the i gni ti on off.
NOTE: Ensurethevoltmeter leads meet theterminals in theconnector and
that there is good terminal to wire connection.
NOTE: Ensure the voltmeter leads are connected for positive polarity.
Perform a vol tage drop test by back probi ng the (K21) I ATSensor Si gnal ci rcui t at the
I AT Sensor harness connector and PCM harness connector.
Start the engi ne.
Al l ow the engi ne to i dl e.
I s the vol tage bel ow 0.10 of a vol t?
Al l
Yes → Go To 5
No → Repai r the excessi ve resi stance i n the (K21) I AT Sensor Si gnal
ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
5 Turn the i gni ti on off.
NOTE: Ensurethevoltmeter leads meet theterminals in theconnector and
that there is good terminal to wire connection.
NOTE: Ensure the voltmeter leads are connected for positive polarity.
Perform a vol tage drop test by back probi ng the (K4) Sensor ground ci rcui t at the I AT
Sensor harness connector and PCM harness connector.
Start the engi ne.
Al l ow the engi ne to i dl e.
I s the vol tage bel ow 0.10 of a vol t?
Al l
Yes → Go To 6
No → Repai r the excessi ve resi stance i n the (K4) Sensor ground ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
NOTE: Turn the ignition off before continuing.
6 NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Usi ng the schemati cs as a gui de, i nspect the wi re harness and connectors. Pay
parti cul ar attenti on to al l Power and Ground ci rcui ts.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace and program the Powertrai n Control Modul e per Servi ce
I nformati on.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
40
DRIVEABILITY - GAS
P0111-INTAKE AIR TEMP PERFORMANCE — Continued
Symptom:
P0112-INTAKE AIR TEMP SENSOR VOLTAGE TOO LOW
When Monitored and Set Condition:
P0112-INTAKE AIR TEMP SENSOR VOLTAGE TOO LOW
When Moni tored: Wi th the i gni ti on on and battery vol tage greater than 10.4 vol ts.
Set Condi ti on: The I ntake Ai r Temperature (I AT) Sensor ci rcui t vol tage at the PCM goes
bel ow 0.8 of a vol t.
POSSIBLE CAUSES
I AT SENSOR VOLTAGE BELOW 1.0 VOLT
I AT SENSOR
(K21) I AT SENSOR SI GNAL SHORTED TO GROUND
(K21) I AT SENSOR SI GNAL SHORTED TO (K4) SENSOR GROUND CI RCUI T
PCM
TEST ACTION APPLICABILITY
1 Check for any rel ated TSBs.
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, read DTCs and record the rel ated Freeze Frame data.
Wi th the DRBI I I ௡, read the I AT Sensor vol tage.
I s the vol tage bel ow 1.0 vol t?
Al l
Yes → Go To 2
No → Refer to the I NTERMI TTENT CONDI TI ON Symptom (Di agnos-
ti c Procedure).
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
2 Turn the i gni ti on off.
Di sconnect the I ntake Ai r Temp Sensor harness connector.
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, read I AT Sensor vol tage.
I s the vol tage above 1.0 vol t?
Al l
Yes → Repl ace the I AT Sensor.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 3
3 Turn the i gni ti on off.
Di sconnect the PCM harness connectors.
Measure the resi stance between ground and the (K21) I AT Sensor Si gnal ci rcui t i n
the I AT Sensor harness connector.
I s the resi stance bel ow 100 ohms?
Al l
Yes → Repai r the short to ground i n the (K21) I ATSensor Si gnal ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 4
41
DRIVEABILITY - GAS
TEST ACTION APPLICABILITY
4 Measure the resi stance between the (K21) I AT Sensor Si gnal ci rcui t and the (K4)
Sensor ground ci rcui t at the I AT Sensor harness connector.
I s the resi stance bel ow 100 ohms?
Al l
Yes → Repai r the short between the (K4) Sensor ground and the (K21)
I AT Sensor Si gnal ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 5
5 NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Usi ng the schemati cs as a gui de, i nspect the wi re harness and connectors. Pay
parti cul ar attenti on to al l Power and Ground ci rcui ts.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace and program the Powertrai n Control Modul e per Servi ce
I nformati on.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
42
DRIVEABILITY - GAS
P0112-INTAKE AIR TEMP SENSOR VOLTAGE TOO LOW— Continued
Symptom:
P0113-INTAKE AIR TEMP SENSOR VOLTAGE TOO HIGH
When Monitored and Set Condition:
P0113-INTAKE AIR TEMP SENSOR VOLTAGE TOO HIGH
When Moni tored: Wi th the i gni ti on on and battery vol tage greater than 10.4 vol ts.
Set Condi ti on: The I ntake Ai r Temperature (I AT) Sensor ci rcui t vol tage at the PCM goes
above 4.9 vol ts.
POSSIBLE CAUSES
I AT SENSOR VOLTAGE ABOVE 4.8 VOLTS
(K21) I AT SENSOR SI GNAL CI RCUI T SHORTED TO VOLTAGE
I AT SENSOR
(K21) I AT SENSOR SI GNAL CI RCUI T OPEN
(K4) SENSOR GROUND CI RCUI T OPEN
PCM
TEST ACTION APPLICABILITY
1 Check for any rel ated TSBs.
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, read DTCs and record the rel ated Freeze Frame data.
Wi th the DRBI I I ௡, read the I AT Sensor vol tage.
I s the vol tage above 4.8 vol ts?
Al l
Yes → Go To 2
No → Refer to the I NTERMI TTENT CONDI TI ON Symptom (Di agnos-
ti c Procedure).
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
2 Turn the i gni ti on off.
Di sconnect the I ntake Ai r Temp Sensor harness connector.
Connect a jumper wi re between the (K21) I AT Sensor Si gnal ci rcui t and the (K4)
Sensor ground ci rcui t at the Sensor harness connector.
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, read the I AT Sensor vol tage.
I s the vol tage bel ow 1.0 vol t?
Al l
Yes → Repl ace the I AT Sensor.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 3
NOTE: Remove the jumper wire before continuing.
43
DRIVEABILITY - GAS
TEST ACTION APPLICABILITY
3 Turn the i gni ti on off.
Di sconnect the PCM harness connectors.
I gni ti on on, engi ne not runni ng.
Measure the vol tage on the (K21) I AT Sensor Si gnal ci rcui t at the Sensor harness
connector.
I s the vol tage above 0 vol ts?
Al l
Yes → Repai r the short to vol tage i n the (K21) I ATSensor Si gnal ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 4
4 Turn the i gni ti on off.
Measure the resi stance of the (K21) I AT Sensor Si gnal ci rcui t from the I AT Sensor
harness connector to the PCM harness connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 5
No → Repai r the open i n the (K21) I AT Sensor Si gnal ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
5 Measure the resi stance of the (K4) Sensor ground ci rcui t from the I AT Sensor
harness connector to the PCM harness connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 6
No → Repai r the open i n the (K4) Sensor ground ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
6 NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Usi ng the schemati cs as a gui de, i nspect the wi re harness and connectors. Pay
parti cul ar attenti on to al l Power and Ground ci rcui ts.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace and program the Powertrai n Control Modul e per Servi ce
I nformati on.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
44
DRIVEABILITY - GAS
P0113-INTAKE AIR TEMP SENSOR VOLTAGE TOO HIGH — Continued
Symptom:
P0117-ENGINE COOLANT TEMP SENSOR VOLTAGE TOO LOW
When Monitored and Set Condition:
P0117-ENGINE COOLANT TEMP SENSOR VOLTAGE TOO LOW
When Moni tored: Wi th the i gni ti on on and battery vol tage greater than 10.4 vol ts.
Set Condi ti on: The Engi ne Cool ant Temperature (ECT) Si gnal ci rcui t vol tage at the PCM
goes bel ow 0.8 of a vol t for more than 3 seconds.
POSSIBLE CAUSES
ECT VOLTAGE BELOW 1.0 VOLT
ECT SENSOR
(K2) ECT SENSOR SI GNAL CI RCUI T SHORTED TO GROUND
(K2) ECT SENSOR SI GNAL SHORTED TO (K4) SENSOR GROUND CI RCUI T
PCM
TEST ACTION APPLICABILITY
1 Check for any rel ated TSBs.
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, read DTCs and record the rel ated Freeze Frame data.
Wi th the DRBI I I ௡, read the ECT Sensor vol tage.
I s the vol tage bel ow 1.0 vol t?
Al l
Yes → Go To 2
No → Refer to the I NTERMI TTENT CONDI TI ON Symptom (Di agnos-
ti c Procedure).
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
2 Turn the i gni ti on off.
Di sconnect the Engi ne Cool ant Temp Sensor harness connector.
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, read ECT vol tage.
I s the vol tage above 1.0 vol t?
Al l
Yes → Repl ace the ECT Sensor.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 3
3 Turn the i gni ti on off.
Di sconnect the PCM harness connectors.
Measure the resi stance between ground and the (K2) ECT Sensor Si gnal ci rcui t at
the ECT Sensor harness connector.
I s the resi stance bel ow 100 ohms?
Al l
Yes → Repai r the short to ground i n the (K2) ECT Sensor Si gnal ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 4
45
DRIVEABILITY - GAS
TEST ACTION APPLICABILITY
4 Measure the resi stance between the (K2) ECT Sensor Si gnal ci rcui t and the (K4)
Sensor ground ci rcui t at the ECT Sensor harness connector.
I s the resi stance bel ow 100 ohms?
Al l
Yes → Repai r the short between the (K4) Sensor ground and the (K2)
ECT Sensor Si gnal ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 5
5 NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Usi ng the schemati cs as a gui de, i nspect the wi re harness and connectors. Pay
parti cul ar attenti on to al l Power and Ground ci rcui ts.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace and program the Powertrai n Control Modul e per Servi ce
I nformati on.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
46
DRIVEABILITY - GAS
P0117-ENGINE COOLANT TEMP SENSOR VOLTAGE TOO LOW —
Continued
Symptom:
P0118-ENGINE COOLANT TEMP SENSOR VOLTAGE TOO HIGH
When Monitored and Set Condition:
P0118-ENGINE COOLANT TEMP SENSOR VOLTAGE TOO HIGH
When Moni tored: Wi th the i gni ti on on and battery vol tage greater than 10.4 vol ts.
Set Condi ti on: The Engi ne Cool ant Temperature (ECT) Sensor ci rcui t vol tage at the PCM
goes above 4.94 vol ts for more than 3 seconds.
POSSIBLE CAUSES
ECT VOLTAGE ABOVE 4.9 VOLTS
ECT SENSOR
(K2) ECT SENSOR SI GNAL CI RCUI T SHORTED TO VOLTAGE
(K2) ECT SENSOR SI GNAL CI RCUI T OPEN
(K4) SENSOR GROUND CI RCUI T OPEN
PCM
TEST ACTION APPLICABILITY
1 Check for any rel ated TSBs.
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, read DTCs and record the rel ated Freeze Frame data.
Wi th the DRBI I I ௡, read the ECT Sensor vol tage.
I s the vol tage above 4.9 vol ts?
Al l
Yes → Go To 2
No → Refer to the I NTERMI TTENT CONDI TI ON Symptom (Di agnos-
ti c Procedure).
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
2 Turn the i gni ti on off.
Di sconnect the Engi ne Cool ant Temp Sensor harness connector.
I gni ti on on, engi ne not runni ng.
Connect a jumper wi re between the (K2) ECT Sensor Si gnal ci rcui t and the (K4)
Sensor ground ci rcui t i n the ECT Sensor harness connector.
Wi th the DRBI I I ௡, read the ECT Sensor vol tage.
I s the vol tage bel ow 1.0 vol t?
Al l
Yes → Repl ace the ECT Sensor.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 3
NOTE: Remove the jumper wire before continuing.
47
DRIVEABILITY - GAS
TEST ACTION APPLICABILITY
3 Turn the i gni ti on off.
Di sconnect the PCM harness connectors.
I gni ti on on, engi ne not runni ng.
Measure the vol tage on the (K2) ECT Sensor Si gnal ci rcui t i n the ECT Sensor
harness connector.
I s the vol tage above 0 vol ts?
Al l
Yes → Repai r the short to vol tage i n the (K2) ECT Sensor Si gnal ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 4
4 Turn the i gni ti on off.
Measure the resi stance of the (K2) ECT Sensor Si gnal ci rcui t from the ECT Sensor
harness connector to the PCM harness connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 5
No → Repai r the open i n the (K2) ECT Sensor Si gnal ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
5 Measure the resi stance of the (K4) Sensor ground ci rcui t from the ECT Sensor
harness connector to the PCM harness connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 6
No → Repai r the open i n the (K4) Sensor ground ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
6 NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Usi ng the schemati cs as a gui de, i nspect the wi re harness and connectors. Pay
parti cul ar attenti on to al l Power and Ground ci rcui ts.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace and program the Powertrai n Control Modul e per Servi ce
I nformati on.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
48
DRIVEABILITY - GAS
P0118-ENGINE COOLANT TEMP SENSOR VOLTAGE TOO HIGH —
Continued
Symptom:
P0121-TP SENSOR VOLTAGE DOES NOT AGREE WITH MAP SEN-
SOR
When Monitored and Set Condition:
P0121-TP SENSOR VOLTAGE DOES NOT AGREE WITH MAP SENSOR
When Moni tored: Wi th the engi ne runni ng and no MAP sensor or TPS DTC’s set. Engi ne
speed must be greater than 1600 RPM.
Set Condi ti on: The PCM performs two separate tests. When the mani fol d vacuum i s l ow,
the TPS si gnal shoul d be hi gh. When the mani fol d vacuum i s hi gh, the TPS si gnal shoul d
be l ow. I f the proper TPS vol tage i s not detected when the two condi ti ons are met, a DTC
wi l l be set after 4 seconds.
POSSIBLE CAUSES
GOOD TRI P EQUAL TO ZERO
RESI STANCE I N (K7) MAP 5-VOLT SUPPLY CI RCUI T
(K7) MAP 5-VOLT SUPPLY CI RCUI T SHORTED TO GROUND
MAP SENSOR
RESI STANCE I N THE (K1) MAP SENSOR SI GNAL CI RCUI T
(K1) MAP SENSOR SI GNAL CI RCUI T SHORTED TO GROUND
RESI STANCE I N (K4) MAP SENSOR GROUND CI RCUI T
TP SENSOR OPERATI ON
RESI STANCE I N (K7) TP SENSOR 5-VOLT SUPPLY CI RCUI T
(K7) TP SENSOR 5-VOLT SUPPLY CI RCUI T SHORTED TO GROUND
THROTTLE POSI TI ON SENSOR
RESI STANCE I N (K22) TP SENSOR NO.1 SI GNAL CI RCUI T
(K22) TP SENSOR NO.1 SI GNAL CI RCUI T SHORTED TO GROUND
RESI STANCE I N (K4) SENSOR GROUND CI RCUI T
PCM
49
DRIVEABILITY - GAS
TEST ACTION APPLICABILITY
1 Check for any rel ated TSBs.
NOTE:DiagnoseanyTP Sensor or MAP component DTCsbeforecontinuing.
NOTE: If the P0500 - No Vehicle Speed Signal is set along with this DTC,
refer to the P0500 diagnostics before continuing.
NOTE: Thethrottleplateand linkageshould befreeof bindingand carbon
build up.
NOTE: Ensure the throttle plate is at the idle position.
I gni ti on on, engi ne not runni ng.
NOTE: Repair any vacuumleaks that are present before continuing.
Wi th the DRBI I I ௡, read DTCs and record the rel ated Freeze Frame data.
I s the Good Tri p Counter di spl ayed and equal to zero?
Al l
Yes → Go To 2
No → Refer to the I NTERMI TTENTCONDTI ON Symptom (Di agnosti c
Procedure).
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
2 Start the engi ne.
Wi th the DRBI I I ௡, moni tor the MAP Sensor vol tage.
Snap the throttl e.
Does the DRBI I I ௡ di spl ay MAP vol tage from bel ow 2.0 vol ts at i dl e to above 3.5 vol ts
at WOT?
Al l
Yes → Go To 3
No → Go To 10
3 I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, moni tor the TP Sensor vol tage whi l e sl owl y pressi ng the
accel erator pedal from the i dl e posi ti on to the wi de open throttl e posi ti on.
Does vol tage start at approxi matel y 0.8 of a vol t and go above 3.5 vol ts wi th a smooth
transi ti on?
Al l
Yes → Refer to the I NTERMI TTENTCONDTI ON Symptom (Di agnosti c
Procedure).
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 4
4 Turn the i gni ti on off.
Di sconnect the TP Sensor harness connector.
Di sconnect the PCM harness connectors.
Measure the resi stance of the (K7) 5-vol t Suppl y ci rcui t from the TP Sensor harness
connector to the PCM harness connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 5
No → Repai r the excessi ve resi stance i n the (K7) 5-vol t Suppl y ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
5 Measure the resi stance between ground and the (K7) 5-vol t Suppl y ci rcui t at the TP
Sensor harness connector.
I s the resi stance bel ow 100 ohms?
Al l
Yes → Repai r the short to ground i n the (K7) 5-vol t Suppl y ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 6
50
DRIVEABILITY - GAS
P0121-TP SENSOR VOLTAGE DOES NOT AGREE WITH MAP SENSOR —
Continued
TEST ACTION APPLICABILITY
6 Connect the PCM harness connectors.
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, moni tor the TP Sensor vol tage.
Connect a jumper wi re between the (K22) TP Sensor No.1 Si gnal ci rcui t and the (K4)
Sensor ground ci rcui t i n the Sensor harness connector.
Does the DRBI I I ௡ di spl ay TP Sensor vol tage from approxi matel y 4.9 vol ts to bel ow
0.5 of a vol t?
Al l
Yes → Repl ace the Throttl e Posi ti on Sensor.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 7
NOTE: Remove the jumper wire before continuing.
7 Turn the i gni ti on off.
Di sconnect the PCM harness connectors.
Measure the resi stance of the (K22) TP Sensor No.1 Si gnal ci rcui t from the TP Sensor
harness connector to the PCM harness connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 8
No → Repai r the excessi ve resi stance i n the (K22) TP Sensor No.1
Si gnal ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
8 Measure the resi stance between ground and the (K22) TP Sensor No.1 Si gnal ci rcui t
from the TP Sensor harness connector.
I s the resi stance bel ow 100 ohms?
Al l
Yes → Go To 9
No → Repai r the short to ground i n the (K22) TP Sensor No.1 Si gnal
ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
9 Measure the resi stance of the (K4) Sensor ground ci rcui t from the TP Sensor harness
connector to the PCM harness connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 16
No → Repai r the excessi ve resi stance i n the (K4) Sensor ground ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
10 Turn the i gni ti on off.
Di sconnect the MAP Sensor harness connector.
Di sconnect the PCM harness connectors.
Measure the resi stance of the (K7) 5-vol t Suppl y ci rcui t from the MAP Sensor
harness connector to the PCM harness connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 11
No → Repai r the excessi ve resi stance i n the (K7) 5-vol t Suppl y ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
51
DRIVEABILITY - GAS
P0121-TP SENSOR VOLTAGE DOES NOT AGREE WITH MAP SENSOR —
Continued
TEST ACTION APPLICABILITY
11 Measure the resi stance between ground and the (K7) 5-vol t Suppl y ci rcui t at the
MAP Sensor harness connector.
I s the resi stance above 100k ohms?
Al l
Yes → Go To 12
No → Repai r the short to ground i n the (K7) MAP 5-vol t Suppl y ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
12 Connect the PCM harness connector.
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, moni tor the MAP Sensor vol tage.
Connect a jumper wi re between the (K1) MAP Sensor Si gnal ci rcui t and the (K4)
Sensor ground ci rcui t i n the Sensor harness connector.
Cycl e the i gni ti on swi tch from off to on.
Does the DRBI I I ௡ di spl ay MAP vol tage from approxi matel y 4.9 vol ts to bel ow 0.5 of
a vol t?
Al l
Yes → Repl ace the MAP Sensor.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 13
NOTE: Disconnect the jumper wire before continuing.
13 Turn the i gni ti on off.
Di sconnect the PCM harness connectors.
Measure the resi stance of the (K1) MAP Sensor Si gnal ci rcui t from the MAP Sensor
harness connector to the PCM harness connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 14
No → Repai r the excessi ve resi stance i n the (K1) MAP Sensor Si gnal
ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
14 Measure the resi stance between ground and the (K1) MAP Sensor Si gnal ci rcui t from
the MAP Sensor harness connector.
I s the resi stance bel ow 100 ohms?
Al l
Yes → Go To 15
No → Repai r the short to ground i n the (K1) MAP Sensor Si gnal ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
15 Measure the resi stance of the (K4) Sensor ground ci rcui t from the MAP Sensor
harness connector to the PCM harness connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 16
No → Repai r the excessi ve resi stance i n the (K4) Sensor ground ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
52
DRIVEABILITY - GAS
P0121-TP SENSOR VOLTAGE DOES NOT AGREE WITH MAP SENSOR —
Continued
TEST ACTION APPLICABILITY
16 NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Usi ng the schemati cs as a gui de, i nspect the wi re harness and connectors. Pay
parti cul ar attenti on to al l Power and Ground ci rcui ts.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace and program the Powertrai n Control Modul e per Servi ce
I nformati on.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
53
DRIVEABILITY - GAS
P0121-TP SENSOR VOLTAGE DOES NOT AGREE WITH MAP SENSOR —
Continued
Symptom:
P0122-THROTTLE POSITION SENSOR VOLTAGE TOO LOW
When Monitored and Set Condition:
P0122-THROTTLE POSITION SENSOR VOLTAGE TOO LOW
When Moni tored: Wi th the i gni ti on on and battery vol tage above 10.4 vol ts.
Set Condi ti on: Throttl e Posi ti on Sensor vol tage at the PCM i s l ower than 0.1 of a vol t for
1.3 seconds.
POSSIBLE CAUSES
TP SENSOR SWEEP
I NTERMI TTENT CONDI TI ON
(K7) 5-VOLT SUPPLY CI RCUI T OPEN
(K7) 5-VOLT SUPPLY CI RCUI T SHORTED TO GROUND
TP SENSOR
(K22) TP SENSOR NO.1 SI GNAL CI RCUI T SHORTED TO GROUND
(K22) TP SENSOR NO.1 SI GNAL CI RCUI T SHORTED TO (K4) SENSOR GROUND CI RCUI T
TCM I NTERNALLY SHORTED THROTTLE POSI TI ON SI GNAL CI RCUI T
PCM
TEST ACTION APPLICABILITY
1 I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, read DTCs and record the rel ated Freeze Frame data.
Check for any rel ated TSBs.
Wi th the DRBI I I ௡, read the Throttl e Posi ti on Sensor vol tage.
I s the vol tage bel ow 0.2 of a vol t?
Al l
Yes → Go To 2
No → Go To 10
2 Turn the i gni ti on off.
Di sconnect the Throttl e Posi ti on Sensor harness connector.
I gni ti on on, engi ne not runni ng.
Measure the vol tage on the (K7) 5-vol t Suppl y ci rcui t i n the TP Sensor harness
connector.
I s the vol tage between 4.5 to 5.2 vol ts?
Al l
Yes → Go To 3
No → Go To 7
3 Wi th the DRBI I I ௡, moni tor the TP Sensor vol tage wi th the Sensor di sconnected.
I s the vol tage above 4.5 vol ts?
Al l
Yes → Repl ace the Throttl e Posi ti on Sensor.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 4
54
DRIVEABILITY - GAS
TEST ACTION APPLICABILITY
4 Turn the i gni ti on off.
Di sconnect the PCM harness connectors.
Measure the resi stance between ground and the (K22) TP Sensor No.1 Si gnal ci rcui t
i n the TP Sensor harness connector.
I s the resi stance bel ow 100 ohms?
Al l
Yes → Repai r the short to ground i n the (K22) TP Sensor No.1 Si gnal
ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 5
5 Measure the resi stance between the (K22) TP Sensor No.1 Si gnal ci rcui t and the (K4)
Sensor ground ci rcui t i n the TP Sensor harness connector.
I s the resi stance bel ow 100 ohms?
Al l
Yes → Repai r the short between the (K4) Sensor ground and the (K22)
TP Sensor No.1 Si gnal ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 6
6 NOTE: If thevehicleisnot equippedwith aTCM, answer Notothistest and
continue.
Connect the PCM harness connectors.
Di sconnect the TCM harness connector.
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, moni tor the Throttl e Posi ti on Sensor vol tage.
I s the vol tage above 4.5 vol ts?
Al l
Yes → Repl ace the TCM i n accordance wi th the Servi ce I nformati on.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 9
7 Turn the i gni ti on off.
Di sconnect the PCM harness connectors.
Measure the resi stance of the (K7) 5-vol t Suppl y ci rcui t from the TP Sensor harness
connector to the PCM harness connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 8
No → Repai r the open i n the (K7) 5-vol t Suppl y ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
8 Measure the resi stance between ground and the (K7) 5-vol t Suppl y ci rcui t i n the TP
Sensor harness connector.
I s the resi stance bel ow 100 ohms?
Al l
Yes → Repai r the short to ground i n the (K7) 5-vol t Suppl y ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 9
55
DRIVEABILITY - GAS
P0122-THROTTLE POSITION SENSOR VOLTAGE TOO LOW— Continued
TEST ACTION APPLICABILITY
9 Turn the i gni ti on off.
NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Usi ng the schemati cs as a gui de, i nspect the wi re harness and connectors. Pay
parti cul ar attenti on to al l Power and Ground ci rcui ts.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace and program the Powertrai n Control Modul e per Servi ce
I nformati on.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
10 I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, moni tor the Throttl e Posi ti on Sensor vol tage.
Sl owl y open the throttl e from the i dl e posi ti on to the wi de open throttl e posi ti on.
Does vol tage start at approxi matel y 0.8 of a vol t and go above 3.5 vol ts wi th a smooth
transi ti on?
Al l
Yes → Refer to the I NTERMI TTENT CONDI TI ON Symptom (Di agnos-
ti c Procedure).
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Repl ace the Throttl e Posi ti on Sensor.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
56
DRIVEABILITY - GAS
P0122-THROTTLE POSITION SENSOR VOLTAGE TOO LOW— Continued
Symptom:
P0123-THROTTLE POSITION SENSOR VOLTAGE TOO HIGH
When Monitored and Set Condition:
P0123-THROTTLE POSITION SENSOR VOLTAGE TOO HIGH
When Moni tored: Wi th the i gni ti on on and battery vol tage above 10.4 vol ts.
Set Condi ti on: Throttl e Posi ti on Sensor si gnal vol tage at the PCM goes above 4.5 vol ts for
3.2 seconds.
POSSIBLE CAUSES
TP SENSOR SWEEP
TP SENSOR
I NTERMI TTENT CONDI TI ON
(K22) TP SENSOR NO.1 SI GNAL CI RCUI T SHORTED TO VOLTAGE
(K22) TP SENSOR NO.1 SI GNAL CI RCUI T OPEN
(K22) TP SENSOR NO.1 SI GNAL CI RCUI T SHORTED TO (K7) 5-VOLT SUPPLY CI RCUI T
(K4) SENSOR GROUND CI RCUI T OPEN
PCM
TEST ACTION APPLICABILITY
1 I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, read DTCs and record the rel ated Freeze Frame data.
Check for any rel ated TSBs.
NOTE: Ensure the throttle is fully closed and free frombinding or carbon
build up.
Start the engi ne.
Wi th the DRBI I I ௡, read the Throttl e Posi ti on Sensor vol tage.
I s the vol tage above 4.5 vol ts?
Al l
Yes → Go To 2
No → Go To 8
2 Turn the i gni ti on off.
Di sconnect the Throttl e Posi ti on Sensor harness connector.
Connect a jumper wi re between the (K22) TP Sensor No.1 Si gnal ci rcui t and the (K4)
Sensor ground ci rcui t i n the Sensor harness connector.
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, moni tor the TP Sensor vol tage.
I s the vol tage bel ow 0.5 of a vol t?
Al l
Yes → Repl ace the Throttl e Posi ti on Sensor.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 3
NOTE: Remove the jumper wire before continuing.
57
DRIVEABILITY - GAS
TEST ACTION APPLICABILITY
3 I gni ti on on, engi ne not runni ng.
Measure the vol tage on the (K22) TP Sensor No.1 Si gnal ci rcui t at the TP Sensor
harness connector.
NOTE: If the voltage reading is below 5.2 volts answer NO to this test and
continue.
I f the vol tage i s above 5.3 vol ts, di sconnect the Cl ock Spri ng harness connector per
Servi ce I nformati on.
I f the Cl ockspri ng harness connector i s di sconnected and the TP Sensor vol tage drops
to 5.0 vol ts, repl ace the Cl ockspri ng per Servi ce I nformati on.
I s the vol tage above 5.3 vol ts wi th the Cl ock Spri ng harness di sconnected?
Al l
Yes → Repai r the short to vol tage i n the (K22) TP Sensor No.1 Si gnal
ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 4
NOTE: Turn the ignition off and connect the Clockspring harness connec-
tors per Service Information before continuing.
4 Di sconnect the PCM harness connectors.
Measure the resi stance of the (K22) TP Sensor No.1 Si gnal ci rcui t from the TP Sensor
harness connector to the PCM harness connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 5
No → Repai r the open i n the (K22) TP Sensor No.1 Si gnal ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
5 Measure the resi stance between the (K22) TP Sensor No.1 Si gnal ci rcui t and the (K7)
5-vol t Suppl y ci rcui t at the TP Sensor harness connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Repai r the short between the (K7) 5-vol t Suppl y ci rcui t and the
(K22) TP Sensor No.1 Si gnal ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 6
6 Measure the resi stance of the (K4) Sensor ground ci rcui t from the TP Sensor harness
connector to the PCM harness connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 7
No → Repai r the open i n the (K4) Sensor ground ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
7 NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Usi ng the schemati cs as a gui de, i nspect the wi re harness and connectors. Pay
parti cul ar attenti on to al l Power and Ground ci rcui ts.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace and program the Powertrai n Control Modul e per Servi ce
I nformati on.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
58
DRIVEABILITY - GAS
P0123-THROTTLE POSITION SENSOR VOLTAGE TOO HIGH — Continued
TEST ACTION APPLICABILITY
8 I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, moni tor the Throttl e Posi ti on Sensor vol tage.
Sl owl y open the throttl e from the i dl e posi ti on to the wi de open throttl e posi ti on.
Does vol tage start at approxi matel y 0.8 of a vol t and go above 3.5 vol ts wi th a smooth
transi ti on?
Al l
Yes → Refer to the I NTERMI TTENT CONDI TI ON Symptom (Di agnos-
ti c Procedure).
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Repl ace the Throttl e Posi ti on Sensor.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
59
DRIVEABILITY - GAS
P0123-THROTTLE POSITION SENSOR VOLTAGE TOO HIGH — Continued
Symptom:
P0125-CLOSED LOOP TEMP NOT REACHED
When Monitored and Set Condition:
P0125-CLOSED LOOP TEMP NOT REACHED
When Moni tored: Wi th battery vol tage greater than 10.4 vol ts, after engi ne i s started, for
ten mi nutes.
Set Condi ti on: The engi ne temperature does not go above 18 deg. F after the engi ne has
been runni ng for 10 mi nutes. Two tri ps are requi red to set thi s DTC.
POSSIBLE CAUSES
GOOD TRI P EQUAL TO ZERO
LOW COOLANT LEVEL
THERMOSTAT OPERATI ON
ECT SENSOR
TEST ACTION APPLICABILITY
1 Check for any rel ated TSBs.
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, read DTCs and record the rel ated Freeze Frame data.
I s the Good Tri p Counter di spl ayed and equal to zero?
Al l
Yes → Go To 2
No → Refer to the I NTERMI TTENT CONDI TI ON Symptom (Di agnos-
ti c Procedure).
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
2 NOTE: If a ECT Sensor DTC set along with this code, diagnose the ECT
Sensor DTC first.
NOTE: Inspect the ECT terminals and related PCM terminals. Ensure the
terminals are free fromcorrosion and damage.
NOTE: The best way to diagnose this DTC is to allow the vehicle to sit
overnight outside in order to have a totally cold soaked engine.
Note: Extremely cold outside ambient temperatures may have caused this
DTC to set.
WARNING: Never open the cooling system when the engine is hot. The
systemis under pressure. Extreme burns or scaldingmay result. Allow the
engine to cool before opening the cooling system.
Check the cool ant system to make sure that the cool ant i s i n good condi ti on and at
the proper l evel .
I s the cool ant l evel and condi ti on OK?
Al l
Yes → Go To 3
No → I nspect the vehi cl e for a cool ant l eak and add the necessary
amount of cool ant.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
60
DRIVEABILITY - GAS
TEST ACTION APPLICABILITY
3 Note: This test works best if performed on a cold engine (cold soak)
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, read the Eng Cool ant Tmp Deg val ue. I f the engi ne was al l owed
to si t overni ght (col d soak), the temperature val ue shoul d be a sensi bl e val ue that i s
somewhere cl ose to the ambi ent temperature.
Note: If enginecoolant temperatureis above82°C (180°F), allowtheengine
to cool until 65°C (150°F) is reached.
Start the Engi ne.
Duri ng engi ne warm-up moni tor the Eng Cool ant Tmp Deg val ue. The temp deg
val ue change shoul d be a smooth transi ti on from start up to normal operati ng temp
82°C (180°F) . Al so moni tor the actual cool ant temperature wi th a thermometer.
NOTE:Astheenginewarmsuptooperatingtemperature, theactual coolant
temperature (thermometer reading) and the Eng Coolant Tmp Deg in the
DRBIII௡ values should stay relatively close to each other.
Usi ng the appropri ate servi ce i nformati on, determi ne the proper openi ng tempera-
ture of the thermostat.
Di d the thermostat open at the proper temperature?
Al l
Yes → Go To 4
No → Repl ace the thermostat.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
4 Note: For this test to be valid, the thermostat must be operating correctly.
Note: This test works best if performed on a cold engine (cold soak)
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡ i n sensors, read the Eng Cool ant Tmp Deg val ue. I f the engi ne was
al l owed to si t overni ght (col d soak), the temperature val ue shoul d be a sensi bl e val ue
that i s somewhere cl ose to the surroundi ng temperature (ambi ent temperature).
Note: If enginecoolant temperatureis above82°C (180°F), allowtheengine
to cool until 65°C (150°F) is reached.
Start the engi ne.
Duri ng engi ne warm-up, moni tor the Eng Cool ant Tmp Deg val ue. The temp deg
val ue change shoul d be a smooth transi ti on from start up to normal operati ng temp
82°C (180°F). The val ue shoul d reach at l east 82°C (180°F).
Was the Eng Cool ant Tmp Deg val ue i ncrease a smooth transi ti on and di d i t reach at
l east 180°?
Al l
Yes → Test Compl ete.
No → Repl ace the Engi ne Cool ant Temperature Sensor.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
61
DRIVEABILITY - GAS
P0125-CLOSED LOOP TEMP NOT REACHED — Continued
SymptomList:
P0131-O2 SENSOR 1/1 CIRCUIT VOLTAGE LOW
P0137-O2 SENSOR 1/2 CIRCUIT VOLTAGE LOW
P0151-O2 SENSOR 2/1 CIRCUIT VOLTAGE LOW
P0157-O2 SENSOR 2/2 CIRCUIT VOLTAGE LOW
Test Note: All symptomslistedabovearediagnosedusingthesametests.
The title for the tests will be P0131-O2SENSOR 1/1CIRCUIT
VOLTAGE LOW.
When Monitored and Set Condition:
P0131-O2 SENSOR 1/1 CIRCUIT VOLTAGE LOW
When Moni tored: At a col d start, engi ne cool ant bel ow 98°F, Ambi ent/Battery Sensor
readi ng wi thi n 27°F, and Engi ne Cool ant Temperature above 170°F on the previ ous key off.
Set Condi ti on: The Oxygen Sensor si gnal vol tage i s bel ow 0.156 of a vol t for 28 seconds
after starti ng engi ne.
P0137-O2 SENSOR 1/2 CIRCUIT VOLTAGE LOW
When Moni tored: At a col d start, engi ne cool ant bel ow 98°F, Ambi ent/Battery Sensor
readi ng wi thi n 27°F, and Engi ne Cool ant Temperature above 170°F on the previ ous key off.
Set Condi ti on: The Oxygen Sensor si gnal vol tage i s bel ow 0.156 of a vol t for 28 seconds
after starti ng engi ne.
P0151-O2 SENSOR 2/1 CIRCUIT VOLTAGE LOW
When Moni tored: At a col d start, engi ne cool ant bel ow 98°F, Ambi ent/Battery Sensor
readi ng wi thi n 27°F, and Engi ne Cool ant Temperature above 170°F on the previ ous key off.
Set Condi ti on: The Oxygen Sensor si gnal vol tage i s bel ow 0.156 of a vol t for 28 seconds
after starti ng engi ne.
P0157-O2 SENSOR 2/2 CIRCUIT VOLTAGE LOW
When Moni tored: At a col d start, engi ne cool ant bel ow 98°F, Ambi ent/Battery Sensor
readi ng wi thi n 27°F, and Engi ne Cool ant Temperature above 170°F on the previ ous key off.
Set Condi ti on: The Oxygen Sensor si gnal vol tage i s bel ow 0.156 of a vol t for 28 seconds
after starti ng engi ne.
POSSIBLE CAUSES
O2 SENSOR BELOW 0.16 OF A VOLT
O2 SENSOR OPERATI ON
O2 SENSOR SI GNAL CI RCUI T SHORTED TO GROUND
O2 SENSOR SI GNAL CI RCUI T SHORTED TO (K4) SENSOR GROUND CI RCUI T
62
DRIVEABILITY - GAS
POSSIBLE CAUSES
O2 SENSOR SI GNAL SHORTED TO HEATER GROUND CI RCUI T
PCM
TEST ACTION APPLICABILITY
1 I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, read DTCs and record the rel ated Freeze Frame data.
Check for any rel ated TSBs.
Start the engi ne.
Al l ow the engi ne to i dl e for 4 to 5 mi nutes.
Wi th the DRBI I I ௡, read the O2 Sensor vol tage.
Does the vol tage stay bel ow 0.16 of a vol t?
Al l
Yes → Go To 2
No → Refer to the I NTERMI TTENT CONDI TI ON Symptom (Di agnos-
ti c Procedure).
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
2 Turn the i gni ti on off.
WARNING: 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.
Di sconnect the O2 Sensor harness connector.
Start the engi ne.
Wi th the DRBI I I ௡, moni tor the O2 Sensor vol tage.
I s the O2 Sensor vol tage above 0.16 of a vol t?
Al l
Yes → Repl ace the O2 Sensor
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 3
3 Turn the i gni ti on off.
Di sconnect the PCM harness connectors.
Measure the resi stance between ground and the O2 Sensor Si gnal ci rcui t at the O2
Sensor harness connector.
I s the resi stance bel ow 100 ohms?
Al l
Yes → Repai r the short to ground i n the O2 Sensor Si gnal ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 4
4 Measure the resi stance between the O2 Sensor Si gnal ci rcui t and the (K4) Sensor
ground ci rcui t at the O2 Sensor harness connector.
I s the resi stance bel ow 100 ohms?
Al l
Yes → Repai r the short between the (K4) Sensor ground ci rcui t and the
O2 Sensor Si gnal ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 5
63
DRIVEABILITY - GAS
P0131-O2 SENSOR 1/1 CIRCUIT VOLTAGE LOW— Continued
TEST ACTION APPLICABILITY
5 NOTE: Theremay betwotypesof O2Sensor Heater groundcircuitsusedon
this vehicle. One type uses an engine ground and the other type uses the
PCM as a ground through the Pulse Width Modulated circuit.
* Measure the resi stance between the PWM O2 Sensor Heater Control ci rcui t and the
O2 Sensor Si gnal ci rcui t i f i t appl i es to the O2 Sensor bei ng tested.
OR
* Measure the resi stance between the O2 Sensor Si gnal ci rcui t and the O2 Heater
ground ci rcui t i f i t appl i es to the O2 Sensor bei ng tested.
I s the resi stance bel ow 100 ohms?
Al l
Yes → Repai r the short between the O2 Sensor Si gnal ci rcui t and the
Heater ground ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 6
6 NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Usi ng the schemati cs as a gui de, i nspect the wi re harness and connectors. Pay
parti cul ar attenti on to al l Power and Ground ci rcui ts.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace and program the Powertrai n Control Modul e per Servi ce
I nformati on.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
64
DRIVEABILITY - GAS
P0131-O2 SENSOR 1/1 CIRCUIT VOLTAGE LOW— Continued
SymptomList:
P0132-O2 SENSOR 1/1 CIRCUIT VOLTAGE HIGH
P0138-O2 SENSOR 1/2 CIRCUIT VOLTAGE HIGH
P0152-O2 SENSOR 2/1 CIRCUIT VOLTAGE HIGH
P0158-O2 SENSOR 2/2 CIRCUIT VOLTAGE HIGH
Test Note: All symptomslistedabovearediagnosedusingthesametests.
The title for the tests will be P0132-O2SENSOR 1/1CIRCUIT
VOLTAGE HIGH.
When Monitored and Set Condition:
P0132-O2 SENSOR 1/1 CIRCUIT VOLTAGE HIGH
When Moni tored: Wi th battery vol tage greater than 10.4 vol ts, engi ne runni ng for more
than 4 mi nutes and cool ant temperature above 180°F.
Set Condi ti on: The oxygen sensor vol tage i s above 1.5 vol ts.
P0138-O2 SENSOR 1/2 CIRCUIT VOLTAGE HIGH
When Moni tored: Wi th battery vol tage greater than 10.4 vol ts, engi ne runni ng for more
than 4 mi nutes and cool ant temperature above 180°F.
Set Condi ti on: The oxygen sensor vol tage i s above 1.5 vol ts.
P0152-O2 SENSOR 2/1 CIRCUIT VOLTAGE HIGH
When Moni tored: Wi th battery vol tage greater than 10.4 vol ts, engi ne runni ng for more
than 4 mi nutes and cool ant temperature above 180°F.
Set Condi ti on: The oxygen sensor vol tage i s above 1.5 vol ts.
P0158-O2 SENSOR 2/2 CIRCUIT VOLTAGE HIGH
When Moni tored: Wi th battery vol tage greater than 10.4 vol ts, engi ne runni ng for more
than 4 mi nutes and cool ant temperature above 180°F.
Set Condi ti on: The oxygen sensor vol tage i s above 1.5 vol ts.
POSSIBLE CAUSES
O2 SENSOR ABOVE 1.5 VOLTS
O2 SENSOR OPERATI ON
O2 SENSOR SI GNAL CI RCUI T OPEN
O2 SENSOR SI GNAL CI RCUI T SHORTED TO O2 HEATER SUPPLY CI RCUI T
(K4) SENSOR GROUND CI RCUI T OPEN
O2 SENSOR HEATER CONTROL CI RCUI T OPEN
O2 SENSOR HEATER SUPPLY CI RCUI T OPEN
65
DRIVEABILITY - GAS
POSSIBLE CAUSES
O2 SENSOR SI GNAL SHORTED TO VOLTAGE
PCM
TEST ACTION APPLICABILITY
1 I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, read DTCs and record the rel ated Freeze Frame data.
Check for any rel ated TSBs.
Start the engi ne.
Al l ow the engi ne to i dl e for 4 to 5 mi nutes.
Wi th the DRBI I I ௡, read the O2 Sensor vol tage.
I s the vol tage above 1.5 vol ts?
Al l
Yes → Go To 2
No → Refer to the I NTERMI TTENT CONDI TI ON Symptom (Di agnos-
ti c Procedure).
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
2 WARNING: 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.
Turn the i gni ti on off.
Di sconnect the O2 Sensor harness connector.
Start the engi ne.
Wi th the DRBI I I ௡, moni tor the O2 Sensor vol tage.
I s the O2 Sensor vol tage bel ow 1.5 vol ts?
Al l
Yes → Repl ace the O2 Sensor.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 3
3 Turn the i gni ti on off.
Di sconnect the PCM harness connectors.
Measure the resi stance of the O2 Sensor Si gnal ci rcui t from the O2 Sensor harness
connector to the PCM harness connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 4
No → Repai r the open i n the O2 Sensor Si gnal ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
4 NOTE: Tworelaysmay beusedfor thedifferent typesof HeatedO2Sensors.
One uses theASD Relay which is only used with PWM Heated O2 Sensors,
while the other uses an O2 Heater Relay.
Veri fy whi ch rel ay i s used to suppl y power for the O2 Sensor Heater bei ng tested.
Measure the resi stance between the O2 Sensor Si gnal ci rcui t and the O2 Heater
Suppl y ci rcui t at the O2 Sensor harness connector.
I s the resi stance bel ow 100 ohms?
Al l
Yes → Repai r the short between the O2 Sensor Si gnal ci rcui t and the
ASD Rel ay Output or O2 Heater Rel ay Output ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 5
66
DRIVEABILITY - GAS
P0132-O2 SENSOR 1/1 CIRCUIT VOLTAGE HIGH — Continued
TEST ACTION APPLICABILITY
5 Measure the resi stance of the (K4) Sensor ground ci rcui t from the O2 Sensor harness
connector to the PCM harness connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 6
No → Repai r the open i n the (K4) Sensor ground ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
6 NOTE: The O2 Sensor Heater ground may be a Pulse Width Modulated
circuit or an engine ground depending on the type of O2 Sensor being
tested.
* Measure the resi stance of the PWM O2 Sensor Heater Control ci rcui t from the O2
Sensor harness connector to the PCM harness connector i f i t appl i es to the O2 Sensor
bei ng tested
OR
* Measure the resi stance between ground and the O2 Sensor Heater ground ci rcui t
at the O2 Sensor harness connector i f i t appl i es to the O2 Sensor bei ng tested.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 7
No → Repai r the open i n the O2 Sensor (PWM) Heater Control or
Heater ground ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
7 The PCM harness connectors and O2 Sensor harness connector sti l l di sconnected.
I gni ti on on, engi ne not runni ng.
Usi ng a 12-vol t test l i ght connected to ground, probe the O2 Sensor Si gnal ci rcui t at
the O2 Sensor harness connector.
Does the test l i ght i l l umi nate bri ghtl y?
Al l
Yes → Repai r the short to vol tage i n the O2 Sensor Si gnal ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 8
8 Turn the i gni ti on off.
Connect the PCM harness connectors.
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡ actuate the O2 Heater Test.
Measure the vol tage on the O2 Heater Suppl y ci rcui t.
I s the vol tage above 11.0 vol ts?
Al l
No → Repai r the open i n the Heater Suppl y ci rcui t. The Heater Suppl y
ci rcui t can be an output from the ASD Rel ay or the O2 Heater
Rel ay.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
Yes → Go To 9
9 NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Usi ng the schemati cs as a gui de, i nspect the wi re harness and connectors. Pay
parti cul ar attenti on to al l Power and Ground ci rcui ts.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace and program the Powertrai n Control Modul e per Servi ce
I nformati on.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
67
DRIVEABILITY - GAS
P0132-O2 SENSOR 1/1 CIRCUIT VOLTAGE HIGH — Continued
SymptomList:
P0133-O2 SENSOR 1/1 SLOWRESPONSE
P0139-O2 SENSOR 1/2 SLOWRESPONSE
P0153-O2 SENSOR 2/1 SLOWRESPONSE
P0159-O2 SENSOR 2/2 SLOWRESPONSE
Test Note: All symptomslistedabovearediagnosedusingthesametests.
The title for the tests will be P0133-O2 SENSOR 1/1 SLOW
RESPONSE.
When Monitored and Set Condition:
P0133-O2 SENSOR 1/1 SLOWRESPONSE
When Moni tored: Wi th ECTgreater than 147°F, after reachi ng a vehi cl e speed of 10 mph,
and the throttl e remai ni ng open (off i dl e) for 2 mi nutes, bri ng the vehi cl e to a stop and
al l ow the engi ne to i dl e wi th the transmi ssi on i n DRI VE.
Set Condi ti on: The oxygen sensor si gnal vol tage i s swi tchi ng from bel ow 0.27 of a vol t to
above 0.62 of a vol t and back fewer ti mes than requi red.
P0139-O2 SENSOR 1/2 SLOWRESPONSE
When Moni tored: Start engi ne. Al l ow engi ne to i dl e. For 1st part of test, i f l i mi ts are
exceeded, test passes. I f not, 2nd part of test runs. amb/batt temp >44°F, Baro >22.13Љ
H2O, battery >10.5 vol ts, MAP >11.79 & <18.15Љ H2O, RPM >1350 & <2200 and vss >50
and <65.
Set Condi ti on: The oxygen sensor si gnal vol tage i s swi tchi ng from bel ow 0.39 of a vol t to
above 0.58 of a vol t and back fewer ti mes than requi red.
P0153-O2 SENSOR 2/1 SLOWRESPONSE
When Moni tored: Wi th ECTgreater than 147°F, after reachi ng a vehi cl e speed of 10 mph,
and the throttl e remai ni ng open (off i dl e) for 2 mi nutes, bri ng the vehi cl e to a stop and
al l ow the engi ne to i dl e wi th the transmi ssi on i n DRI VE.
Set Condi ti on: The oxygen sensor si gnal vol tage i s swi tchi ng from bel ow 0.27 of a vol t to
above 0.62 of a vol t and back fewer ti mes than requi red.
P0159-O2 SENSOR 2/2 SLOWRESPONSE
When Moni tored: Start engi ne. Al l ow engi ne to i dl e. For 1st part of test, i f l i mi ts are
exceeded, test passes. I f not, 2nd part of test runs. amb/batt temp >44°F, Baro >22.13Љ
H2O, battery >10.5 vol ts, MAP >11.79 & <18.15Љ H2O, RPM >1350 & <2200 and vss >50
and <65.
Set Condi ti on: The oxygen sensor si gnal vol tage i s swi tchi ng from bel ow 0.39 of a vol t to
above 0.58 of a vol t and back fewer ti mes than requi red.
68
DRIVEABILITY - GAS
POSSIBLE CAUSES
GOOD TRI P EQUAL TO ZERO
EXHAUST LEAK
RESI STANCE I N THE O2 SENSOR SI GNAL CI RCUI T
RESI STANCE I N THE (K4) SENSOR GROUND CI RCUI T
O2 SENSOR
TEST ACTION APPLICABILITY
1 Check for any rel ated TSBs.
NOTE: Check for contaminants that may have damaged the O2 Sensor:
contaminated fuel, unapproved silicone, oil and coolant.
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, read DTCs and record the rel ated Freeze Frame data.
I s the Good Tri p Counter di spl ayed and equal to zero?
Al l
Yes → Go To 2
No → Refer to the I NTERMI TTENT CONDI TI ON Symptom (Di agnos-
ti c Procedure).
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
2 Start the engi ne.
I nspect the exhaust for l eaks between the engi ne and the rel ated O2 Sensor.
Are there any exhaust l eaks?
Al l
Yes → Repai r or repl ace the l eaki ng exhaust parts as necessary.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 3
3 Turn the i gni ti on off.
Backprobe the O2 Sensor Si gnal ci rcui t at the O2 Sensor harness connector and PCM
harness connector.
NOTE: Ensurethevoltmeter leads meet theterminals in theconnector and
that there is good terminal to wire connection and are connected for
positive polarity.
Start the engi ne.
Al l ow the engi ne to i dl e.
I s the vol tage bel ow 0.10 of a vol t?
Al l
Yes → Go To 4
No → Repai r the excessi ve resi stance i n the O2 Sensor Si gnal ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
69
DRIVEABILITY - GAS
P0133-O2 SENSOR 1/1 SLOWRESPONSE — Continued
TEST ACTION APPLICABILITY
4 Turn the i gni ti on off.
Backprobe the (K4) Sensor ground ci rcui t at the O2 Sensor harness connector and
PCM harness connector.
NOTE: Ensurethevoltmeter leads meet theterminals in theconnector and
that there is good terminal to wire connection.
NOTE: Ensure the voltmeter leads are connected for positive polarity
Start the engi ne.
Al l ow the engi ne to i dl e.
I s the vol tage bel ow 0.10 of a vol t?
Al l
Yes → Go To 5
No → Repai r the excessi ve resi stance i n the (K4) Sensor ground ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
NOTE: Turn the ignition off before continuing.
5 I f there are no possi bl e causes remai ni ng, vi ew repai r. Al l
Repai r
Repl ace the O2 Sensor
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
70
DRIVEABILITY - GAS
P0133-O2 SENSOR 1/1 SLOWRESPONSE — Continued
SymptomList:
P0135-O2 SENSOR 1/1 HEATER FAILURE
P0141-O2 SENSOR 1/2 HEATER FAILURE
P0155-O2 SENSOR 2/1 HEATER FAILURE
P0161-O2 SENSOR 2/2 HEATER FAILURE
Test Note: All symptomslistedabovearediagnosedusingthesametests.
The title for the tests will be P0135-O2SENSOR 1/1HEATER
FAILURE.
When Monitored and Set Condition:
P0135-O2 SENSOR 1/1 HEATER FAILURE
When Moni tored: Wi th battery vol tage greater than 9 vol ts, at a col d start, ECTl ess than
147°F, battery temperature sensor equal to or l ess than 27°F, and engi ne at i dl e for at l east
12 seconds.
Set Condi ti on: O2 sensor vol tage greater than 3 vol ts for 30 to 90 seconds.
P0141-O2 SENSOR 1/2 HEATER FAILURE
When Moni tored: Wi th battery vol tage greater than 9 vol ts, at a col d start, ECTl ess than
147°F, battery temperature sensor equal to or l ess than 27°F, and engi ne at i dl e for at l east
12 seconds.
Set Condi ti on: O2 sensor vol tage greater than 3 vol ts for 60 to 240 seconds.
P0155-O2 SENSOR 2/1 HEATER FAILURE
When Moni tored: Wi th battery vol tage greater than 9 vol ts, at a col d start, ECTl ess than
147°F, battery temperature sensor equal to or l ess than 27°F, and engi ne at i dl e for at l east
12 seconds.
Set Condi ti on: O2 sensor vol tage greater than 3 vol ts for 30 to 90 seconds.
P0161-O2 SENSOR 2/2 HEATER FAILURE
When Moni tored: Wi th battery vol tage greater than 9 vol ts, at a col d start, ECTl ess than
147°F, battery temperature sensor equal to or l ess than 27°F, and engi ne at i dl e for at l east
12 seconds.
Set Condi ti on: O2 sensor vol tage greater than 3 vol ts for 60 to 240 seconds.
POSSIBLE CAUSES
GOOD TRI P EQUAL TO ZERO
O2 SENSOR HEATER OPERATI ON
O2 HEATER ELEMENT
O2 HEATER SUPPLY CI RCUI T OPEN
71
DRIVEABILITY - GAS
POSSIBLE CAUSES
HEATER CONTROL CI RCUI T OPEN
HEATER CONTROL CI RCUI T SHORTED TO GROUND
PCM
TEST ACTION APPLICABILITY
1 NOTE: Check for contaminants that may have damaged the O2 Sensor:
contaminated fuel, unapproved silicone, oil and coolant.
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, read DTCs and record the rel ated Freeze Frame data.
I s the Good Tri p Counter di spl ayed and equal to zero?
Al l
Yes → Go To 2
No → Refer to the I NTERMI TTENT CONDI TI ON Symptom (Di agnos-
ti c Procedure).
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
2 Check for any rel ated TSBs.
Turn the i gni ti on off.
NOTE: Wait a minimum of 8 minutes to allow the O2 Sensor to cool down
before continuing the test.
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, actuate the O2 Heater Test.
Wi th the DRBI I I ௡, moni tor O2 Sensor vol tage for at l east 2 mi nutes.
Does the vol tage stabi l i ze between 0.1 and 0.3 of a vol t duri ng the Heater test?
Al l
Yes → Refer to the I NTERMI TTENT CONDI TI ON Symptom (Di agnos-
ti c Procedure).
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 3
3 Turn the i gni ti on off.
NOTE: Allow the O2 Sensor to cool to roomtemperature.
Di sconnect the O2 Sensor harness connector.
Measure the resi stance across the O2 Sensor Heater el ement component si de.
I s the resi stance val ue between 2.0 and 30 ohms?
Al l
Yes → Go To 4
No → Repl ace the O2 Sensor.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
4 NOTE:TheO2Heater Supplycircuit maybeafusedASDRelayOutput or an
O2Sensor Heater Relay Output, depending on the O2Sensor being tested.
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, actuate the O2 Heater Test.
Measure the vol tage on the O2 Heater Suppl y ci rcui t at the O2 Sensor harness
connector.
I s the vol tage above 10.0 vol ts?
Al l
Yes → Go To 5
No → Repai r the open i n the O2 Sensor Heater Suppl y cri cui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
72
DRIVEABILITY - GAS
P0135-O2 SENSOR 1/1 HEATER FAILURE — Continued
TEST ACTION APPLICABILITY
5 Turn the i gni ti on off.
Di sconnect the PCM harness connectors.
Remove the O2 Heater Rel ay, i f i t appl i es to the O2 Sensor bei ng tested.
* Measure the resi stance of the O2 Heater Control ci rcui t (PWM) from the O2 Sensor
to the PCM harness connector i f i t appl i es to the O2 Sensor bei ng tested.
OR
* Measure the resi stance of the (K512) O2 Heater Rel ay Control ci rcui t from the O2
Heater Rel ay to the PCM harness connector, i f i t appl i es to the O2 Sensor bei ng
tested.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 6
No → Repai r the excessi ve resi stance i n the O2 Heater Control ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
6 NOTE: Before beginning this test, verify what type of Heated O2 Sensor is
being tested, either the PWM Heated O2 Sensor or the Heater Relay
controlled Heated O2 Sensor.
Remove the O2 Heater Rel ay i f i t appl i es to the type of Heated O2 Sensor bei ng
tested.
* Measure the resi stance between ground and the PWM ci rcui t at the O2 Sensor
harness connector i f i t appl i es to the Heated O2 Sensor bei ng tested.
OR
* Measure the resi stance between ground and the (K512) O2 Heater Rel ay Control
ci rcui t i f i t appl i es to the Heated O2 Sensor bei ng tested.
I s the resi stance bel ow 100 ohms?
Al l
Yes → Repai r the short to ground i n the O2 Heater Control ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 7
7 NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Usi ng the schemati cs as a gui de, i nspect the wi re harness and connectors. Pay
parti cul ar attenti on to al l Power and Ground ci rcui ts.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace and program the Powertrai n Control Modul e per Servi ce
I nformati on.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
73
DRIVEABILITY - GAS
P0135-O2 SENSOR 1/1 HEATER FAILURE — Continued
Symptom:
P0136-O2 SENSOR 1/2 HEATER CIRCUIT MALFUNCTION
When Monitored and Set Condition:
P0136-O2 SENSOR 1/2 HEATER CIRCUIT MALFUNCTION
When Moni tored: I gni ti on ON, wi th battery vol tage greater than 10.4 vol ts.
Set Condi ti on: The state of the PCM rel ay control ci rcui t, between the PCM and rel ay
coi l , does not match the desi red state.
POSSIBLE CAUSES
GOOD TRI P EQUAL TO ZERO
O2 SENSOR HEATER RELAY
(F142) FUSED ASD RELAY OUTPUT CI RCUI T
(K512) O2 HEATER RELAY CONTROL CI RCUI T OPEN
(K512) O2 HEATER RELAY CONTROL CI RCUI T SHORTED TO GROUND
O2 HEATER ELEMENT
(A242) O2 HEATER RELAY OUTPUT CI RCUI T
PCM
TEST ACTION APPLICABILITY
1 I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, read DTCs and record the rel ated Freeze Frame data.
Check for any rel ated TSBs.
NOTE: If P0031and P0051areset alongwith P0136, inspect therelated fuse
and repair as necessary.
I s the Good Tri p Counter di spl ayed and equal to zero?
Al l
Yes → Go To 2
No → Refer to the I NTERMI TTENT CONDI TI ON Symptom (Di agnos-
ti c Procedure).
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
2 Turn the i gni ti on off.
Remove the Heater Rel ay from the PDC.
Measurement i s taken at the Heater Rel ay component.
Measure the resi stance of the O2 Sensor Heater Rel ay Coi l .
I s the resi stance above 100 ohms?
Al l
Yes → Repl ace the O2 Sensor Heater Rel ay.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 3
74
DRIVEABILITY - GAS
TEST ACTION APPLICABILITY
3 I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, actuate the ASD Rel ay.
Usi ng a 12-vol t test l i ght connected to ground, probe the (F142) Fused ASD Rel ay
Output ci rcui t of the O2 Heater Rel ay i n the PDC.
Does the test l i ght i l l umi nate bri ghtl y when the rel ay actuates?
Al l
Yes → Go To 4
No → Repai r the open or short to ground i n the (F142) ASD Rel ay
Output ci rcui t. I nspect the rel ated fuse and repai r as necessary.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
4 Turn the i gni ti on off.
Di sconnect the PCM harness connectors.
Measure the resi stance of the (K512) O2 Heater Rel ay Control ci rcui t from the PDC
(Heater Rel ay) connector to the PCM harness connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 5
No → Repai r the open i n the (K512) O2 Heater Rel ay Control ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
5 Measure the resi stance between ground and the (K512) O2 Heater Rel ay Control
ci rcui t at the PDC connector.
I s the resi stance bel ow 100 ohms?
Al l
Yes → Repai r the short to ground i n the (K512) O2 Sensor Heater Rel ay
Control ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 6
6 Turn the i gni ti on off.
NOTE: Allow the O2 Sensor to cool to roomtemperature.
Di sconnect the 1/2 and 2/2, i f appl i cabl e, O2 Sensor harness connectors.
Measure the resi stance across each of the O2 Sensor Heater el ements, component
si de.
I s the resi stance val ue between 2.0 and 30 ohms?
Al l
Yes → Go To 7
No → Repl ace the O2 Sensor.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
7 I nstal l the O2 Sensor Heater Rel ay.
Connect the PCM harness connectors.
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, actuate the O2 Heater Test.
Usi ng a 12-vol t test l i ght connected to ground, probe the (A242) O2 Heater Rel ay
Output ci rcui t at the 1/2 and 2/2, i f appl i cabl e, O2 Sensor harness connectors.
Does the test l i ght i l l umi nate bri ghtl y when the Rel ay i s actuated?
Al l
Yes → Go To 8
No → Repai r the open or short to ground i n the (A242) O2 Heater Rel ay
Output ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
75
DRIVEABILITY - GAS
P0136-O2 SENSOR 1/2 HEATER CIRCUIT MALFUNCTION — Continued
TEST ACTION APPLICABILITY
8 NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Usi ng the schemati cs as a gui de, i nspect the wi re harness and connectors. Pay
parti cul ar attenti on to al l Power and Ground ci rcui ts.
I f there are not possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace and program the Powertrai n Control Modul e per Servi ce
I nformati on.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
76
DRIVEABILITY - GAS
P0136-O2 SENSOR 1/2 HEATER CIRCUIT MALFUNCTION — Continued
SymptomList:
P0171-1/1 FUEL SYSTEM LEAN
P0174-2/1 FUEL SYSTEM LEAN
Test Note: All symptomslistedabovearediagnosedusingthesametests.
Thetitlefor thetests will beP0171-1/1FUEL SYSTEM LEAN.
When Monitored and Set Condition:
P0171-1/1 FUEL SYSTEM LEAN
When Moni tored: Wi th the engi ne runni ng i n cl osed l oop mode, the ambi ent/battery
temperature above 20° F and al ti tude bel ow 8000 ft.
Set Condi ti on: I f the PCM mul ti pl i es short term compensati on by l ong term adapti ve and
a certai n percentage i s exceeded for two tri ps, a freeze frame i s stored, the MI L i l l umi nates
and a troubl e code i s stored.
P0174-2/1 FUEL SYSTEM LEAN
When Moni tored: Wi th the engi ne runni ng i n cl osed l oop mode, the ambi ent/battery
temperature above 20° F and al ti tude bel ow 8000 ft.
Set Condi ti on: I f the PCM mul ti pl i es short term compensati on by l ong term adapti ve and
a certai n percentage i s exceeded for two tri ps, a freeze frame i s stored, the MI L i l l umi nates
and a troubl e code i s stored.
POSSIBLE CAUSES
GOOD TRI P EQUAL TO ZERO
FUEL PRESSURE OUT OF SPECS
RESTRI CTED FUEL SUPPLY LI NE
FUEL PUMP I NLET STRAI NER PLUGGED
FUEL PUMP MODULE
O2 SENSOR
O2 SENSOR SI GNAL CI RCUI T SHORTED TO GROUND
O2 SENSOR HEATER OPERATI ON
TP SENSOR VOLTAGE GREATER THAN 0.92 OF A VOLT WI TH THROTTLE CLOSED
TP SENSOR SWEEP
MAP SENSOR OPERATI ON
ECT SENSOR OPERATI ON
ENGI NE MECHANI CAL PROBLEM
FUEL FI LTER/PRESSURE REGULATOR
I NTERMI TTENT CONDI TI ON
PCM
77
DRIVEABILITY - GAS
TEST ACTION APPLICABILITY
1 NOTE: Check for contaminates that may have damaged the O2 Sensor:
contaminated fuel, unapproved silicone, oil and coolant.
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, read DTCs and record the rel ated Freeze Frame data.
I s the Good Tri p Counter di spl ayed and equal to zero?
Al l
Yes → Go To 2
No → Refer to the I NTERMI TTENT CONDI TI ON Symptom (Di agnos-
ti c Procedure).
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
2 Warning:Thefuel systemisunder aconstant pressure(evenwiththeengine
off). Beforetestingor servicingany fuel systemhose, fittingor line, thefuel
systempressure must be released.
I nstal l a fuel pressure gauge.
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, actuate the ASD Fuel System test and observe the fuel pressure
gauge.
NOTE: Fuel pressure specification is 400 KPa +/- 34 KPa (58 psi +/- 5 psi).
Turn the i gni ti on off.
Choose a concl usi on that best matches your fuel pressure readi ng.
Al l
Bel ow Speci fi cati on
Go To 3
Wi thi n Speci fi cati on
Go To 6
Above Speci fi cati on
Repl ace the fuel fi l ter/pressure regul ator.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
CAUTION: Stop All Actuations.
3 Turn the i gni ti on off.
Warning:Thefuel systemisunder aconstant pressure(evenwiththeengine
off). Beforetestingor servicingany fuel systemhose, fittingor line, thefuel
systempressure must be released.
Rai se vehi cl e on hoi st, and di sconnect the fuel pressure l i ne at the fuel pump modul e.
I nstal l speci al 5/16 fuel l i ne adapter tool #6539 or #6631 between di sconnected fuel
l i ne and the fuel pump modul e.
Attach a fuel pressure test gauge to the T fi tti ng on tool #6539 or #6631.
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, actuate the ASD Fuel System test and observe the fuel pressure
gauge.
NOTE: Fuel pressure specification is 400 KPa +/- 34 KPa (58 psi +/- 5 psi).
I s the fuel pressure wi thi n speci fi cati on?
Al l
Yes → Repai r or repl ace fuel suppl y l i ne as necessary.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 4
Caution: Stop All Actuations.
78
DRIVEABILITY - GAS
P0171-1/1 FUEL SYSTEM LEAN — Continued
TEST ACTION APPLICABILITY
4 Turn the i gni ti on off.
WARNING: The fuel system is under a constant pressure (even with the
engineoff). Beforetestingor servicingany fuel systemhose, fittingor line,
the fuel systempressure must be released.
Remove the Fuel Pump Modul e and i nspect the Fuel I nl et Strai ner.
I s the Fuel I nl et Strai ner pl ugged?
Al l
Yes → Repl ace the Fuel Pump I nl et Strai ner.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 5
5 I f there are no possi bl e causes remai ni ng, vi ew repai r. Al l
Repai r
Repl ace the Fuel Pump Modul e.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
6 Turn the i gni ti on off.
NOTE: Wait a minimumof 10 minutes to allow the O2 Sensor and Exhaust
Systemto cool down before continuing the test.
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, moni tor al l of the O2 Sensor vol tage readi ngs.
I s the vol tage above 4.5 vol ts for al l of the O2 Sensors?
Al l
Yes → Go To 7
No → Go To 13
7 Turn the i gni ti on off.
NOTE: Wait a minimumof 10 minutes to allow the O2 Sensor to cool down
before continuing the test.
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, actuate the O2 Heater Test.
Wi th the DRBI I I ௡, moni tor al l O2 Sensor vol tage readi ngs for at l east 2 mi nutes.
Does the vol tage stay above 4.5 vol ts for any of the O2 Sensors?
Al l
Yes → Repl ace the O2 Sensor that had the vol tage readi ng above 4.5
vol ts.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 8
8 I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, read TP Sensor vol tage.
NOTE: The throttle must be against the stop.
I s the vol tage 0.92 of a vol t or l ess wi th the Throttl e cl osed?
Al l
Yes → Go To 9
No → Check for a bi ndi ng throttl e condi ti on. I f OK, repl ace the Throttl e
Posi ti on Sensor.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
9 Wi th the DRBI I I ௡, read the TP Sensor vol tage.
Whi l e moni tori ng the DRBI I I ௡, sl owl y open and cl ose the throttl e.
Does the vol tage i ncrease and decrease smoothl y?
Al l
Yes → Go To 10
No → Repl ace the Throttl e Posi ti on Sensor.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
79
DRIVEABILITY - GAS
P0171-1/1 FUEL SYSTEM LEAN — Continued
TEST ACTION APPLICABILITY
10 Turn the i gni ti on off.
Connect a Vacuum Gauge to a Mani fol d Vacuum source.
Start the engi ne.
Al l ow the engi ne to i dl e.
Note: If engine will not idle, maintain a constant RPM above idle.
Wi th the DRBI I I ௡ i n Sensors, read the MAP Sensor vacuum val ue.
I s the DRBI I I ௡ readi ng wi thi n 1Љ of the Vacuum Gauge readi ng?
Al l
Yes → Go To 11
No → Repl ace the MAP Sensor.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
NOTE: Remove the vacuumgauge before continuing.
11 Note: For this test to be valid, the thermostat must be operating correctly.
Note: This test works best if performed on a cold engine (cold soak)
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, read the Engi ne Cool ant Temperature Sensor val ue. I f the engi ne
was al l owed to si t overni ght (col d soak), the temperature val ue shoul d be a sensi bl e
val ue that i s somewhere cl ose to the ambi ent temperature.
Note: If enginecoolant temperatureis above82°C (180°F), allowtheengine
to cool until 65°C (150°F) is reached.
Start the Engi ne.
Duri ng engi ne warm-up, moni tor the Engi ne Cool ant Temperature val ue. The temp
val ue change shoul d be a smooth transi ti on from start up to normal operati ng temp
82°C (180°F). The val ue shoul d reach at l east 82°C (180°F).
Di d the Engi ne Cool ant Temperature i ncrease smoothl y and di d i t reach at l east 82°C
(180°F)?
Al l
Yes → Go To 12
No → Repl ace the Engi ne Cool ant Temperature Sensor.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
12 Check for any of the fol l owi ng condi ti ons/mechani cal probl ems.
AI R I NDUCTI ON SYSTEM - must be free from l eaks.
ENGI NE VACUUM - must be at l east 13 i nches i n neutral
ENGI NE VALVE TI MI NG - must be wi thi n speci fi cati ons
ENGI NE COMPRESSI ON - must be wi thi n speci fi cati ons
ENGI NE EXHAUST SYSTEM - must be free of any restri cti ons or l eaks.
ENGI NE PCV SYSTEM - must fl ow freel y
TORQUE CONVERTER STALL SPEED - must be wi thi n speci fi cati ons
POWER BRAKE BOOSTER - no i nternal vacuum l eaks
FUEL - must be free of contami nati on
FUEL I NJECTOR - pl ugged or restri cted i njector; control wi re not connected to
correct i njector
Are there any engi ne mechani cal probl ems?
Al l
Yes → Repai r as necessary.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Refer to the I NTERMI TTENT CONDI TI ON Symptom (Di agnos-
ti c Procedure).
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
80
DRIVEABILITY - GAS
P0171-1/1 FUEL SYSTEM LEAN — Continued
TEST ACTION APPLICABILITY
13 NOTE: Wait a minimumof 10 minutes to allow the O2 Sensor to cool down
before continuing the test.
I gni ti on on, engi ne not runni ng.
Di sconnect the harness connector(s) of the O2 Sensor(s) that had a vol tage readi ng
bel ow 4.5 vol ts i n the previ ous step.
Wi th the DRBI I I ௡, moni tor the O2 Sensor vol tage readi ng(s).
I s the O2 Sensor vol tage above 4.5 vol ts?
Al l
Yes → Repl ace the O2 Sensor that had the vol tage readi ng above 4.5
vol ts.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 14
14 Turn the i gni ti on off.
Di sconnect the PCM harness connectors.
Measure the resi stance between ground and the O2 Sensor Si gnal ci rcui t at the PCM
harness connector.
I s the resi stance bel ow 100 ohms?
Al l
Yes → Repai r the short to ground i n the O2 Sensor Si gnal ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 15
15 NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Usi ng the schemati cs as a gui de, i nspect the wi re harness and connectors. Pay
parti cul ar attenti on to al l Power and Ground ci rcui ts.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace and program the Powertrai n Control Modul e per Servi ce
I nformati on.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
81
DRIVEABILITY - GAS
P0171-1/1 FUEL SYSTEM LEAN — Continued
SymptomList:
P0172-1/1 FUEL SYSTEM RICH
P0175-2/1 FUEL SYSTEM RICH
Test Note: All symptomslistedabovearediagnosedusingthesametests.
The title for the tests will be P0172-1/1FUEL SYSTEM RICH.
When Monitored and Set Condition:
P0172-1/1 FUEL SYSTEM RICH
When Moni tored: Wi th the engi ne runni ng i n cl osed l oop mode, the ambi ent/battery
temperature above 20° F and al ti tude bel ow 8000 ft.
Set Condi ti on: I f the PCM mul ti pl i es short term compensati on by l ong term adapti ve and
the resul t i s bel ow a certai n val ue for two tri ps, a freeze frame i s stored, the MI L
i l l umi nates and a troubl e code i s stored.
P0175-2/1 FUEL SYSTEM RICH
When Moni tored: Wi th the engi ne runni ng i n cl osed l oop mode, the ambi ent/battery
temperature above 20° F and al ti tude bel ow 8000 ft.
Set Condi ti on: I f the PCM mul ti pl i es short term compensati on by l ong term adapti ve and
the resul t i s bel ow a certai n val ue for two tri ps, a freeze frame i s stored, the MI L
i l l umi nates and a troubl e code i s stored.
POSSIBLE CAUSES
GOOD TRI P EQUAL TO ZERO
O2 SENSOR
O2 SENSOR SI GNAL CI RCUI T OPEN
O2 SENSOR SI GNAL CI RCUI T SHORTED TO VOLTAGE
O2 SENSOR HEATER OPERATI ON
EVAP SYSTEM OPERATI ON
TP SENSOR VOLTAGE GREATER THAN 0.92 OF A VOLT WI TH THROTTLE CLOSED
TP SENSOR SWEEP
FUEL FI LTER/PRESSURE REGULATOR
MAP SENSOR OPERATI ON
ECT SENSOR OPERATI ON
ENGI NE MECHANI CAL PROBLEM
I NTERMI TTENT CONDI TI ON
PCM
82
DRIVEABILITY - GAS
TEST ACTION APPLICABILITY
1 Check for any rel ated TSBs.
NOTE: Check for contaminants that may have damaged the O2 Sensor:
contaminated fuel, unapproved silicone, oil and coolant.
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, read DTCs and record the rel ated Freeze Frame data.
NOTE: Any O2 Sensor, TPS, ECT, MAP, or EVAP DTCs must be repaired
before continuing.
I s the Good Tri p Counter di spl ayed and equal to zero?
Al l
Yes → Go To 2
No → Refer to the I NTERMI TTENT CONDI TI ON Symptom (Di agnos-
ti c Procedure).
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
2 Turn the i gni ti on off.
Warning:Thefuel systemisunder aconstant pressure(evenwiththeengine
off). Beforetestingor servicingany fuel systemhose, fittingor line, thefuel
systempressure must be released.
I nstal l a fuel pressure gauge.
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, actuate the ASD Fuel System test and observe the fuel pressure
gauge.
NOTE: Fuel pressure specification is 400 KPa +/- 34 KPa (58 psi +/- 5 psi).
Choose a concl usi on that best matches your fuel pressure readi ng.
Al l
Wi thi n Speci fi cati on
Go To 3
Above Speci fi cati on
Repl ace the fuel fi l ter/pressure regul ator.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
Caution: Stop All Actuations.
3 I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, moni tor al l of the O2 Sensor vol tage readi ngs.
I s the vol tage above 4.5 vol ts for al l of the O2 Sensors?
Al l
Yes → Go To 4
No → Go To 11
4 Turn the i gni ti on off.
NOTE: Wait a minimumof 10 minutes to allow the O2 Sensor to cool down
beforecontinuingthetest.AllowtheO2Sensor voltagetostabilizebetween
4 and 5 volts.
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, actuate the O2 Heater Test.
Wi th the DRBI I I ௡, moni tor al l of the O2 Sensor vol tage val ues for at l east 2 mi nutes.
Does the vol tage stay above 4.5 vol ts for any of the O2 Sensors?
Al l
Yes → Repl ace the O2 Sensor that had the vol tage readi ng above 4.5
vol ts.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 5
83
DRIVEABILITY - GAS
P0172-1/1 FUEL SYSTEM RICH — Continued
TEST ACTION APPLICABILITY
5 NOTE: The engine must be at operating temperature and in closed loop to
performthis test.
Start the engi ne.
WARNING: 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.
Al l ow the engi ne to reach normal operati ng temperature.
Wi th the DRBI I I ௡ sel ect System Tests, perform the Purge Vapors Test.
Observe the Short Term Adapti ve val ue and press 3 to fl ow.
NOTE: Short TermAdaptive value change.
Di d the Short Term Adapti ve val ue change?
Al l
Yes → Go To 6
No → Refer to the Dri veabi l i ty category and perform the appropri ate
symptom.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
6 I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, read TP Sensor vol tage.
NOTE: The throttle must be against the stop.
I s the vol tage 0.92 of a vol t or l ess wi th the Throttl e cl osed?
Al l
Yes → Go To 7
No → Check for a bi ndi ng throttl e condi ti on. I f OK, repl ace the Throttl e
Posi ti on Sensor.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
7 Wi th the DRBI I I ௡, read the TP Sensor vol tage.
Whi l e moni tori ng the DRBI I I ௡, sl owl y open and cl ose the throttl e.
Does the vol tage i ncrease and decrease smoothl y?
Al l
Yes → Go To 8
No → Repl ace the Throttl e Posi ti on Sensor.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
8 Turn the i gni ti on off.
Connect a Vacuum Gauge to a Mani fol d Vacuum source.
Start the engi ne.
Al l ow the engi ne to i dl e.
Note: If engine will not idle, maintain a constant RPM above idle.
Wi th the DRBI I I ௡ i n Sensors, read the MAP Sensor vacuum val ue.
I s the DRBI I I ௡ readi ng wi thi n 1Љ of the Vacuum Gauge readi ng?
Al l
Yes → Go To 9
No → Repl ace the MAP Sensor.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
NOTE: Remove the vacuumgauge before continuing.
84
DRIVEABILITY - GAS
P0172-1/1 FUEL SYSTEM RICH — Continued
TEST ACTION APPLICABILITY
9 Note: For this test to be valid, the thermostat must be operating correctly.
Note: This test works best if performed on a cold engine (cold soak)
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, read the Engi ne Cool ant Temperature Sensor val ue. I f the engi ne
was al l owed to si t overni ght (col d soak), the temperature val ue shoul d be a sensi bl e
val ue that i s somewhere cl ose to the ambi ent temperature.
Note: If enginecoolant temperatureis above82°C (180°F), allowtheengine
to cool until 65°C (150°F) is reached.
Start the Engi ne.
Duri ng engi ne warm-up, moni tor the Engi ne Cool ant Temperature val ue. The temp
val ue change shoul d be a smooth transi ti on from start up to normal operati ng temp
82°C (180°F). The val ue shoul d reach at l east 82°C (180°F).
Di d the Engi ne Cool ant Temperature val ue i ncrease smoothl y and reach at l east
82°C?
Al l
Yes → Go To 10
No → Repl ace the Engi ne Cool ant Temperature Sensor.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
10 Check for any of the fol l owi ng condi ti ons/mechani cal probl ems.
AI R I NDUCTI ON SYSTEM - must be free from restri cti ons.
ENGI NE VACUUM - must be at l east 13 i nches i n neutral
ENGI NE VALVE TI MI NG - must be wi thi n speci fi cati ons
ENGI NE COMPRESSI ON - must be wi thi n speci fi cati ons
ENGI NE EXHAUST SYSTEM - must be free of any restri cti ons or l eaks.
ENGI NE PCV SYSTEM - must fl ow freel y
TORQUE CONVERTER STALL SPEED - must be wi thi n speci fi cati ons
POWER BRAKE BOOSTER - no i nternal vacuum l eaks
FUEL - must be free of contami nati on
FUEL I NJECTOR - pl ugged or restri cted i njector; control wi re not connected to
correct i njector
Are there any engi ne mechani cal probl ems?
Al l
Yes → Repai r as necessary.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Refer to the I NTERMI TTENT CONDI TI ON Symptom (Di agnos-
ti c Procedure).
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
11 Turn the i gni ti on off.
Di sconnect the sensor harness connector of the O2 Sensor(s) that had a vol tage val ue
greater than 4.5 vol ts i n the previ ous step.
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, moni tor the O2 Sensor vol tage readi ng(s).
I s the O2 Sensor vol tage above 4.5 vol ts?
Al l
Yes → Repl ace the O2 Sensor that had the vol tage readi ng above 4.5
vol ts.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 12
85
DRIVEABILITY - GAS
P0172-1/1 FUEL SYSTEM RICH — Continued
TEST ACTION APPLICABILITY
12 Turn the i gni ti on off.
Di sconnect the PCM harness connectors.
Measure the resi stance of the O2 Sensor Si gnal ci rcui t from the PCM harness
connector to the O2 Sensor harness connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 13
No → Repai r the open i n the O2 Sensor Si gnal ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
13 Leave the O2 Sensor and PCM harness connectors di sconnected.
I gni ti on on, engi ne not runni ng.
Measure the vol tage on the O2 Sensor Si gnal ci rcui t at the O2 Sensor harness
connector.
I s the vol tage above 5.2 vol ts?
Al l
Yes → Repai r the short to vol tage i n the O2 Sensor Si gnal ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 14
NOTE: Turn the ignition off before continuing.
14 NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Usi ng the schemati cs as a gui de, i nspect the wi re harness and connectors. Pay
parti cul ar attenti on to al l Power and Ground ci rcui ts.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace and program the Powertrai n Control Modul e per Servi ce
I nformati on.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
86
DRIVEABILITY - GAS
P0172-1/1 FUEL SYSTEM RICH — Continued
SymptomList:
P0201-INJ ECTOR #1 CONTROL CIRCUIT
P0202-INJ ECTOR #2 CONTROL CIRCUIT
P0203-INJ ECTOR #3 CONTROL CIRCUIT
P0204-INJ ECTOR #4 CONTROL CIRCUIT
P0205-INJ ECTOR #5 CONTROL CIRCUIT
P0206-INJ ECTOR #6 CONTROL CIRCUIT
Test Note: All symptomslistedabovearediagnosedusingthesametests.
The title for the tests will be P0201-INJ ECTOR #1CONTROL
CIRCUIT.
When Monitored and Set Condition:
P0201-INJ ECTOR #1 CONTROL CIRCUIT
When Moni tored: Wi th battery vol tage greater than 10.4 vol ts, the auto shutdown rel ay
energi zed, i njector pul se wi dth l ess than 10ms, and engi ne speed l ess than 3000 rpm.
Set Condi ti on: Thi s troubl e code takes .64 to 10.0 seconds to set when no i nducti ve ki ck
i s sensed .18ms after i njector turn off, and wi th no other i njectors on.
P0202-INJ ECTOR #2 CONTROL CIRCUIT
When Moni tored: Wi th battery vol tage greater than 10.4 vol ts, the auto shutdown rel ay
energi zed, i njector pul se wi dth l ess than 10ms, and engi ne speed l ess than 3000 rpm.
Set Condi ti on: Thi s troubl e code takes .64 to 10.0 seconds to set when no i nducti ve ki ck
i s sensed .18ms after i njector turn off, and wi th no other i njectors on.
P0203-INJ ECTOR #3 CONTROL CIRCUIT
When Moni tored: Wi th battery vol tage greater than 10.4 vol ts, the auto shutdown rel ay
energi zed, i njector pul se wi dth l ess than 10ms, and engi ne speed l ess than 3000 rpm.
Set Condi ti on: Thi s troubl e code takes .64 to 10.0 seconds to set when no i nducti ve ki ck
i s sensed .18ms after i njector turn off, and wi th no other i njectors on.
P0204-INJ ECTOR #4 CONTROL CIRCUIT
When Moni tored: Wi th battery vol tage greater than 10.4 vol ts, the auto shutdown rel ay
energi zed, i njector pul se wi dth l ess than 10ms, and engi ne speed l ess than 3000 rpm.
Set Condi ti on: Thi s troubl e code takes .64 to 10.0 seconds to set when no i nducti ve ki ck
i s sensed .18ms after i njector turn off, and wi th no other i njectors on.
P0205-INJ ECTOR #5 CONTROL CIRCUIT
When Moni tored: Wi th battery vol tage greater than 10.4 vol ts, the auto shutdown rel ay
energi zed, i njector pul se wi dth l ess than 10ms, and engi ne speed l ess than 3000 rpm.
Set Condi ti on: Thi s troubl e code takes .64 to 10.0 seconds to set when no i nducti ve ki ck
i s sensed .18ms after i njector turn off, and wi th no other i njectors on.
87
DRIVEABILITY - GAS
P0206-INJ ECTOR #6 CONTROL CIRCUIT
When Moni tored: Wi th battery vol tage greater than 10.4 vol ts, the auto shutdown rel ay
energi zed, i njector pul se wi dth l ess than 10ms, and engi ne speed l ess than 3000 rpm.
Set Condi ti on: Thi s troubl e code takes .64 to 10.0 seconds to set when no i nducti ve ki ck
i s sensed .18ms after i njector turn off, and wi th no other i njectors on.
POSSIBLE CAUSES
GOOD TRI P EQUAL TO ZERO
(F42) ASD RELAY OUTPUT CI RCUI T
FUEL I NJECTOR
FUEL I NJECTOR CONTROL CI RCUI T OPEN
FUEL I NJECTOR CONTROL CI RCUI T SHORTED TO GROUND
PCM
TEST ACTION APPLICABILITY
1 I gni ti on on, engi ne not runni ng.
NOTE:DiagnoseanyMisfireDTCsbeforecontinuing. If aMisfireisdetected
for a particular cylinder, the PCM will shut down that Injectors Control
circuit.
Wi th the DRBI I I ௡, read DTCs and record the rel ated Freeze Frame data.
I s the Good Tri p Counter di spl ayed and equal to zero?
Al l
Yes → Go To 2
No → Refer to the I NTERMI TTENT CONDI TI ON Symptom (Di agnos-
ti c Procedure).
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
2 Turn the i gni ti on off.
Di sconnect the Fuel I njector harness connector.
I gni ti on on, engi ne not runni ng.
Usi ng a 12-vol t test l i ght connected to ground, probe the (F42) ASD Rel ay Output
ci rcui t at the Fuel I njector harness connector.
Wi th the DRBI I I ௡, actuate the ASD Rel ay.
Di d the test l i ght i l l umi nate bri ghtl y when the ASD Rel ay was actuati ng?
Al l
Yes → Go To 3
No → Repai r the open or short to ground i n the (F42)ASD Rel ay Output
ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
88
DRIVEABILITY - GAS
P0201-INJ ECTOR #1 CONTROL CIRCUIT — Continued
TEST ACTION APPLICABILITY
3 Usi ng a 12-vol t test l i ght connected to 12-vol ts, probe the Fuel I njector Control
ci rcui t.
Wi th the DRBI I I ௡, actuate the Fuel I njector.
What i s the state of the test l i ght whi l e actuati ng the Fuel I njector?
Al l
Bri ghtl y bl i nki ng.
Repl ace the Fuel I njector.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
ON constantl y.
Go To 4
OFF constantl y.
Go To 5
4 Turn the i gni ti on off.
Di sconnect the PCM harness connectors.
Measure the resi stance between ground and the Fuel I njector Control ci rcui t i n the
Fuel I njector harness connector.
I s the resi stance bel ow 100 ohms?
Al l
Yes → Repai r the short to ground i n the Fuel I njector Control ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 6
5 Turn the i gni ti on off.
Di sconnect the PCM harness connectors.
Measure the resi stance of the Fuel I njector Control ci rcui t from the Fuel I njector
harness connector to the PCM harness connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 6
No → Repai r the open i n the Fuel I njector Control ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
6 NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Usi ng the schemati cs as a gui de, i nspect the wi re harness and connectors. Pay
parti cul ar attenti on to al l Power and Ground ci rcui ts.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r.
Repl ace and program the Powertrai n Control Modul e per Servi ce
I nformati on.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
89
DRIVEABILITY - GAS
P0201-INJ ECTOR #1 CONTROL CIRCUIT — Continued
SymptomList:
P0300-MULTIPLE CYLINDER MIS-FIRE
P0301-CYLINDER #1 MISFIRE
P0302-CYLINDER #2 MISFIRE
P0303-CYLINDER #3 MISFIRE
P0304-CYLINDER #4 MISFIRE
P0305-CYLINDER #5 MISFIRE
P0306-CYLINDER #6 MISFIRE
Test Note: All symptomslistedabovearediagnosedusingthesametests.
The title for the tests will be P0300-MULTIPLE CYLINDER
MIS-FIRE.
When Monitored and Set Condition:
P0300-MULTIPLE CYLINDER MIS-FIRE
When Moni tored: Any ti me the engi ne i s runni ng, and the adapti ve numerator has been
successful l y updated.
Set Condi ti on: When more than a 1% mi sfi re rate i s measured duri ng two tri ps, or wi th
a 6% to 30% mi sfi re rate duri ng one tri p.
P0301-CYLINDER #1 MISFIRE
When Moni tored: Any ti me the engi ne i s runni ng, and the adapti ve numerator has been
successful l y updated.
Set Condi ti on: When more than a 1% mi sfi re rate i s measured duri ng two tri ps, or wi th
a 6% to 30% mi sfi re rate duri ng one tri p.
P0302-CYLINDER #2 MISFIRE
When Moni tored: Any ti me the engi ne i s runni ng, and the adapti ve numerator has been
successful l y updated.
Set Condi ti on: When more than a 1% mi sfi re rate i s measured duri ng two tri ps, or wi th
a 6% to 30% mi sfi re rate duri ng one tri p.
P0303-CYLINDER #3 MISFIRE
When Moni tored: Any ti me the engi ne i s runni ng, and the adapti ve numerator has been
successful l y updated.
Set Condi ti on: When more than a 1% mi sfi re rate i s measured duri ng two tri ps, or wi th
a 6% to 30% mi sfi re rate duri ng one tri p.
P0304-CYLINDER #4 MISFIRE
When Moni tored: Any ti me the engi ne i s runni ng, and the adapti ve numerator has been
successful l y updated.
Set Condi ti on: When more than a 1% mi sfi re rate i s measured duri ng two tri ps, or wi th
a 6% to 30% mi sfi re rate duri ng one tri p.
90
DRIVEABILITY - GAS
P0305-CYLINDER #5 MISFIRE
When Moni tored: Any ti me the engi ne i s runni ng, and the adapti ve numerator has been
successful l y updated.
Set Condi ti on: When more than a 1% mi sfi re rate i s measured duri ng two tri ps, or wi th
a 6% to 30% mi sfi re rate duri ng one tri p.
P0306-CYLINDER #6 MISFIRE
When Moni tored: Any ti me the engi ne i s runni ng, and the adapti ve numerator has been
successful l y updated.
Set Condi ti on: When more than a 1% mi sfi re rate i s measured duri ng two tri ps, or wi th
a 6% to 30% mi sfi re rate duri ng one tri p.
POSSIBLE CAUSES
I NTERMI TTENT MI SFI RE
VI SUAL I NSPECTI ON
I GNI TI ON WI RE
(F42) ASD RELAY OUPUT CI RCUI T
ENGI NE MECHANI CAL PROBLEM
I GNI TI ON COI L
COI L CONTROL CI RCUI T
SPARK PLUG
CHECKI NG FUEL PRESSURE
FUEL PUMP I NLET STRAI NER PLUGGED
RESTRI CTED FUEL SUPPLY LI NE
FUEL PUMP MODULE
CHECKI NG FUEL LEAK DOWN
FUEL I NJECTOR
I NJECTOR CONTROL CI RCUI T
PCM
91
DRIVEABILITY - GAS
P0300-MULTIPLE CYLINDER MIS-FIRE — Continued
TEST ACTION APPLICABILITY
1 NOTE: Check for any TSB’s that apply to a Misfire condition. Review the
vehicle repair history for any misfire condition repairs that have been
performed.
Read and record the FREEZE FRAME DATA. Sel ect OBD I I MONI TORS. Read and
record the MI S-FI RE SI MI LAR CONDI TI ONS WI NDOW DATA.
Wi th these screens, attempt to dupl i cate the condi ti on(s) that has set thi s DTC.
When the vehi cl e i s operati ng i n the SI MI LAR CONDI TI ONS WI NDOW, refer to the
WHI CH CYLI NDER I S MI SFI RI NG screen.
Observe the WHI CH CYLI NDER I S MI SFI RI NG screen for at l east one mi nute.
I s there a mi sfi re present?
Al l
Yes → Go To 2
No → Refer to the I NTERMI TTENT CONDI TI ON Symptom (Di agnos-
ti c Procedure).
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
2 NOTE:Anythingthat affectsthespeedof thecrankshaft can causeamisfire
DTC.
NOTE: When a Misfire is detected for a particular cylinder, the PCM will
shut down that cylinders Injector Control circuit.
- Vi sual l y i nspect the engi ne for any of the fol l owi ng condi ti ons.
- Worn serpenti ne bel t
- Bi ndi ng Engi ne-Dri ven accessori es: A/C Compressor, P/S Pump, Water pump.
- Mi sal i gned Water pump, P/S Pump and A/C Compressor pul l eys
- Corroded PCM power and ground ci rcui ts.
- I mproper CKP, CMP, MAP, and TP Sensor mounti ng
- Poor connector/termi nal to component connecti on. i .e., CKP sensor, Fuel I njector,
I gn coi l , etc.
- Vacuum l eaks
- Restri cted Ai r I nducti on system or Exhaust system.
Were any of the above condi ti ons present?
Al l
Yes → Repai r as necessary.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 3
3 Turn the i gni ti on off.
Di sconnect the I gni ti on Coi l harness connector.
Di sconnect the Fuel I njector harness connector.
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, actuate the ASD Rel ay.
Usi ng a 12-vol t test l i ght connected to ground, probe the (F42) ASD Rel ay Output
ci rcui t at the I gni ti on Coi l harness connector and Fuel I njector harness connector.
Does the test l i ght i l l umi nate bri ghtl y?
Al l
Yes → Go To 4
No → Repai r the excessi ve resi stance or short to ground i n the (F42)
ASD Rel ay Output ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
92
DRIVEABILITY - GAS
P0300-MULTIPLE CYLINDER MIS-FIRE — Continued
TEST ACTION APPLICABILITY
4 Turn the i gni ti on off.
Di sconnect the I gni ti on wi re from the spark pl ug of the cyl i nder(s) mi sfi ri ng.
Di sconnect the Fuel I njector harness connector of the cyl i nder(s) bei ng tested.
NOTE: Before continuing inspect the ignition wire for damage or carbon
tracking. Replace as necessary.
I nstal l a spark tester on the i gni ti on wi re.
Whi l e cranki ng the engi ne observe the spark comi ng from the spark tester.
NOTE: A crisp blue spark that is able to jump the gap of the spark tester
should be generated.
I s good spark present?
Al l
Yes → Go To 5
No → Go To 14
5 Turn the i gni ti on off.
Remove the Spark Pl ug of the mi sfi ri ng cyl i nder.
I nspect the Spark Pl ug for the fol l owi ng condi ti ons.
- Cracks
- Carbon Tracki ng
- Forei gn Materi al
- Gap si ze out of speci fi cati ons
- Loose or broke el ectrode
NOTE: Lightly tap the bottom of the spark plug on a solid surface. The
electrode in the spark plug should not move.
Were any of the above condi ti on present?
Al l
Yes → Repl ace the Spark Pl ug.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 6
6 Warning:Thefuel systemisunder aconstant pressure(evenwiththeengine
off). Beforetestingor servicingany fuel systemhose, fittingor line, thefuel
systempressure must be released.
I nstal l a fuel pressure gauge.
Start the engi ne and observe the fuel pressure readi ng.
NOTE: Fuel pressure specification is 400 KPa +/- 34 KPa (58 psi +/- 5 psi).
Choose a concl usi on that best matches your fuel pressure readi ng.
Al l
Wi thi n Speci fi cati on
Go To 7
Bel ow Speci fi cati on
Go To 12
Above Speci fi cati on
Repl ace the fuel fi l ter/pressure regul ator.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
93
DRIVEABILITY - GAS
P0300-MULTIPLE CYLINDER MIS-FIRE — Continued
TEST ACTION APPLICABILITY
7 NOTE: Before continuing visually and physically inspect the fuel delivery
systemfor external leaks or damage. Repair /replace as necessary.
Turn the i gni ti on off.
WARNING: The fuel system is under a constant pressure even with the
engine off. Before testing or servicing any fuel systemhose, fitting or line,
the fuel systempressure must be released.
I nstal l speci al tool #6539 (5/16Љ) fuel l i ne adapter.
I nstal l the fuel pressure gauge.
Start the engi ne and al l ow the fuel system to reach maxi mum pressure.
Turn the i gni ti on off.
NOTE: Fuel specification is 400 KPa +/- 34 KPa (58 psi +/- 5 psi).
Usi ng speci al tool #C4390, Hose Cl amp Pl i ers, pi nch the rubber fuel l i ne between the
fuel pressure gauge and the engi ne.
Moni tor the fuel pressure gauge for a mi ni mum of 5 mi nutes.
NOTE: The pressure should not fall below 241 KPa (35 psi)
Does the Upstream gauge fal l bel ow the above speci fi cati on?
Al l
Yes → Repl ace the l eaki ng Fuel I njector(s).
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 8
8 Warning:Thefuel systemisunder aconstant pressure(evenwiththeengine
off). Beforetestingor servicingany fuel systemhose, fittingor line, thefuel
systempressure must be released.
CAUTION: After each Fuel Injector actuation, start the engine to clean the
cylinder of fuel. Failure to do so could cause engine damage.
Remove speci al tool #C4390.
Start the engi ne and al l ow the fuel pressure to reach maxi mum pressure.
I gni ti on on, engi ne not runni ng.
Usi ng the DRBI I I ௡, actuate the Fuel I njector for the cyl i nder that i ndi cated the
mi sfi re.
Moni tor the fuel pressure gauge.
Does the fuel pressure gauge i ndi cate a drop i n fuel pressure?
Al l
Yes → Go To 9
No → Go To 10
NOTE: Turn the ignition off, remove the fuel pressure gauge, and connect
the fuel lines before continuing.
9 Check for any of the fol l owi ng condi ti ons/mechani cal probl ems.
ENGI NE VACUUM - must be at l east 13 i nches i n neutral
ENGI NE VALVE TI MI NG - must be wi thi n speci fi cati ons
ENGI NE COMPRESSI ON - must be wi thi n speci fi cati ons
ENGI NE EXHAUST SYSTEM - must be free of any restri cti ons or l eaks.
ENGI NE PCV SYSTEM - must fl ow freel y
TORQUE CONVERTER STALL SPEED - must be wi thi n speci fi cati ons
POWER BRAKE BOOSTER - no i nternal vacuum l eaks
FUEL - must be free of contami nati on
CAM LOBES - must not be worn excessi vel y
CYLI NDER LEAKAGE TEST - must be wi thi n speci fi cati ons
VALVE SPRI NGS - cannot be weak or broken
Are there any engi ne mechani cal probl ems?
Al l
Yes → Repai r as necessary.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 17
94
DRIVEABILITY - GAS
P0300-MULTIPLE CYLINDER MIS-FIRE — Continued
TEST ACTION APPLICABILITY
10 Turn the i gni ti on off.
Di sconnect the Fuel I njector harness connector.
I gni ti on on, engi ne not runni ng.
NOTE: When a Misfire is detected for a particular cylinder, the PCM will
shut down that cylinders Injector Control circuit.
Wi th the DRBI I I ௡, erase DTCs.
Usi ng a 12-vol t test l i ght connected to 12-vol ts, probe the I njector Control ci rcui t.
Wi th the DRBI I I ௡, actuate the Fuel I njector.
Does the test l i ght bl i nk/fl i cker?
Al l
Yes → Repl ace the Fuel I njector.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 11
11 Turn the i gni ti on off.
Di sconnect the PCM harness connectors.
Check the I njector Control ci rcui t for an open, short to ground, and short to vol tage.
Was a probl em found wi th the I njector Control ci rcui t?
Al l
Yes → Repai r the excessi ve resi stance or short to ground i n the I njector
Control ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 17
12 Turn the i gni ti on off.
Warning:Thefuel systemisunder aconstant pressure(evenwiththeengine
off). Beforetestingor servicingany fuel systemhose, fittingor line, thefuel
systempressure must be released.
Rai se vehi cl e on hoi st, and di sconnect the fuel pressure l i ne at the fuel pump modul e.
I nstal l speci al tool #6539 (5/16Љ) fuel l i ne adapter fuel pressure gauge between the
fuel suppl y l i ne and the fuel pump modul e.
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, actuate the ASD Fuel System test and observe the fuel pressure
gauge.
NOTE: Fuel pressure specification is 400 KPa +/- 34 KPa (58 psi +/- 5 psi).
I s the fuel pressure wi thi n speci fi cati on?
Al l
Yes → Repai r or repl ace fuel suppl y l i ne as necessary.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 13
13 Turn the i gni ti on off.
Warning:Thefuel systemisunder aconstant pressure(evenwiththeengine
off). Beforetestingor servicingany fuel systemhose,fittingor line, thefuel
systempressure must be released.
Remove the Fuel Pump Modul e and i nspect the Fuel I nl et Strai ner.
I s the Fuel I nl et Strai ner pl ugged?
Al l
Yes → Repl ace the Fuel Pump I nl et Strai ner.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → NOTE: Before conti nui ng, check the Fuel Pump Modul e harness
connector termi nal s for corrosi on, damage, or termi nal push out.
Ensure the ground ci rcui t i s operati ng properl y. Repai r as neces-
sary. Repl ace the Fuel Pump Modul e.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
95
DRIVEABILITY - GAS
P0300-MULTIPLE CYLINDER MIS-FIRE — Continued
TEST ACTION APPLICABILITY
14 Turn the i gni ti on off.
Remove the i gni ti on wi re.
Measure the resi stance of the i gni ti on wi re.
I s the resi stance bel ow 10K ohms?
Al l
Yes → Go To 15
No → Repl ace the I gni ti on Wi re.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
15 Turn the i gni ti on off.
Di sconnect the I gni ti on Coi l harness connector.
Remove the Fuel Pump Rel ay or ASD Rel ay.
Usi ng a 12-vol t test l i ght connected to 12-vol ts, probe the I gni ti on Coi l Control
ci rcui t.
Crank the engi ne for 5 second whi l e observi ng the test l i ght.
NOTE: Theresistanceof thePrimary Ignition Coil on a2.4L is0.51to0.61of
an ohmandthe4.0L Primary Coil Rail resistanceis0.53to0.63of an ohmat
77°F (25°C).
Does the test l i ght bri ghtl y bl i nk/fl i cker?
Al l
Yes → Repl ace the I gni ti on Coi l .
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 16
16 Turn the i gni ti on off.
Di sconnect the PCM harness connectors.
Check the Coi l Control ci rcui t for an open, short to ground, and short to vol tage.
Was a probl em found wi th the Coi l Control ci rcui t?
Al l
Yes → Repai r the Coi l Control ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 17
17 NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Usi ng the schemati cs as a gui de, i nspect the wi re harness and connectors. Pay
parti cul ar attenti on to al l Power and Ground ci rcui ts.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace and program the Powertrai n Control Modul e per Servi ce
I nformati on.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
96
DRIVEABILITY - GAS
P0300-MULTIPLE CYLINDER MIS-FIRE — Continued
Symptom:
P0320-NO CRANK REFERENCE SIGNAL AT PCM
When Monitored and Set Condition:
P0320-NO CRANK REFERENCE SIGNAL AT PCM
When Moni tored: Wi th the i gni ti on on.
Set Condi ti on: No si gnal from the Crankshaft Posi ti on Sensor i s present duri ng engi ne
cranki ng, and at l east 3 Camshaft Posi ti on Sensor si gnal s have occurred.
POSSIBLE CAUSES
I NTERMI TTENT CRANK POSI TI ON SI GNAL
CAM POSI TI ON SENSOR SI GNAL
(K7) 5-VOLT SUPPLY CI RCUI T SHORTED TO VOLTAGE
(K7) 5-VOLT SUPPLY CI RCUI T OPEN
(K7) 5-VOLT SUPPLY CI RCUI T SHORTED TO GROUND
(K24) CKP SENSOR SI GNAL CI RCUI T SHORTED TO VOLTAGE
(K24) CKP SENSOR SI GNAL CI RCUI T OPEN
(K24) CKP SENSOR SI GNAL CI RCUI T SHORTED GROUND
(K24) CKP SENSOR SI GNAL SHORTED TO (K7) 5-VOLT SUPPLY CI RCUI T
(K4) SENSOR GROUND CI RCUI T OPEN
CRANKSHAFT POSI TI ON SENSOR
PCM
TEST ACTION APPLICABILITY
1 I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, read DTCs and record the rel ated Freeze Frame data.
Wi th the DRBI I I ௡, erase DTCs.
Start the engi ne.
I f the DTC does not set ri ght away i t may be necessary to take the vehi cl e on a test
dri ve.
Does the DTC return?
Al l
Yes → Go To 2
No → Go To 14
2 Turn the i gni ti on off.
Di sconnect the CKP Sensor harness connector.
I gni ti on on, engi ne not runni ng.
Measure the vol tage on the (K7) 5-vol t Suppl y ci rcui t i n the CKP Sensor harness
connector.
I s the vol tage between 4.8 and 5.2 vol ts?
Al l
Yes → Go To 3
No → Go To 10
97
DRIVEABILITY - GAS
TEST ACTION APPLICABILITY
3 Measure the vol tage on the (K24) CKP Sensor Si gnal ci rcui t i n the CKP Sensor
harness connector.
I s the vol tage between 4.5 and 5.0 vol ts?
Al l
Yes → Go To 4
No → Go To 6
4 Turn the i gni ti on off.
Di sconnect the PCM harness connectors.
Measure the resi stance of the (K4) Sensor ground ci rcui t from the CKP Sensor
harness connector to the PCM harness connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 5
No → Repai r the open i n the (K4) Sensor ground ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
5 NOTE: Inspect the slots on the flywheel for damage. If a problemis found
repair as necessary.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace the Crankshaft Posi ti on Sensor.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
6 Turn the i gni ti on off.
Di sconnect the PCM harness connectors.
I gni ti on on, engi ne not runni ng.
Measure the vol tage on the (K24) CKP Sensor Si gnal ci rcui t i n the CKP Sensor
harness connector.
Di d the vol tage i ncrease above 5.2 vol ts wi th the I gni ti on on?
Al l
Yes → Repai r the short to vol tage i n the (K24) CKP Sensor Si gnal
ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 7
7 Turn the i gni ti on off.
Measure the resi stance of the (K24) CKP Sensor Si gnal ci rcui t from the CKP Sensor
harness connector to the PCM harness connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 8
No → Repai r the open i n the (K24) CKP Sensor Si gnal ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
8 Measure the resi stance between ground and the (K24) CKP Sensor Si gnal ci rcui t i n
the CKP Sensor harness connector.
I s the resi stance bel ow 100 ohms?
Al l
Yes → Repai r the short to ground i n the (K24) CKP Sensor Si gnal ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 9
98
DRIVEABILITY - GAS
P0320-NO CRANK REFERENCE SIGNAL AT PCM — Continued
TEST ACTION APPLICABILITY
9 Measure the resi stance between the (K24) CKP Sensor Si gnal ci rcui t and the (K7)
5-vol t Suppl y ci rcui t i n the CKP Sensor harness connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Repai r the short between the (K7) 5-vol t Suppl y ci rcui t and the
(K24) CKP Sensor Si gnal ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 13
10 Turn the i gni ti on off.
Di sconnect the PCM harness connectors.
I gni ti on on, engi ne not runni ng.
Measure the vol tage on the (K7) 5-vol t Suppl y ci rcui t at the CKP Sensor harness
connector.
Di d the vol tage i ncrease above 5.2 vol ts wi th the I gni ti on on?
Al l
Yes → Repai r the short to vol tage i n the (K7) 5-vol t Suppl y ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 11
NOTE: Turn the ignition off before continuing.
11 Turn the i gni ti on off.
Measure the resi stance of the (K7) 5-vol t Suppl y ci rcui t from the CKP Sensor harness
connector to the PCM harness connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 12
No → Repai r the open i n the (K7) 5-vol t Suppl y ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
12 Measure the resi stance between ground and the (K7) 5-vol t Suppl y ci rcui t at the CKP
Sensor harness connector.
I s the resi stance bel ow 100 ohms?
Al l
Yes → Repai r the short to ground i n the (K7) 5-vol t Suppl y ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 13
13 NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Usi ng the schemati cs as a gui de, i nspect the wi re harness and connectors. Pay
parti cul ar attenti on to al l Power and Ground ci rcui ts.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace and program the Powertrai n Control Modul e per Servi ce
I nformati on.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
99
DRIVEABILITY - GAS
P0320-NO CRANK REFERENCE SIGNAL AT PCM — Continued
TEST ACTION APPLICABILITY
14 NOTE: The following tests may help in identifying a possible intermittent
condition with the Crank Sensor or its related wire harness.
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡ as a Dual Channel Lab Scope and the Mi l l er speci al tool #6801,
backprobe the (K24) CKP Si gnal ci rcui t i n the Crank Sensor connector and the PCM
harness connector.
Wi ggl e the rel ated wi re harness and connecti ons.
Moni tor the l ab scope screen.
WARNING: 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.
Start the engi ne.
Li ghtl y tap on the Crank Sensor and wi ggl e the CKP Sensor connector and the
rel ated wi re harness.
Observe the l ab scope screen.
Look for any errati c pul ses generated by the CKP Sensor.
Di d the CKP Sensor generate any errati c pul ses?
Al l
Yes → Careful l y i nspect the wi re harness and connecti ons, repai r as
necessary, i f ok, repl ace the Crank Posi ti on Sensor.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 15
15 NOTE:An intermittent failurewith theCamPosition Sensor may causethe
P0320 code to set.
Turn the i gni ti on off.
Wi th the DRBI I I ௡ as a Dual Channel Lab Scope and the Mi l l er speci al tool #6801,
backprobe the (K44) CMP Si gnal ci rcui t i n the CMP Sensor connector and the PCM
harness connector.
WARNING: 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.
I gni ti on on, engi ne not runni ng.
Wi ggl e the rel ated wi re harness and gentl y tap on the Cam Posi ti on Sensor.
Moni tor the l ab scope screen.
Start the engi ne.
Li ghtl y tap on the CMP Sensor and wi ggl e the rel ated wi re harness.
Observe the l ab scope screen, l ooki ng for any errati c pul ses generated by the CMP
Sensor.
Di d the CMP Sensor generate any errati c pul ses?
Al l
Yes → Careful l y i nspect the wi re harness and connecti ons, repai r as
necessary, i f ok, repl ace the Cam Posi ti on Sensor.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Test Compl ete.
100
DRIVEABILITY - GAS
P0320-NO CRANK REFERENCE SIGNAL AT PCM — Continued
Symptom:
P0340-NO CAM REFERENCE SIGNAL AT PCM
When Monitored and Set Condition:
P0340-NO CAM REFERENCE SIGNAL AT PCM
When Moni tored: Engi ne cranki ng/runni ng.
Set Condi ti on: At l east 5 seconds have el apsed wi th Crankshaft Posi ti on Sensor si gnal s
present but no Camshaft Posi ti on Sensor si gnal .
POSSIBLE CAUSES
CHECKI NG I NTERMI TTENT CMP SI GNAL WI TH LAB SCOPE
CRANK POSI TI ON SENSOR SI GNAL
(K7) 5-VOLT SUPPLY CI RCUI T SHORTED TO VOLTAGE
(K7) 5-VOLT SUPPLY CI RCUI T OPEN
(K7) 5-VOLT SUPPLY CI RCUI T SHORTED TO GROUND
(K44) CMP SENSOR SI GNAL CI RCUI T SHORTED TO VOLTAGE
(K44) CMP SENSOR SI GNAL CI RCUI T OPEN
(K44) CMP SENSOR SI GNAL CI RCUI T SHORTED GROUND
(K44) CMP SENSOR SI GNAL SHORTED TO (K7) 5-VOLT SUPPLY CI RCUI T
(K4) SENSOR GROUND CI RCUI T OPEN
CAMSHAFT POSI TI ON SENSOR
PCM
TEST ACTION APPLICABILITY
1 Wi th the DRBI I I ௡, read DTCs and record the rel ated Freeze Frame data.
Wi th the DRBI I I ௡, erase DTCs.
Start the engi ne.
I f the DTC does not set ri ght away i t may be necessary to take the vehi cl e on a test
dri ve.
Does the DTC return?
Al l
Yes → Go To 2
No → Go To 14
2 Turn the i gni ti on off.
Di sconnect the CMP Sensor harness connector.
I gni ti on on, engi ne not runni ng.
Measure the vol tage on the (K7) 5-vol t Suppl y ci rcui t at the CMP Sensor harness
connector.
I s the vol tage between 4.8 and 5.2 vol ts?
Al l
Yes → Go To 3
No → Go To 10
101
DRIVEABILITY - GAS
TEST ACTION APPLICABILITY
3 Measure the vol tage on the (K44) CMP Sensor Si gnal ci rcui t at the CMP Sensor
harness connector.
I s the vol tage between 4.5 and 5.0 vol ts?
Al l
Yes → Go To 4
No → Go To 6
4 Turn the I gni ti on off.
Di sconnect the PCM harness connectors.
Measure the resi stance of the (K4) Sensor ground ci rcui t from the CMP Sensor
harness connector to the PCM harness connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 5
No → Repai r the open i n the (K4) Sensor ground ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
5 NOTE: Inspect theCamshaft sprocket for damageper theServiceInforma-
tion. If a problemis found repair as necessary.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace the Camshaft Posi ti on Sensor.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
6 Turn the i gni ti on off.
Di sconnect the PCM harness connectors.
I gni ti on on, engi ne not runni ng.
Measure the vol tage on the (K44) CMP Sensor Si gnal ci rcui t at the CMP Sensor
harness connector.
I s the vol tage above 5.2 vol ts?
Al l
Yes → Repai r the short to vol tage i n the (K44) CMP Sensor Si gnal
ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 7
7 Turn the i gni ti on off.
Measure the resi stance of the (K44) CMP Sensor Si gnal ci rcui t from the CMP Sensor
harness connector to the PCM harness connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 8
No → Repai r the open i n the (K44) CMP Sensor Si gnal ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
8 Measure the resi stance between ground and the (K44) CMP Sensor Si gnal ci rcui t at
the CMP Sensor harness connector.
I s the resi stance bel ow 100 ohms?
Al l
Yes → Repai r the short to ground i n the (K44) CMP Sensor Si gnal
ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 9
102
DRIVEABILITY - GAS
P0340-NO CAM REFERENCE SIGNAL AT PCM — Continued
TEST ACTION APPLICABILITY
9 Measure the resi stance between the (K44) CMP Sensor Si gnal ci rcui t and the (K7)
5-vol t Suppl y ci rcui t i n the CMP Sensor harness connector.
I s the resi stance bel ow 100 ohms?
Al l
Yes → Repai r the short between the (K7) 5-vol t Suppl y ci rcui t and the
(K44) CMP Sensor Si gnal ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 13
10 Turn the i gni ti on off.
Di sconnect the PCM harness connectors.
I gni ti on on, engi ne not runni ng.
Measure the vol tage on the (K7) 5-vol t Suppl y ci rcui t at the CMP Sensor harness
connector.
I s the vol tage above 5.2 vol ts?
Al l
Yes → Repai r the short to vol tage i n the (K7) 5-vol t Suppl y ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 11
11 Turn the i gni ti on off.
Measure the resi stance of the (K7) 5-vol t Suppl y ci rcui t from the CMP Sensor
harness connector to the PCM harness connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 12
No → Repai r the open i n the (K7) 5-vol t Suppl y ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
12 Measure the resi stance between ground and the (K7) 5-vol t Suppl y ci rcui t at the
CMP Sensor harness connector.
I s the resi stance bel ow 100 ohms?
Al l
Yes → Repai r the short to ground i n the (K7) 5-vol t Suppl y ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 13
13 NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Usi ng the schemati cs as a gui de, i nspect the wi re harness and connectors. Pay
parti cul ar attenti on to al l Power and Ground ci rcui ts.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace and program the Powertrai n Control Modul e per Servi ce
I nformati on.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
103
DRIVEABILITY - GAS
P0340-NO CAM REFERENCE SIGNAL AT PCM — Continued
TEST ACTION APPLICABILITY
14 NOTE: The following tests may help in identifying a possible intermittent
condition with the CamSensor or its related wire harness.
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡ as a Dual Channel Lab Scope and the Mi l l er speci al tool #6801,
backprobe the (K44) CMP Si gnal ci rcui t i n the Cam Sensor connector and the PCM
harness connector.
Wi ggl e the rel ated wi re harness and connecti ons.
Moni tor the l ab scope screen.
WARNING: 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.
Start the engi ne.
Li ghtl y tap on the Cam Sensor and wi ggl e the CMP Sensor connector and wi re
harness.
Observe the l ab scope screen.
Look for any errati c pul ses generated by the CMP Sensor.
Di d the CMP Sensor generate any errati c pul ses?
Al l
Yes → Careful l y i nspect the wi re harness and connecti ons, repai r as
necessary, i f ok, repl ace the Cam Posi ti on Sensor.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 15
15 NOTE: An intermittent Crank Position Sensor failure may cause the P0340
code to set.
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡ as a Dual Channel Lab Scope and the Mi l l er speci al tool #6801,
backprobe the (K24) CKP Si gnal ci rcui t i n the Crank Sensor connector and the PCM
harness connector.
Wi ggl e the rel ated wi re harness and connecti ons.
Moni tor the l ab scope screen.
WARNING: 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.
Start the engi ne.
Li ghtl y tap on the Crank Sensor and wi ggl e the CKP Sensor connector and wi re
harness.
Observe the l ab scope screen.
Look for any errati c pul ses generated by the CKP Sensor.
Di d the CKP Sensor generate any errati c pul ses?
Al l
Yes → Careful l y i nspect the wi re harness and connecti ons, repai r as
necessary, i f ok, repl ace the Crank Posi ti on Sensor.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Test Compl ete.
104
DRIVEABILITY - GAS
P0340-NO CAM REFERENCE SIGNAL AT PCM — Continued
SymptomList:
P0351-IGNITION COIL #1 PRIMARY CIRCUIT
P0352-IGNITION COIL #2 PRIMARY CIRCUIT
P0353-IGNITION COIL #3 PRIMARY CIRCUIT
Test Note: All symptomslistedabovearediagnosedusingthesametests.
The title for the tests will be P0351-IGNITION COIL # 1
PRIMARY CIRCUIT.
When Monitored and Set Condition:
P0351-IGNITION COIL #1 PRIMARY CIRCUIT
When Moni tored: Wi th battery vol tage greater than 8 vol ts duri ng engi ne cranki ng or
greater than 12 vol ts wi th engi ne runni ng, engi ne rpm l ess than 2016, and none of the coi l s
i n dwel l when checked.
Set Condi ti on: Peak current i s not achi eved wi th battery based dwel l pl us 1.5 msec of
di agnosti c offset. I t takes l ess than 3 seconds duri ng cranki ng or up to 6 seconds whi l e
runni ng to set.
P0352-IGNITION COIL #2 PRIMARY CIRCUIT
When Moni tored: Wi th battery vol tage greater than 8 vol ts duri ng engi ne cranki ng or
greater than 12 vol ts wi th engi ne runni ng, engi ne rpm l ess than 2016, and none of the coi l s
i n dwel l when checked.
Set Condi ti on: Peak current i s not achi eved wi th battery based dwel l pl us 1.5 msec of
di agnosti c offset. I t takes l ess than 3 seconds duri ng cranki ng or up to 6 seconds whi l e
runni ng to set.
P0353-IGNITION COIL #3 PRIMARY CIRCUIT
When Moni tored: Wi th battery vol tage greater than 8 vol ts duri ng engi ne cranki ng or
greater than 12 vol ts wi th engi ne runni ng, engi ne rpm l ess than 2016, and none of the coi l s
i n dwel l when checked.
Set Condi ti on: Peak current i s not achi eved wi th battery based dwel l pl us 1.5 msec of
di agnosti c offset. I t takes l ess than 3 seconds duri ng cranki ng or up to 6 seconds whi l e
runni ng to set.
POSSIBLE CAUSES
GOOD TRI P EQUAL TO ZERO
(F42) ASD RELAY OUTPUT CI RCUI T
I GNI TI ON COI L RESI STANCE
I GNI TI ON COI L
I GNI TI ON COI L CONTROL CI RCUI T OPEN
I GNI TI ON COI L CONTROL CI RCUI T SHORTED TO GROUND
105
DRIVEABILITY - GAS
POSSIBLE CAUSES
PCM
TEST ACTION APPLICABILITY
1 I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, read DTCs and record the rel ated Freeze Frame data.
I s the Good Tri p Counter di spl ayed and equal to zero?
Al l
Yes → Go To 2
No → Refer to the I NTERMI TTENT CONDI TI ON Symptom (Di agnos-
ti c Procedure).
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
2 Turn the i gni ti on off.
Di sconnect the I gni ti on Coi l harness connector.
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, actuate the ASD Rel ay.
Usi ng a 12-vol t test l i ght connected to ground, probe the (F42) ASD Rel ay Output
ci rcui t at the coi l rai l harness connector.
Does the test l i ght i l l umi nate bri ghtl y?
Al l
Yes → Go To 3
No → Repai r the excessi ve resi stance or short to ground i n the (F42)
ASD Rel ay Output ci rcui t. I nspect the rel ated fuses and repai r as
necessary.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
CAUTION: Stop All Actuations
3 Turn the i gni ti on off.
Di sconnect the I gni ti on Coi l harness connector.
NOTE: The resistance of the 2.4L Primary Ignition Coil is 0.53to 0.63of an
ohmand theresistanceof a 4.0L Primary Coil Rail is 0.51to 0.61of an ohm
at 70°F (21.1°C).
Measure the resi stance of the pri mary i gni ti on coi l .
I s the resi stance val ue wi thi n the l i sted speci fi cati ons?
Al l
Yes → Go To 4
No → Repl ace the i gni ti on coi l .
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
4 Turn the i gni ti on off.
Di sconnect the I gni ti on Coi l harness connector.
Usi ng a 12-vol t test l i ght connected to 12-vol ts, probe the I gni ti on Coi l Control
ci rcui t.
Crank the engi ne for 5 second whi l e observi ng the test l i ght.
What i s the state of the test l i ght whi l e cranki ng the engi ne?
Al l
Bri ghtl y bl i nki ng.
Repl ace the I gni ti on Coi l .
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
ON constantl y.
Go To 5
OFF constantl y.
Go To 6
106
DRIVEABILITY - GAS
P0351-IGNITION COIL #1 PRIMARY CIRCUIT — Continued
TEST ACTION APPLICABILITY
5 Turn the i gni ti on off.
Di sconnect the PCM harness connectors.
Measure the resi stance between the I gni ti on Coi l Control ci rcui t and ground.
I s the resi stance bel ow 100 ohms?
Al l
Yes → Repai r the short to ground i n the I gni ti on Coi l Control ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 7
6 Turn the i gni ti on off.
Di sconnect the PCM harness connectors.
Measure the resi stance of the I gni ti on Coi l Control ci rcui t from the I gni ti on Coi l
connector to the PCM connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 7
No → Repai r the open i n the I gni ti on Coi l Control ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
7 NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Usi ng the schemati cs as a gui de, i nspect the wi re harness and connectors. Pay
parti cul ar attenti on to al l Power and Ground ci rcui ts.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace and program the Powertrai n Control Modul e per Servi ce
I nformati on.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
107
DRIVEABILITY - GAS
P0351-IGNITION COIL #1 PRIMARY CIRCUIT — Continued
SymptomList:
P0420-1/1 CATALYTIC CONVERTER EFFICIENCY
P0432-2/1 CATALYTIC CONVERTER EFFICIENCY
Test Note: All symptomslistedabovearediagnosedusingthesametests.
The title for the tests will be P0420-1/1 CATALYTIC CON-
VERTER EFFICIENCY.
When Monitored and Set Condition:
P0420-1/1 CATALYTIC CONVERTER EFFICIENCY
When Moni tored: After engi ne warm up to 147° F, 180 seconds of open throttl e operati on,
at a speed greater than 20 mph, wi th the engi ne at 1200-1700 rpm and MAP vacuum
between 15.0 and 21.0 i nches of mercury (Hg).
Set Condi ti on: As catal yst effi ci ency deteri orates, the swi tch rate of the downstream O2
sensor approaches that of the upstream O2 sensor. I f at any poi nt duri ng the test the
swi tch rati o reaches a predetermi ned val ue a counter i s i ncremented by one.
P0432-2/1 CATALYTIC CONVERTER EFFICIENCY
When Moni tored: After engi ne warm up to 147° F, 180 seconds of open throttl e operati on,
at a speed greater than 20 mph, wi th the engi ne at 1200-1700 rpm and MAP vacuum
between 15.0 and 21.0 i nches of mercury (Hg).
Set Condi ti on: As catal yst effi ci ency deteri orates, the swi tch rate of the downstream O2
sensor approaches that of the upstream O2 sensor. I f at any poi nt duri ng the test the
swi tch rati o reaches a predetermi ned val ue a counter i s i ncremented by one.
POSSIBLE CAUSES
GOOD TRI P EQUAL TO ZERO
VI SUALLY I NSPECT CATALYTI C CONVERTER
EXHAUST LEAK
ENGI NE MECHANI CAL PROBLEM
UPSTREAM O2 SENSOR OLDER THAN DOWNSTREAM O2 SENSOR
CATALYTI C CONVERTER
108
DRIVEABILITY - GAS
TEST ACTION APPLICABILITY
1 Check for any rel ated TSBs.
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, read DTCs and record the rel ated Freeze Frame data.
I s the Good Tri p Counter di spl ayed and equal to zero?
Al l
Yes → Go To 2
No → Refer to the I NTERMI TTENT CONDI TI ON Symptom (Di agnos-
ti c Procedure).
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
2 I nspect the Catal yti c Converter for the fol l owi ng damage.
Damaged Catal yti c Converter, dent and hol es.
Severe di scol orati on caused by overheati ng the Catal yti c Converter.
Catal yti c Converter broken i nternal l y.
Leaki ng Catal yti c Converter.
Were any probl ems found?
Al l
Yes → Repl ace the Catal yti c Converter. Repai r the condi ti on that may
have caused the fai l ure.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 3
3 Start Engi ne and l et i dl e.
WARNING: 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.
Check for exhaust l eaks between the engi ne and the appropri ate downstream O2
Sensor.
I s there any exhaust l eaks?
Al l
Yes → Repai r or repl ace l eaki ng exhaust parts as necessary.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 4
4 Check the exhaust for excessive smoke frominternal oil or coolant leaks.
I s there an oi l or cool ant consumpti on condi ti on present?
Al l
Yes → Repai r the engi ne mechani cal condi ti on as necessary and repl ace
Catal yti c Converter.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 5
5 Turn the i gni ti on off.
NOTE: A new Downstream O2 Sensor along with an aging Upstream O2
Sensor may cause this trouble code to set.
Revi ew vehi cl e repai r hi story.
Has the Downstream O2 Sensor been repl aced wi thout repl aci ng the Upstream O2
Sensor?
Al l
Yes → Repl ace the appropri ate Upstream Oxygen Sensor.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 6
6 I f there are no possi bl e causes remai ni ng, vi ew repai r. Al l
Repai r
Repl ace the Catal yti c Converter.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
109
DRIVEABILITY - GAS
P0420-1/1 CATALYTIC CONVERTER EFFICIENCY — Continued
Symptom:
P0441-EVAP PURGE FLOWMONITOR
When Monitored and Set Condition:
P0441-EVAP PURGE FLOWMONITOR
When Moni tored: Wi th engi ne temperature greater than 170° F, fuel control i n cl osed
l oop, engi ne i dl i ng for 2 mi nutes, no l ow fuel , MAP l ess than 15.7 i nches mercury and
barometri c al ti tude l ess than 8,000 feet.
Set Condi ti on: After havi ng passed the Leak Detecti on Pump (LDP) test, no ai r fl ow
through the evaporati ve system i s detected by the EVAP moni tor.
POSSIBLE CAUSES
GOOD TRI P EQUAL TO ZERO
I NTERMI TTENT CONDI TI ON
VI SUAL I NSPECTI ON
EVAP PURGE HOSE (SOLENOI D TO CANI STER)
EVAP PURGE HOSE (CANI STER TO FUEL TANK)
EVAP PURGE SOLENOI D VACUUM SUPPLY
EVAP PURGE SOLENOI D (LEAKI NG/STUCK OPEN)
EVAP PURGE SOLENOI D
TEST ACTION APPLICABILITY
1 Check for any rel ated TSBs.
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, read DTCs and record the rel ated Freeze Frame data.
I s the Good Tri p Counter di spl ayed and equal to zero?
Al l
Yes → Go To 2
No → Refer to the I NTERMI TTENT CONDI TI ON Symptom (Di agnos-
ti c Procedure).
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
2 Vi sual l y i nspect the Evap cani ster. Look for any physi cal damage or any si gns of fuel
that has entered the cani ster. Any si gns of fuel may i ndi cate a fuel tank vent.
Were any probl ems found?
Al l
Yes → Repai r or Repl ace as necessary.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 3
110
DRIVEABILITY - GAS
TEST ACTION APPLICABILITY
3 Vi sual l y i nspect the Evap purge hose that goes from the Purge Sol enoi d to the Evap
Cani ster. Look for any physi cal damage such as a pi nched, pl ugged, ri pped or dry
rotted hose.
Were any probl ems found?
Al l
Yes → Repai r or repl ace hose as necessary.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 4
4 Vi sual l y i nspect the Evap Purge hose that goes between the Evap cani ster and the
fuel tank. Look for any physi cal damage such as a pi nched, pl ugged, ri pped or dry
rotted hose.
Were any probl ems found?
Al l
Yes → Repai r or repl ace hose as necessary.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 5
5 Careful l y i nspect the Evap Purge Sol enoi d vacuum suppl y hose for proper routi ng.
Al so check for a pi nched or pl ugged hose from the throttl e body to the Purge Sol enoi d.
I nspect the vacuum ni ppl e at the throttl e body for any damage or pl uggi ng.
Make sure vacuum fi tti ng at the purge sol enoi d i s not over i nstal l ed, pushed i n too
far.
I s the vacuum suppl y hose and throttl e body vacuum ni ppl e free from defects?
Al l
Yes → Go To 6
No → Repai r the vacuum suppl y hose/tube as necessary.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
6 Note: After disconnecting the Evap Purge Solenoid vacuum connections,
inspect thelinesandsolenoidfor anysignsof contaminationfromtheEVAP
Canister. This may indicatea faulty fuel tank vent. Replacepurgesolenoid
if contamination is found
Di sconnect the vacuum hoses at the EVAP Purge Sol enoi d.
Usi ng a hand vacuum pump, appl y 10 i nches of vacuum to the Evap Purge Sol enoi d
vacuum source port. (component si de)
Does the Evap Purge Sol enoi d hol d vacuum?
Al l
Yes → Go To 7
No → Repl ace the Evap Purge Sol enoi d and the Evap Cani ster and
cl ean out Evap l i nes as necessary.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
7 Usi ng a hand vacuum pump, appl y 10 i nches of vacuum to the Evap Purge Sol enoi d
vacuum source port. (component si de)
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, actuate the EVAP Purge Sol enoi d and observe the vacuum gauge.
Does the vacuum drop when the sol enoi d i s actuated?
Al l
Yes → Refer to the I NTERMI TTENTCONDTI ON Symptom (Di agnosti c
Procedure).
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Repl ace the Evap Purge Sol enoi d.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
111
DRIVEABILITY - GAS
P0441-EVAP PURGE FLOWMONITOR — Continued
SymptomList:
P0442-EVAP LEAK MONITOR MEDIUM (0.040) LEAK DETECTED
P0455-EVAP LEAK MONITOR LARGE LEAK DETECTED
P0456-EVAP LEAK MONITOR SMALL (0.020) LEAK DETECTED
Test Note: All symptomslistedabovearediagnosedusingthesametests.
The title for the tests will be P0442-EVAP LEAK MONITOR
MEDIUM (0.040) LEAK DETECTED.
When Monitored and Set Condition:
P0442-EVAP LEAK MONITOR MEDIUM (0.040) LEAK DETECTED
When Moni tored: I mmedi atel y after a col d start, wi th battery/ambi ent temperature
between 40° F and 90° F and cool ant temperature wi thi n 10° F of battery/ambi ent.
Set Condi ti on: I f there i s a l eak l arger than 0.040Љ and smal l er than 0.080Љ i n the
evaporati ve system.
P0455-EVAP LEAK MONITOR LARGE LEAK DETECTED
When Moni tored: I mmedi atel y after a col d start, wi th battery/ambi ent temperature
between 40° F and 90° F and cool ant temperature wi thi n 10° F of battery/ambi ent.
Set Condi ti on: There i s a l eak l arger than 0.080Љ i n the evaporati ve system.
P0456-EVAP LEAK MONITOR SMALL (0.020) LEAK DETECTED
When Moni tored: I mmedi atel y after a col d start, wi th battery/ambi ent temperature
between 40° F and 90° F and cool ant temperature wi thi n 10° F of battery/ambi ent.
Set Condi ti on: There i s a l eak l arger than 0.020Љ and smal l er than 0.040Љ i n the
evaporati ve system.
POSSIBLE CAUSES
GOOD TRI P EQUAL TO ZERO
I NTERMI TTENT CONDI TI ON
EVAPORATI VE EMI SSI ON LEAK DETECTI ON
EVAP PURGE SOLENOI D
112
DRIVEABILITY - GAS
TEST ACTION APPLICABILITY
1 Check for any rel ated TSBs.
Note: A loosegas cap could havecaused this DTC to set. Makesuregas cap
istight andingoodcondition. EnsurethegascapmeetsOEMspecifications.
Veri fy wi th customer that the gas cap has not been ti ghtened si nce the MI L
i l l umi nated.
NOTE: Engine vacuumat must be present at the LDP vacuumport.
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, read DTCs and record the rel ated Freeze Frame data.
I s the Good Tri p Counter di spl ayed and equal to zero?
Al l
Yes → Go To 2
No → Refer to the I NTERMI TTENT CONDI TI ON Symptom (Di agnos-
ti c Procedure).
Perform POWERTRAI N VERI FI CATI ON TEST VER - 6.
113
DRIVEABILITY - GAS
P0442-EVAP LEAK MONITOR MEDIUM (0.040) LEAK DETECTED —
Continued
TEST ACTION APPLICABILITY
2 To conti nue testi ng you wi l l need Mi l l er Tool #8404A Evaporati ve Emi ssi on Leak
Detector (EELD).
WARNING: Keep lit cigarettes, sparks, flames, and other ignition sources
away fromthetest area toprevent theignition of explosivegases. Keep the
test area well ventilated.
NOTE:Thefuel tank shouldhavebetween20%and80%of fuel tank capacity
and the fuel must be cool to properly test the Evap system.
Di sconnect the vacuum suppl y hose at the Leak Detecti on Pump.
Connect and appl y a conti nuous vacuum suppl y (i .e. 20ЉHg) to the Leak Detecti on
Pump. A vacuum pump such as an A/C recovery uni t works wel l .
Usi ng the DRBI I I ௡, sel ect Engi ne/System Tests and actuate the Leak Detect Pump
Test (Opti on 3/Hol d PSI ).
NOTE: The above energizes the LDP solenoid and allows the constant
vacuumsourcetoapply vacuumtotheLDP pump diaphragm. This lifts the
diaphragmup and seals the atmospheric canister vent valve at the bottom
of the Leak Detection Pump.
Connect the red power l ead of Mi l l er Tool #8404A to the battery posi ti ve termi nal and
the bl ack ground l ead to battery negati ve termi nal .
NOTE: SeeCharts and Graph support material EELD Calibration Setup for
an example.
Connect shop ai r to the #8404A EELD.
Set the smoke/ai r control swi tch to AI R.
I nsert the tester’s AI R suppl y ti p (cl ear hose) i nto the appropri ate cal i brati on ori fi ce
on the tester’s control panel (based on DTC l eak si ze).
Press the remote smoke/ai r start button.
Posi ti on the red fl ag on the ai r fl ow meter so i t i s al i gned wi th the i ndi cator bal l .
When the cal i brati on i s compl ete, rel ease the remote button. The EELD fl ow meter
i s now cal i brated i n l i ters per mi nute to the si ze l eak i ndi cated by the DTC set i n the
PCM.
I nstal l the servi ce port adapter #8404-14 on the vehi cl e’s servi ce port (i f equi pped) or
i nstal l the #8404-ADP servi ce adapter i n the LDP fi l ter l i ne.
Connect the Ai r suppl y hose from the EELD to the servi ce port or the #8404-ADP.
Press the remote button to acti vate AI R fl ow.
NOTE: Larger volumefuel tanks, and/or thosewith less fuel, may require4
to 5 minutes to fill.
Compare the fl ow meter i ndi cator bal l readi ng to the red fl ag.
ABOVE the red fl ag i ndi cates a l eak present.
BELOW the red fl ag i ndi cates a seal ed system.
I s the i ndi cator bal l above the red fl ag?
Al l
Yes → Go To 3
No → Refer to the I NTERMI TTENTCONDTI ON Symptom (Di agnosti c
Procedure).
Perform POWERTRAI N VERI FI CATI ON TEST VER - 6.
114
DRIVEABILITY - GAS
P0442-EVAP LEAK MONITOR MEDIUM (0.040) LEAK DETECTED —
Continued
TEST ACTION APPLICABILITY
3 NOTE: A thorough visual inspection of the Evap system hoses, tubes, and
connectionsmay savetimein your diagnosis. Look for any physical damage
or signs of wetness at connections. Thestrongsmell of fuel vapors may aid
diagnosis also.
To conti nue testi ng, you wi l l need Mi l l er Tool #8404A Evaporati ve Emi ssi ons Leak
Detector (EELD).
Remove the Ai r suppl y hose from the servi ce port.
Connect the SMOKE suppl y ti p (bl ack hose) to the servi ce port i f equi pped or
#8404-ADP.
Set the smoke/ai r control swi tch to SMOKE.
NOTE: The flow meter indicator ball will not move at this point.
Press the remote smoke/ai r start button.
NOTE:Ensurethat smokehasfilledtheEVAP systemby continuingtopress
theremotesmoke/air start button, removethevehiclefuel cap, andwait for
the smoke to exit. Once smoke is indicated reinstall the fuel cap.
NOTE: For optimal performance, introduce smoke into the system for an
additional 60 seconds; continue introducing smoke at 15 second intervals,
as necessary.
Whi l e sti l l hol di ng the remote smoke/ai r start button, use the whi te l i ght (#8404-
CLL) to fol l ow the EVAP system path, and l ook for the source of the l eak i ndi cated by
exi ti ng smoke.
I f a l eak i s conceal ed from vi ew (i .e., top of fuel tank), rel ease the remote smoke/ai r
start button, and use the ul travi ol et (UV) bl ack l i ght #8404-UVL and the yel l ow
goggl es 8404-20 to l ook for resi dual traces of dye that i s l eft behi nd by the smoke.
The exi ti ng smoke deposi ts a resi dual fl ui d that i s ei ther bri ght green or bri ght
yel l ow i n col or when vi ewed wi th a UV l i ght.
Was a l eak found?
Al l
Yes → Repai r or repl ace the l eaki ng component as necessary.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 6.
No → Go To 4
4 NOTE: After disconnecting the Evap Purge Solenoid vacuum connections,
inspect thelinesandsolenoidfor anysignsof contaminationfromtheEVAP
Canister. This may indicate a faulty fuel tank vent. Replace/repair as
necessary.
Turn the i gni ti on off.
Di sconnect the vacuum hoses at the EVAP Purge Sol enoi d.
Usi ng a hand vacuum pump, appl y 10 i nches of vacuum to the Evap Purge Sol enoi d
vacuum source port on the component si de.
NOTE: Monitor the vacuumgauge for at least 15 seconds.
Does the Evap Purge Sol enoi d hol d vacuum?
Al l
Yes → Refer to the I NTERMI TTENTCONDTI ON Symptom (Di agnosti c
Procedure).
Perform POWERTRAI N VERI FI CATI ON TEST VER - 6.
No → Repl ace the Evap Purge Sol enoi d.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 6.
115
DRIVEABILITY - GAS
P0442-EVAP LEAK MONITOR MEDIUM (0.040) LEAK DETECTED —
Continued
Symptom:
P0443-EVAP PURGE SOLENOID CIRCUIT
When Monitored and Set Condition:
P0443-EVAP PURGE SOLENOID CIRCUIT
When Moni tored: Conti nuousl y after the i gni ti on i s turned on and the battery vol tage i s
above 10.4 vol ts.
Set Condi ti on: Not poweri ng down, not i n l i mp-i n and ti me si nce l ast sol enoi d acti vati on
i s greater than 72 mi cro seconds. The PCM wi l l set a troubl e code i f the actual state of the
sol enoi d does not match the i ntended state on two consecuti ve key cycl es.
POSSIBLE CAUSES
GOOD TRI P EQUAL TO ZERO
EVAP PURGE SOLENOI D
(F12) FUSED I GNI TI ON SWI TCH OUTPUT CI RCUI T
(K52) EVAP PURGE SOLENOI D CONTROL CI RCUI T OPEN
(K52) EVAP PURGE SOLENOI D CONTROL CI RCUI T SHORTED TO GROUND
PCM
TEST ACTION APPLICABILITY
1 Check for any rel ated TSBs.
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, read DTCs and record the rel ated Freeze Frame data.
I s the Good Tri p Counter di spl ayed and equal to zero?
Al l
Yes → Go To 2
No → Refer to the I NTERMI TTENT CONDI TI ON Symptom (Di agnos-
ti c Procedure).
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
2 Turn the i gni ti on off.
Di sconnect the Evap Purge Sol enoi d connector.
Measure the resi stance between the termi nal s of the Evap Purge Sol enoi d.
I s the resi stance between 29.0 and 44.0 ohms?
Al l
Yes → Go To 3
No → Repl ace the Evap Purge Sol enoi d.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
116
DRIVEABILITY - GAS
TEST ACTION APPLICABILITY
3 I gni ti on on, engi ne not runni ng.
Measure the vol tage on the (F12) Fused I gni ti on Swi tch Output ci rcui t at the EVAP
Purge Sol enoi d harness connector.
I s the vol tage above 10.0 vol ts?
Al l
Yes → Go To 4
No → Repai r the open or short to ground i n the (F12) Fused I gni ti on
Swi tch Output ci rcui t. I nspect the rel ated fuse and repai r as
necessary.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
4 Turn the i gni ti on off.
Di sconnect the PCM harness connectors.
Note: Check connectors - Clean/repair as necessary.
Measure the resi stance of the (K52) Evap Purge Sol enoi d Control ci rcui t from the
PCM harness connector to the Evap Purge Sol enoi d harness connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 5
No → Repai r the open i n the (K52) Evap Purge Sol enoi d Control ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
5 Measure the resi stance between ground and the (K52) Evap Purge Sol enoi d Control
ci rcui t.
I s the resi stance bel ow 100 ohms?
Al l
Yes → Repai r the short to ground i n the (K52) Evap Purge Sol enoi d
Control ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 6
6 NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Usi ng the schemati cs as a gui de, i nspect the wi re harness and connectors. Pay
parti cul ar attenti on to al l Power and Ground ci rcui ts.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace and program the Powertrai n Control Modul e per Servi ce
I nformati on.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
117
DRIVEABILITY - GAS
P0443-EVAP PURGE SOLENOID CIRCUIT — Continued
SymptomList:
P0460-FUEL LEVEL UNIT NO CHANGE OVER MILES
P0461-FUEL LEVEL UNIT NO CHANGE OVER TIME
Test Note: All symptomslistedabovearediagnosedusingthesametests.
The title for the tests will be P0460-FUEL LEVEL UNIT NO
CHANGE OVER MILES.
When Monitored and Set Condition:
P0460-FUEL LEVEL UNIT NO CHANGE OVER MILES
When Moni tored: Engi ne runni ng and fuel l evel ei ther bel ow 15% or above 85% of
capaci ty.
Set Condi ti on: The PCM sees l ow fuel , l ess than 15%, for more than 120 mi l es or fuel l evel
does not change by at l east 4% for more than 250 mi l es.
P0461-FUEL LEVEL UNIT NO CHANGE OVER TIME
When Moni tored: Engi ne runni ng and fuel l evel ei ther bel ow 15% or above 85% of
capaci ty.
Set Condi ti on: The PCM sees l ow fuel , l ess than 15%, for more than 120 mi l es or fuel l evel
does not change by at l east 4% for more than 250 mi l es.
POSSIBLE CAUSES
PHYSI CALLY DAMAGED/DEFORMED/OBSTRUCTED FUEL TANK
FUEL LEVEL SENSOR
TEST ACTION APPLICABILITY
1 Check for any rel ated TSBs.
Turn the i gni ti on off.
WARNING: The fuel system is under a constant pressure, even with the
engine off. Before testing or servicing any fuel systemhose, fitting or line,
the fuel systempressure must be released.
I nspect the outsi de of the fuel tank for defects.
Remove the fuel tank.
Remove the fuel pump modul e from the fuel tank.
I nspect the i nsi de of the fuel tank for any obstructi ons or deformi ti es.
I s the fuel tank free from defects?
Al l
Yes → Go To 2
No → Repai r or repl ace the fuel tank as necessary.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 2.
2 I f there are no possi bl e causes remai ni ng, vi ew repai r. Al l
Repai r
Repl ace the Fuel Level Sensor.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 2.
118
DRIVEABILITY - GAS
Symptom:
P0462-FUEL LEVEL SENDING UNIT VOLTAGE TOO LOW
When Monitored and Set Condition:
P0462-FUEL LEVEL SENDING UNIT VOLTAGE TOO LOW
When Moni tored: I gni ti on on and battery vol tage above 10.4 vol ts.
Set Condi ti on: The Fuel Level Sensor si gnal vol tage goes bel ow 0.2 of a vol t at the PCM
for more than 5 seconds.
POSSIBLE CAUSES
FUEL LEVEL SENSOR VOLTAGE BELOW 0.2 VOLT
FUEL LEVEL SENSOR
(K226) FUEL LEVEL SENSOR SI GNAL CI RCUI T SHORTED TO GROUND
(K226) FUEL LEVEL SENSOR SI GNAL CI RCUI T SHORTED TO (K4) SENSOR GROUND CI RCUI T
PCM
TEST ACTION APPLICABILITY
1 I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, read DTCs and record the rel ated Freeze Frame data.
Check for any rel ated TSBs.
Wi th the DRBI I I ௡, read the Fuel Level Sensor vol tage.
I s the Fuel Level Sensor vol tage bel ow 0.2 of a vol t?
Al l
Yes → Go To 2
No → Refer to the I NTERMI TTENT CONDI TI ON Symptom (Di agnos-
ti c Procedure).
Perform POWERTRAI N VERI FI CATI ON TEST VER - 2.
2 Turn the i gni ti on off.
Di sconnect the Fuel Pump Modul e harness connector.
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, read the Fuel Level Sensor vol tage.
Di d the Fuel Level Sensor vol tage change from bel ow 0.2 of a vol t to above 4.0 vol ts?
Al l
Yes → Repl ace the Fuel Level Sensor.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 2.
No → Go To 3
3 Turn the i gni ti on off.
Di sconnect the PCM harness connectors.
Measure the resi stance between ground and the (K226) Fuel Level Sensor Si gnal
ci rcui t.
I s the resi stance bel ow 100 ohms?
Al l
Yes → Repai r the short to ground i n the (K226) Fuel Level Sensor Si gnal
ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 2.
No → Go To 4
119
DRIVEABILITY - GAS
TEST ACTION APPLICABILITY
4 Measure the resi stance between the (K226) Fuel Level Sensor Si gnal ci rcui t and the
(K4) Sensor ground ci rcui t.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Repai r the short between the (K4) Sensor ground and the (K226)
Fuel Level Sensor Si gnal ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 2.
No → Go To 5
5 NOTE: Beforecontinuing, check thePCMharnessconnectorsfor corrosion,
damage, or terminal push out. Repair as necessary.
Usi ng the schemati cs as a gui de, i nspect the wi re harness and connectors. Pay
parti cul ar attenti on to al l Power and Ground ci rcui ts.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace and program the Powertrai n Control Modul e per Servi ce
I nformati on.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 2.
120
DRIVEABILITY - GAS
P0462-FUEL LEVEL SENDING UNIT VOLTAGE TOO LOW— Continued
Symptom:
P0463-FUEL LEVEL SENDING UNIT VOLTAGE TOO HIGH
When Monitored and Set Condition:
P0463-FUEL LEVEL SENDING UNIT VOLTAGE TOO HIGH
When Moni tored: I gni ti on on and battery vol tage above 10.4 vol ts.
Set Condi ti on: The Fuel Level Sensor si gnal vol tage at the PCM goes above 4.95 vol ts for
more than 90 seconds.
POSSIBLE CAUSES
FUEL LEVEL SENSOR VOLTAGE ABOVE 4.9 VOLTS
FUEL LEVEL SENSOR
(K226) FUEL LEVEL SENSOR SI GNAL CI RCUI T SHORT TO VOLTAGE
(K226) FUEL LEVEL SENSOR SI GNAL CI RCUI T OPEN
(K4) SENSOR GROUND CI RCUI T OPEN
PCM
TEST ACTION APPLICABILITY
1 I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, read DTCs and record the rel ated Freeze Frame data.
Check for any rel ated TSBs.
Wi th the DRBI I I ௡, read the Fuel Level Sensor vol tage.
I s the Fuel Level Sensor vol tage above 4.9 vol ts?
Al l
Yes → Go To 2
No → Refer to the I NTERMI TTENT CONDI TI ON Symptom (Di agnos-
ti c Procedure).
Perform POWERTRAI N VERI FI CATI ON TEST VER - 2.
2 Turn the i gni ti on off.
Di sconnect the Fuel Pump Modul e el ectri cal harness connector.
I gni ti on on, engi ne not runni ng.
Connect a jumper wi re between the (K226) Fuel Level Sensor Si gnal ci rcui t and the
(K4) Sensor ground ci rcui t at the Fuel Pump Modul e harness connector.
Wi th the DRBI I I ௡, read the Fuel Level Sensor vol tage.
Di d the Fuel Level Sensor vol tage change from above 4.9 vol ts to bel ow 0.4 of a vol t?
Al l
Yes → Repl ace the Fuel Level Sensor.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 2.
No → Go To 3
NOTE: Remove the jumper wire before continuing.
121
DRIVEABILITY - GAS
TEST ACTION APPLICABILITY
3 Turn the i gni ti on off.
Di sconnect the PCM harness connectors.
I gni ti on on, engi ne not runni ng.
Measure the vol tage on the (K226) Fuel Level Sensor Si gnal ci rcui t at the Fuel Pump
Modul e harness connector.
I s the vol tage above 5.3 vol ts?
Al l
Yes → Repai r the short to vol tage i n the (K226) Fuel Level Sensor Si gnal
ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 2.
No → Go To 4
4 Turn the i gni ti on off.
Measure the resi stance of the (K226) Fuel Level Sensor Si gnal ci rcui t from the PCM
harness connector to the Fuel Pump Modul e harness connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 5
No → Repai r the open i n the (K226) Fuel Level Sensor Si gnal ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 2.
5 Measure the resi stance of the (K4) Sensor ground ci rcui t from the PCM harness
connector to the Fuel Pump Modul e harness connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 6
No → Repai r the open i n the (K4) Sensor ground ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 2.
6 NOTE: Beforecontinuing, check thePCMharnessconnectorsfor corrosion,
damage, or terminal push out. Repair as necessary.
Usi ng the schemati cs as a gui de, i nspect the wi re harness and connectors. Pay
parti cul ar attenti on to al l Power and Ground ci rcui ts.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace and program the Powertrai n Control Modul e per Servi ce
I nformati on.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 2.
122
DRIVEABILITY - GAS
P0463-FUEL LEVEL SENDING UNIT VOLTAGE TOO HIGH — Continued
Symptom:
P0500-NO VEHICLE SPEED SIGNAL CIRCUIT
When Monitored and Set Condition:
P0500-NO VEHICLE SPEED SIGNAL CIRCUIT
When Moni tored: Engi ne Temperature greater than 104 deg F, MAP vacuum approxi -
matel y 15Љ to 16Љ i nches of mercury and Engi ne RPM between 1400 and 3000 rpm.
Set Condi ti on: No Vehi cl e Speed Si gnal for more than 15 seconds on two consecuti ve
tri ps.
POSSIBLE CAUSES
GOOD TRI P EQUAL TO ZERO
(K6) 5-VOLT SUPPLY CI RCUI T OPEN
(K6) 5-VOLT SUPPLY CI RCUI T SHORTED TO GROUND
VEHI CLE SPEED SENSOR
(G7) VEHI CLE SPEED SI GNAL CI RCUI T SHORTED TO VOLTAGE
(G7) VEHI CLE SPEED SI GNAL CI RCUI T OPEN
(G7) VEHI CLE SPEED SI GNAL CI RCUI T SHORTED TO GROUND
(K4) SENSOR GROUND CI RCUI T OPEN
PCM
TEST ACTION APPLICABILITY
1 I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, read DTCs and record the rel ated Freeze Frame data.
I s the Good Tri p Counter di spl ayed and equal to zero?
Al l
Yes → Go To 2
No → Refer to the I NTERMI TTENT CONDI TI ON Symptom (Di agnos-
ti c Procedure).
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
2 Turn the i gni ti on off.
Di sconnect the Vehi cl e Speed Sensor harness connector.
I gni ti on on, engi ne not runni ng.
Measure the vol tage on the (K6) 5-vol t Suppl y ci rcui t at the VSS harness connector.
I s the vol tage between 4.5 to 5.2 vol ts?
Al l
Yes → Go To 3
No → Go To 8
123
DRIVEABILITY - GAS
TEST ACTION APPLICABILITY
3 I gni ti on on, engi ne not runni ng.
Connect a jumper wi re between the (G7) Vehi cl e Speed Si gnal ci rcui t and (K4) Sensor
ground ci rcui t i n the VSS harness connector.
Wi th the DRBI I I ௡ read the Vehi cl e Speed Si gnal vol tage.
Does the vol tage start at 5.0 vol ts and drop to approxi matel y 0 vol ts?
Al l
Yes → Repl ace the Vehi cl e Speed Sensor.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 4
NOTE: Remove the jumper wire before continuing.
4 Turn the i gni ti on off.
Di sconnect the PCM harness connectors.
I gni ti on on, engi ne not runni ng.
Measure the vol tage on the (G7) Vehi cl e Speed Si gnal ci rcui t at the PCM or Sensor
harness connector.
I s the vol tage above 5.2 vol ts?
Al l
Yes → Repai r the short to vol tage i n the (G7) Vehi cl e Speed Si gnal
ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 5
5 Turn the i gni ti on off.
Measure the resi stance of the (G7) Vehi cl e Speed Si gnal ci rcui t from the PCM
harness connector to the VSS harness connector.
I s the resi stance above 5.0 ohms?
Al l
Yes → Repai r the open i n the (G7) Vehi cl e Speed Si gnal ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 6
6 Measure the resi stance between ground and the (G7) Vehi cl e Speed Si gnal ci rcui t at
the Sensor harness connector.
I s the resi stance bel ow 100 ohms?
Al l
Yes → Repai r the short to ground i n the (G7) Vehi cl e Speed Si gnal
ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 7
7 Measure the resi stance of the (K4) Sensor ground ci rcui t from the Sensor harness
connector to the PCM harness connector.
I s the resi stance above 5.0 ohms?
Al l
Yes → Repai r the open i n the (K4) Sensor ground ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 10
124
DRIVEABILITY - GAS
P0500-NO VEHICLE SPEED SIGNAL CIRCUIT — Continued
TEST ACTION APPLICABILITY
8 Turn the i gni ti on off.
Di sconnect the PCM harness connectors.
Measure the resi stance i n the (K6) 5-vol t Suppl y ci rcui t from the VSS harness
connector to the PCM harness connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 9
No → Repai r the open i n the (K6) 5-vol t Suppl y ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
9 Measure the resi stance between ground and the (K6) 5-vol t Suppl y ci rcui t at the VSS
harness connector.
I s the resi stance bel ow 100 ohms?
Al l
Yes → Repai r the short to ground i n the (K6) 5-vol t Suppl y ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 10
10 NOTE: Beforecontinuing, check thePCMharnessconnectorsfor corrosion,
damage, or terminal push out. Repair as necessary.
Usi ng the schemati cs as a gui de, i nspect the wi re harness and connectors. Pay
parti cul ar attenti on to al l Power and Ground ci rcui ts.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace and program the Powertrai n Control Modul e per Servi ce
I nformati on.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
125
DRIVEABILITY - GAS
P0500-NO VEHICLE SPEED SIGNAL CIRCUIT — Continued
Symptom:
P0505-IDLE AIR CONTROL MOTOR CIRCUITS
When Monitored and Set Condition:
P0505-IDLE AIR CONTROL MOTOR CIRCUITS
When Moni tored: At power-up and battery vol tage greater than 11.5 vol ts.
Set Condi ti on: The PCM senses a short to ground or battery vol tage on any of the four
I dl e Ai r Control (I AC) dri ver ci rcui ts for 100 msec whi l e the I AC motor i s acti ve.
POSSIBLE CAUSES
GOOD TRI P EQUAL TO ZERO
I AC #1 CONTROL CI RCUI T SHORTED TO #2, #3, OR #4
I AC #2 CONTROL CI RCUI T SHORTED TO #3 OR #4
I AC #3 CONTROL CI RCUI T SHORTED TO #4
I AC CONTROL CI RCUI T SHORTED TO VOLTAGE
I AC CONTROL CI RCUI T SHORTED TO GROUND
I AC MOTOR OPERATI ON
I AC MOTOR
TEST ACTION APPLICABILITY
1 I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, read DTCs and record the rel ated Freeze Frame data.
I s the Good Tri p Counter di spl ayed and equal to zero?
Al l
Yes → Go To 2
No → Refer to the I NTERMI TTENT CONDI TI ON Symptom (Di agnos-
ti c Procedure).
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
2 Turn the i gni ti on off.
Di sconnect the I AC Motor harness connector.
Di sconnect the PCM harness connectors.
NOTE:Thefollowingstepsarecheckingfor ashort betweentheIAC Control
circuits.
Measure the resi stance between the I AC #1 Control ci rcui t and #2, #3, #4 Control
ci rcui ts.
I s the resi stance bel ow 5.0 ohms on any of the Dri vers?
Al l
Yes → Repai r the short between the appropri ate I AC Control ci rcui ts.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 3
126
DRIVEABILITY - GAS
TEST ACTION APPLICABILITY
3 Measure the resi stance between the I AC #2 Control ci rcui t and #3, #4 Control
ci rcui ts.
I s the resi stance bel ow 5.0 ohms on any of the ci rcui ts?
Al l
Yes → Repai r the short between the appropri ate I AC Control ci rcui ts.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 4
4 Measure the resi stance between the I AC #3 Control ci rcui t and the #4 Control ci rcui t.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Repai r the short between the I AC Control ci rcui ts.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 5
5 I gni ti on on, engi ne not runni ng.
Measure the vol tage on each of the I AC Control ci rcui ts.
I s the vol tage above 1.0 vol t at any I AC Control ci rcui t?
Al l
Yes → Repai r the short to vol tage i n the appropri ate I AC Control ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 6
6 Turn the i gni ti on off.
Repeat each measurement for each I AC Control ci rcui t.
Measure the resi stance between ground and each I AC Control ci rcui t.
I s the resi stance bel ow 100 ohms at any I AC Control ci rcui t?
Al l
Yes → Repai r the short to ground i n the appropri ate I AC Control ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 7
7 Connect the PCM harness connectors.
Start and i dl e the engi ne.
Usi ng a test l i ght connected to ground, probe the I AC #1 Control ci rcui t for 10
seconds.
Repeat the above test for the remai ni ng I AC Motor Dri ver ci rcui ts.
Does the test l i ght turn on and off whi l e probi ng each I AC Motor Dri ver ci rcui t?
Al l
Yes → Repl ace the I dl e Ai r Control Motor.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Repl ace and program the Powertrai n Control Modul e per Servi ce
I nformati on.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
127
DRIVEABILITY - GAS
P0505-IDLE AIR CONTROL MOTOR CIRCUITS — Continued
Symptom:
P0523-OIL PRESSURE VOLTAGE TOO HIGH
When Monitored and Set Condition:
P0523-OIL PRESSURE VOLTAGE TOO HIGH
When Moni tored: Wi th the i gni ti on on and battery vol tage above 10.4 vol ts.
Set Condi ti on: The oi l pressure sensor si gnal at PCM goes above 4.9 vol ts.
POSSIBLE CAUSES
GOOD TRI P EQUAL TO ZERO
OI L PRESSURE SWI TCH
(G60) OI L PRESSURE SI GNAL CI RCUI T SHORTED TO VOLTAGE
(G60) OI L PRESSURE SI GNAL CI RCUI T OPEN
(G60) OI L PRESSURE SI GNAL CI RCUI T SHORTED TO GROUND
GROUND CI RCUI T OPEN
PCM
TEST ACTION APPLICABILITY
1 I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, read DTCs and record the rel ated Freeze Frame data.
I s the Good Tri p Counter di spl ayed and equal to zero?
Al l
Yes → Go To 2
No → Refer to the I NTERMI TTENT CONDI TI ON Symptom (Di agnos-
ti c Procedure).
Perform POWERTRAI N VERI FI CATI ON TEST VER - 2.
2 Turn the i gni ti on off.
Di sconnect the Oi l Pressure Swi tch harness connector.
I gni ti on on, engi ne not runni ng.
Connect a jumper wi re to the (G60) Oi l Pressure Si gnal ci rcui t i n the Sensor harness
connector.
Wi th the DRBI I I ௡ moni tor the Oi l Pressure Swi tch state.
Touch the other end of the jumper wi re to a Ground several ti mes.
Di d the Oi l Pressure Swi tch state change from Hi gh to Low?
Al l
Yes → Repl ace the Oi l Pressure Swi tch.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 2.
No → Go To 3
128
DRIVEABILITY - GAS
TEST ACTION APPLICABILITY
3 Turn the i gni ti on off.
Di sconnect the PCM harness connectors.
I gni ti on on, engi ne not runni ng.
Measure the vol tage on the (G60) Oi l Pressure Si gnal ci rcui t at the Swi tch harness
connector.
I s the vol tage above 5.3 vol ts?
Al l
Yes → Repai r the short to vol tage on the (G60) Oi l Pressure Si gnal
ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 2.
No → Go To 4
4 Turn the i gni ti on off.
Measure the resi stance of the (G60) Oi l Pressure Si gnal ci rcui t from the Oi l Pressure
Swi tch harness connector to the PCM harness connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 5
No → Repai r the open i n the (G60) Oi l Pressure Si gnal ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 2.
5 Measure the resi stance between (G60) Oi l Pressure Si gnal ci rcui t and ground at the
Swi tch connector.
I s the resi stance bel ow 100 ohms?
Al l
Yes → Repai r the short to ground i n the (G60) Oi l Pressure Si gnal
ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 2.
No → Go To 6
6 Measure the resi stance between Ground and the Ground ci rcui t at the Oi l Pressure
Swi tch connector.
I s the resi stance bel ow 100 ohms?
Al l
Yes → Go To 7
No → Repai r the open i n the Ground ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 2.
7 NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Usi ng the schemati cs as a gui de, i nspect the wi re harness and connectors. Pay
parti cul ar attenti on to al l Power and Ground ci rcui ts.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace and program the Powertrai n Control Modul e per Servi ce
I nformati on.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 2.
129
DRIVEABILITY - GAS
P0523-OIL PRESSURE VOLTAGE TOO HIGH — Continued
Symptom:
P0551-POWER STEERING SWITCH FAILURE
When Monitored and Set Condition:
P0551-POWER STEERING SWITCH FAILURE
When Moni tored: Wi th the i gni ti on key on and engi ne runni ng.
Set Condi ti on: Wi th the vehi cl e above 40 mph for over 30 seconds, the power steeri ng
pressure swi tch remai ns open.
POSSIBLE CAUSES
GOOD TRI P EQUAL TO ZERO
POWER STEERI NG PRESSURE SWI TCH
(K10) P/S PRESSURE SWI TCH SI GNAL CI RCUI T OPEN
(K10) P/S PRESSURE SWI TCH SI GNAL CI RCUI T SHORTED TO GROUND
(Z1) P/S PRESSURE SWI TCH GROUND CI RCUI T OPEN
PCM
TEST ACTION APPLICABILITY
1 I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, read DTCs and record the rel ated Freeze Frame data.
I s the Good Tri p Counter di spl ayed and equal to zero?
Al l
Yes → Go To 2
No → Refer to the I NTERMI TTENT CONDI TI ON Symptom (Di agnos-
ti c Procedure).
Perform POWERTRAI N VERI FI CATI ON TEST VER - 2.
2 Turn the i gni ti on off.
Di sconnect the Power Steeri ng Pressure Swi tch harness connector.
I gni ti on on, engi ne not runni ng.
Connect a jumper wi re to the (K10) P/S Pressure Swi tch Si gnal ci rcui t at harness
connector.
Usi ng the DRBI I I ௡, moni tor the Power Steeri ng Pressure Swi tch.
Touch the jumper wi re to the (Z1) Ground ci rcui t at the Power Steeri ng Pressure
Swi tch harness connector several ti mes.
Di d the Power Steeri ng Pressure Swi tch status change from Hi to Low?
Al l
Yes → Repl ace the Power Steeri ng Pressure Swi tch.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 2.
No → Go To 3
NOTE: Remove the jumper wire before continuing.
130
DRIVEABILITY - GAS
TEST ACTION APPLICABILITY
3 Turn the i gni ti on off.
Di sconnect the PCM harness connectors.
Measure resi stance of (K10) P/S Pressure Swi tch Si gnal ci rcui t from PCM harness
connector to P/S Pressure Swi tch harness connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 4
No → Repai r the open i n the (K10) P/S Pressure Swi tch Si gnal ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 2.
4 Measure the resi stance between ground and the (K10) P/S Pressure Swi tch Si gnal
ci rcui t at the Swi tch harness connector.
I s the resi stance bel ow 100 ohms?
Al l
Yes → Repai r the short to ground i n the (K10) P/S Pressure Swi tch
Si gnal ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 2.
No → Go To 5
5 Wi th a 12-vol t test l i ght connect to 12-vol ts, probe the (Z1) P/S Pressure Swi tch
ground ci rcui t at the Swi tch harness connector.
Does the test l i ght i l l umi nate bri ghtl y?
Al l
Yes → Go To 6
No → Repai r the open i n the (Z1) P/S Pressure Swi tch ground ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 2.
6 NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Usi ng the schemati cs as a gui de, i nspect the wi re harness and connectors. Pay
parti cul ar attenti on to al l Power and Ground ci rcui ts.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace and program the Powertrai n Control Modul e per Servi ce
I nformati on.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 2.
131
DRIVEABILITY - GAS
P0551-POWER STEERING SWITCH FAILURE — Continued
Symptom:
P0601-PCM INTERNAL CONTROLLER FAILURE
When Monitored and Set Condition:
P0601-PCM INTERNAL CONTROLLER FAILURE
When Moni tored: I gni ti on key on.
Set Condi ti on: I nternal checksum for software fai l ed, does not match cal cul ated val ue.
POSSIBLE CAUSES
PCM I NTERNAL OR SPI
TEST ACTION APPLICABILITY
1 The Powertrai n Control Modul e i s reporti ng i nternal errors, vi ew repai r to conti nue. Al l
Repai r
Repl ace and program the Powertrai n Control Modul e per Servi ce
I nformati on.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 1.
132
DRIVEABILITY - GAS
Symptom:
P0622-GENERATOR FIELD NOT SWITCHING PROPERLY
When Monitored and Set Condition:
P0622-GENERATOR FIELD NOT SWITCHING PROPERLY
When Moni tored: Wi th the i gni ti on key on and the engi ne runni ng.
Set Condi ti on: When the PCM tri es to regul ate the generator fi el d wi th no resul t duri ng
moni tori ng.
POSSIBLE CAUSES
GENERATOR FI ELD PERFORMANCE
(K125) GEN FI ELD SOURCE CI RCUI T OPEN
(K20) GEN FI ELD CONTROL CI RCUI T OPEN
(K20) GEN FI ELD CONTROL CI RCUI T SHORTED TO GROUND
GENERATOR
PCM
TEST ACTION APPLICABILITY
1 I gni ti on on, engi ne not runni ng.
Record al l DTCs and the rel ated Freeze Frame data.
Check for any rel ated TSBs.
Usi ng a 12-vol t test l i ght connected to ground, backprobe the (K20) Gen Fi el d Control
ci rcui t at the back of the Generator.
Wi th the DRBI I I ௡, actuate the Generator Fi el d Dri ver.
Does the test l i ght bl i nk?
Al l
Yes → Refer to the I NTERMI TTENT CONDI TI ON Symptom (Di agnos-
ti c Procedure).
Perform POWERTRAI N VERI FI CATI ON TEST VER - 3.
No → Go To 2
2 Backprobe the (K125) Generator Fi el d Source ci rcui t at back of Generator wi th a vol t
meter.
Wi th the DRBI I I ௡ actuate the Generator Fi el d Dri ver.
I s the vol tage above 10.0 vol ts?
Al l
Yes → Go To 3
No → Repai r the open i n the (K125) Gen Fi el d Source ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 3.
133
DRIVEABILITY - GAS
TEST ACTION APPLICABILITY
3 Turn the i gni ti on off.
Di sconnect the PCM harness connectors.
Di sconnect the Generator Fi el d harness connector.
Measure the resi stance of the (K20) Generator Fi el d Control ci rcui t from the
Generator Fi el d harness connector to the PCM harness connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 4
No → Repai r the open i n the (K20) Gen Fi el d Control ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 3.
4 Measure the resi stance between ground and the (K20) Generator Fi el d Control
ci rcui t i n the PCM harness connector.
I s the resi stance bel ow 100 ohms?
Al l
Yes → Repai r the short to ground i n the (K20) Gen Fi el d Control ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 3.
No → Go To 5
5 Measure resi stance across the Generator Fi el d Termi nal s at the Generator.
I s the resi stance between 0.5 of an ohm and 15 ohms?
Al l
Yes → Go To 6
No → Repai r the Generator as necessary.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 3.
6 NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Usi ng the schemati cs as a gui de, i nspect the wi re harness and connectors. Pay
parti cul ar attenti on to al l Power and Ground ci rcui ts.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace and program the Powertrai n Control Modul e per Servi ce
I nformati on.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 3.
134
DRIVEABILITY - GAS
P0622-GENERATOR FIELD NOT SWITCHING PROPERLY — Continued
Symptom:
P0645-A/C CLUTCH RELAY CIRCUIT
When Monitored and Set Condition:
P0645-A/C CLUTCH RELAY CIRCUIT
When Moni tored: Wi th the i gni ti on key i n the run posi ti on and battery vol tage above 10.4
vol ts.
Set Condi ti on: An open or shorted condi ti on i s detected i n the A/C cl utch rel ay control
ci rcui t.
POSSIBLE CAUSES
A/C CLUTCH RELAY OPERATI ON
A/C CLUTCH RELAY
(F12) FUSED I GNI TI ON SWI TCH OUTPUT CI RCUI T
(C13) A/C CLUTCH RELAY CONTROL CI RCUI T OPEN
(C13) A/C CLUTCH RELAY CONTROL CI RCUI T SHORTED TO GROUND
PCM
TEST ACTION APPLICABILITY
1 I gni ti on on, engi ne not runni ng
Wi th the DRBI I I ௡, read DTCs and record the rel ated Freeze Frame data.
Check for any rel ated TSBs.
Wi th the DRBI I I ௡, actuate the A/C Cl utch Rel ay.
I s the A/C Cl utch Rel ay cl i cki ng?
Al l
Yes → Refer to the I NTERMI TTENT CONDI TI ON Symptom (Di agnos-
ti c Procedure).
Perform POWERTRAI N VERI FI CATI ON TEST VER - 2.
No → Go To 2
2 Turn the i gni ti on off.
Remove the A/C Cl utch Rel ay from the PDC.
Measure the resi stance between Termi nal s 1(85) and 2 (86) of the A/C Cl utch Rel ay.
I s the resi stance between 50.0 and 90.0 ohms?
Al l
Yes → Go To 3
No → Repl ace the A/C Cl utch Rel ay.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 2.
135
DRIVEABILITY - GAS
TEST ACTION APPLICABILITY
3 I gni ti on on, engi ne not runni ng.
Usi ng a 12-vol t test l i ght connected to ground, probe the (F12) Fused I gni ti on Swi tch
Output ci rcui t i n the A/C Cl utch Rel ay connector.
Does the test l i ght i l l umi nate bri ghtl y?
Al l
Yes → Go To 4
No → Repai r the open or short to ground i n the (F12) Fused I gni ti on
Swi tch Output ci rcui t. I nspect and repl ace the fuse as necessary.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 2.
4 Turn the i gni ti on off.
Di sconnect the PCM harness connectors.
Measure the resi stance of the (C13) A/C Cl utch Rel ay Control ci rcui t between the
PDC termi nal and the PCM harness connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 5
No → Repai r the open i n the (C13) A/C Cl utch Rel ay Control ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 2.
5 Measure the resi stance between ground and the (C13) A/C Cl utch Rel ay Control
ci rcui t at the PCM connector.
I s the resi stance bel ow 100 ohms?
Al l
Yes → Repai r the short to ground i n the (C13) A/C Cl utch Rel ay Control
ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 2.
No → Go To 6
6 NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Usi ng the schemati cs as a gui de, i nspect the wi re harness and connectors. Pay
parti cul ar attenti on to al l Power and Ground ci rcui ts.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace and program the Powertrai n Control Modul e per Servi ce
I nformati on.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 2.
136
DRIVEABILITY - GAS
P0645-A/C CLUTCH RELAY CIRCUIT — Continued
Symptom:
P0700-EATX CONTROLLER DTC PRESENT
When Monitored and Set Condition:
P0700-EATX CONTROLLER DTC PRESENT
When Moni tored: Wi th the i gni ti on key on.
Set Condi ti on: Thi s DTC i s an i ndi cator that a transmi ssi on DTC has previ ousl y been set.
POSSIBLE CAUSES
TCM DTC PRESENT SET I N PCM
TEST ACTION APPLICABILITY
1 Thi s DTC i s an i ndi cator that a Trans DTC has previ ousl y been set. A code may not
currentl y be present i n the TCM i f a Trans repai r was made. I f after readi ng
transmi ssi on DTC’s there are no codes i n the TCM, thi s code can be erased from the
PCM.
Trans DTC present?
Al l
Conti nue
A DTC was regi stered i n the Transmi ssi on Control Modul e. Wi th
the DRB, go to the TCM and read codes. Refer to the appropri ate
symptom (DTC).
137
DRIVEABILITY - GAS
SymptomList:
P1195-1/1 O2 SENSOR SLOWDURING CATALYST MONITOR
P1196-2/1 O2 SENSOR SLOWDURING CATALYST MONITOR
Test Note: All symptomslistedabovearediagnosedusingthesametests.
The title for the tests will be P1195-1/1 O2 SENSOR SLOW
DURING CATALYST MONITOR.
When Monitored and Set Condition:
P1195-1/1 O2 SENSOR SLOWDURING CATALYST MONITOR
When Moni tored: Wi th the engi ne runni ng, cool ant greater than 170°F, open throttl e,
steady to sl i ghtl y i ncreasi ng vehi cl e speed greater than 18 mph but l ess than 55 mph, wi th
a l i ght l oad on the engi ne, for a peri od no l ess than 5 mi nutes.
Set Condi ti on: The oxygen sensor si gnal vol tage i s swi tchi ng from bel ow 0.39 of a vol t to
above 0.6 of a vol t and back fewer ti mes than requi red.
P1196-2/1 O2 SENSOR SLOWDURING CATALYST MONITOR
When Moni tored: Wi th the engi ne runni ng, cool ant greater than 170°F, open throttl e,
steady to sl i ghtl y i ncreasi ng vehi cl e speed greater than 18 mph but l ess than 55 mph, wi th
a l i ght l oad on the engi ne, for a peri od no l ess than 5 mi nutes.
Set Condi ti on: The oxygen sensor si gnal vol tage i s swi tchi ng from bel ow 0.39 of a vol t to
above 0.6 of a vol t and back fewer ti mes than requi red.
POSSIBLE CAUSES
GOOD TRI P EQUAL TO ZERO
EXHAUST LEAK
RESI STANCE I N THE O2 SENSOR SI GNAL CI RCUI T
RESI STANCE I N THE (K4) SENSOR GROUND CI RCUI T
O2 SENSOR
TEST ACTION APPLICABILITY
1 Check for any rel ated TSBs.
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, read DTCs and record the rel ated Freeze Frame data.
I s the Good Tri p Counter di spl ayed and equal to zero?
Al l
Yes → Go To 2
No → Refer to the I NTERMI TTENT CONDI TI ON Symptom (Di agnos-
ti c Procedure).
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
138
DRIVEABILITY - GAS
TEST ACTION APPLICABILITY
2 Start the engi ne.
I nspect the exhaust for l eaks between the engi ne and the appropri ate O2 Sensor.
Are there any exhaust l eaks?
Al l
Yes → Repai r or repl ace the l eaki ng exhaust parts as necessary.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 3
3 Turn the i gni ti on off.
Backprobe the O2 Sensor Si gnal ci rcui t at the O2 Sensor harness connector and PCM
harness connector.
NOTE: Make sure the voltmeter leads are connected for positive polarity,
meet theterminalsin theconnector, andthat thereisgoodterminal towire
connection.
Start the engi ne.
Al l ow the engi ne to i dl e.
I s the vol tage bel ow 0.10 of a vol t?
Al l
Yes → Go To 4
No → Repai r the excessi ve resi stance on the O2 Sensor Si gnal ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
4 Turn the i gni ti on off.
Backprobe the (K4) Sensor ground ci rcui t at the O2 Sensor harness connector and
PCM harness connector.
NOTE: Make sure the voltmeter leads are connected for positive polarity,
meet theterminalsin theconnector, andthat thereisgoodterminal towire
connection.
Start the engi ne.
Al l ow the engi ne to i dl e.
I s the vol tage bel ow 0.10 of a vol t?
Al l
Yes → Go To 5
No → Repai r the excessi ve resi stance on the (K4) Sensor ground ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
5 Turn the i gni ti on off.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace the O2 Sensor
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
139
DRIVEABILITY - GAS
P1195-1/1 O2 SENSOR SLOWDURING CATALYST MONITOR — Continued
Symptom:
P1281-ENGINE IS COLD TOO LONG
When Monitored and Set Condition:
P1281-ENGINE IS COLD TOO LONG
When Moni tored: The i gni ti on key on, engi ne runni ng.
Set Condi ti on: The engi ne does not warm to 176 deg. F whi l e dri vi ng for 20 mi nutes after
start.
POSSIBLE CAUSES
ENGI NE COOLANT TEMP SENSOR
ENGI NE COLD TOO LONG
TEST ACTION APPLICABILITY
1 Note: The best way to diagnose this DTC is to allow the vehicle to remain
outside overnight in order to have a completely cold soaked engine.
Note: Extremely cold outsideambient temperatures may causethis DTC to
set.
Veri fy that the cool ant l evel i s at the correct l evel per servi ce i nformati on.
Start the engi ne.
Wi th the DRBI I I ௡ i n Sensors, read the ECT Sensor temperature val ue.
Use a DVOM that has thermal sensi ng probe to moni tor the Cool ant temperature at
the Thermostat housi ng.
The thermostat housi ng area shoul d be approxi matel y 192-195°F (89-91°C) when the
Thermostat begi ns to open.
I s the DRBI I I ௡ readi ng cool er than the DVOM readi ng?
Al l
Yes → Repl ace the ECT Sensor.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 2.
No → Go To 2
2 Note: The best way to diagnose this DTC is to allow the vehicle to remain
outside overnight in order to have a completely cold soaked engine.
Start the engi ne.
Wi th the DRBI I I ௡, set the engi ne RPM to 1500 and al l ow the engi ne to warm up for
10-15 mi nutes.
Wi th the DRBI I I ௡, moni tor the ENG COOLANT TMP DEG val ue duri ng the warm
up cycl e. Make sure the transi ti on of temperature change i s smooth.
Di d the engi ne temperature reach a mi ni mum of 80° C (176° F)?
Al l
Yes → Test Compl ete.
No → Refer to the Servi ce I nformati on for cool i ng system performance
di agnosi s. The most probabl e cause i s a Thermostat probl em.
Al so, refer to any rel ated TSBs.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 2.
140
DRIVEABILITY - GAS
Symptom:
P1282-FUEL PUMP/SYSTEM RELAY CONTROL CIRCUIT
When Monitored and Set Condition:
P1282-FUEL PUMP/SYSTEM RELAY CONTROL CIRCUIT
When Moni tored: Wi th the i gni ti on on and battery vol tage above 10.4 vol ts.
Set Condi ti on: An open or shorted condi ti on i s detected i n the Fuel Pump Rel ay Control
ci rcui t.
POSSIBLE CAUSES
FUEL PUMP RELAY OPERATI ON
FUEL PUMP RELAY
(A61) FUSED B+ CI RCUI T
(F15) FUSED I GNI TI ON SWI TCH OUTPUT CI RCUI T
(K31) FUEL PUMP RELAY CONTROL CI RCUI T OPEN
(K31) FUEL PUMP RELAY CONTROL CI RCUI T SHORTED TO GROUND
PCM
TEST ACTION APPLICABILITY
1 I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, read DTCs and record the rel ated Freeze Frame data.
Check for any rel ated TSBs.
Wi th the DRBI I I ௡, actuate the Fuel Pump Rel ay.
I s the Fuel Pump Rel ay cl i cki ng?
Al l
Yes → Refer to the I NTERMI TTENT CONDI TI ON Symptom (Di agnos-
ti c Procedure).
Perform POWERTRAI N VERI FI CATI ON TEST VER - 2.
No → Go To 2
2 Turn the i gni ti on off.
Remove the Fuel Pump Rel ay.
Note: Check connectors - Clean/repair as necessary.
Measure the resi stance between termi nal s 1 (85) and 2 (86) of the Fuel Pump Rel ay.
I s the resi stance between 50 and 90 ohms?
Al l
Yes → Go To 3
No → Repl ace the Fuel Pump Rel ay.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 2.
141
DRIVEABILITY - GAS
TEST ACTION APPLICABILITY
3 Usi ng a 12-vol t test l i ght connected to ground probe the (A61) Fused B+ ci rcui t i n the
PDC.
Does the test l i ght i l l umi nate bri ghtl y?
Al l
Yes → Go To 4
No → Repai r the open or short to ground (A61) Fused B+ ci rcui t. I nspect
the rel ated fuse and repai r as necessary.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 2.
4 I gni ti on on, engi ne not runni ng.
Wi th a 12-vol t test l i ght connect to ground, probe the (F15) Fused I gni ti on Swi tch
output ci rcui t i n the PDC.
Does the test l i ght i l l umi nate bri ghtl y?
Al l
Yes → Go To 5
No → Repai r the open or short to ground i n the (F15) Fused I gni ti on
Swi tch Output ci rcui t. I nspect the rel ated fuse and repai r as
necessary.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 2.
5 Turn the i gni ti on off.
Di sconnect the PCM harness connectors.
Measure the resi stance of the (K31) Fuel Pump Rel ay control ci rcui t between the
PDC and the PCM harness connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 6
No → Repai r the open i n the (K31) Fuel Pump Rel ay Control ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 2.
6 Measure the resi stance between ground and the (K31) Fuel Pump Rel ay Control
ci rcui t at the PDC.
I s the resi stance bel ow 100 ohms?
Al l
Yes → Repai r the short to ground i n the (K31) Fuel Pump Rel ay control
ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 2.
No → Go To 7
7 NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Usi ng the schemati cs as a gui de, i nspect the wi re harness and connectors. Pay
parti cul ar attenti on to al l Power and Ground ci rcui ts.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace and program the Powertrai n Control Modul e per Servi ce
I nformati on.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 2.
142
DRIVEABILITY - GAS
P1282-FUEL PUMP/SYSTEM RELAY CONTROL CIRCUIT — Continued
Symptom:
P1294-TARGET IDLE NOT REACHED
When Monitored and Set Condition:
P1294-TARGET IDLE NOT REACHED
When Moni tored: Wi th the engi ne i dl i ng and i n dri ve, i f automati c. There must not be a
MAP sensor troubl e code or a throttl e posi ti on sensor troubl e code.
Set Condi ti on: Engi ne i dl e i s not wi thi n 200 rpm above or 100 rpm bel ow target i dl e for
14 seconds. Three separate fai l ures are requi red to set a bad tri p. Two bad tri ps are
requi red to set the code.
POSSIBLE CAUSES
GOOD TRI P EQUAL TO ZERO
VACUUM LEAK
AI R I NDUCTI ON SYSTEM
THROTTLE BODY AND THROTTLE LI NKAGE
I AC DRI VER CI RCUI T OPEN
PCM
TEST ACTION APPLICABILITY
1 Check for any rel ated TSBs.
I gni ti on on, engi ne not runni ng.
NOTE: All MAP Sensor, IAC, and/or TPS codes present must be diagnosed
first before proceeding.
Wi th the DRBI I I ௡, read DTCs and record the rel ated Freeze Frame data.
I s the Good Tri p Counter di spl ayed and equal to zero?
Al l
Yes → Go To 2
No → Refer to the I NTERMI TTENT CONDI TI ON Symptom (Di agnos-
ti c Procedure).
Perform POWERTRAI N VERI FI CATI ON TEST VER - 2.
2 I nspect the I ntake Mani fol d for vacuum l eaks.
I nspect the Power Brake Booster for any vacuum l eaks.
I nspect the PCV system for proper operati on or any vacuum l eaks.
Were any probl ems found?
Al l
Yes → Repai r vacuum l eak as necessary.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 2.
No → Go To 3
143
DRIVEABILITY - GAS
TEST ACTION APPLICABILITY
3 I nspect the Ai r I nducti on System for the fol l owi ng probl ems.
Restri cti ons: Di rty Ai r Cl eaner, Forei gn materi al i n the ai r i ntake tube, etc.
Leaks: Ai r I ntake tube connecti on, Ai r Cl eaner housi ng, etc.
Were any probl ems found?
Al l
Yes → Repai r or repl ace as necessary.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 2.
No → Go To 4
4 I nspect the throttl e body pl ate for carbon bui l d up or other restri cti ons.
I nspect the throttl e l i nkage for bi ndi ng and smooth operati on.
Ensure the throttl e pl ate i s resti ng on the stop at i dl e.
Remove I AC, i nspect the pi ntl e and i ts seati ng surface i nsi de the throttl e body.
Were any probl ems found?
Al l
Yes → Repai r the reason for the carbon bui l d up and repl ace the Throttl e
Body as needed.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 2.
No → Go To 5
5 Turn the i gni ti on off.
Di sconnect I AC Motor harness connector.
Di sconnect the PCM harness connectors.
Measure the resi stance of each of the I AC Dri ver ci rcui ts from the I AC Motor harness
connector to the PCM harness connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 6
No → Repai r the open i n the appropri ate I AC Dri ver ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 2.
6 NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Usi ng the schemati cs as a gui de, i nspect the wi re harness and connectors. Pay
parti cul ar attenti on to al l Power and Ground ci rcui ts.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace and program the Powertrai n Control Modul e per Servi ce
I nformati on.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 2.
144
DRIVEABILITY - GAS
P1294-TARGET IDLE NOT REACHED — Continued
Symptom:
P1296-NO 5-VOLTS TO MAP SENSOR
When Monitored and Set Condition:
P1296-NO 5-VOLTS TO MAP SENSOR
When Moni tored: Duri ng power-down and battery vol tage greater than 10.4 vol ts.
Set Condi ti on: The MAP sensor si gnal vol tage goes bel ow 2.35 vol ts wi th the key off for
5 seconds.
POSSIBLE CAUSES
MAP SENSOR VOLTS BELOW 2.3 VOLTS
SHORTED SENSOR
(K7) 5-VOLT SUPPLY CI RCUI T OPEN
MAP SENSOR
(K7) 5-VOLT SUPPLY CI RCUI T SHORTED TO GROUND
PCM
TEST ACTION APPLICABILITY
1 NOTE: If the P0107 - MAP Sensor Voltage Too Low is also set, diagnose it
first before continuing with P1296 - No 5-volts To MAP Sensor.
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, read DTCs and record the rel ated Freeze Frame data.
Check for any rel ated TSBs.
Wi th the DRBI I I ௡ i n Sensors, read the MAP Sensor vol tage.
I s the vol tage bel ow 2.35 vol ts?
Al l
Yes → Go To 2
No → Refer to the I NTERMI TTENT CONDI TI ON Symptom (Di agnos-
ti c Procedure).
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
2 Turn the i gni ti on off.
Di sconnect the MAP Sensor harness connector.
I gni ti on on, engi ne not runni ng.
Measure the vol tage on the (K7) 5-vol t Suppl y ci rcui t at the MAP Sensor harness
connector.
I s the vol tage above 4.5 vol ts?
Al l
Yes → Go To 3
No → Go To 4
145
DRIVEABILITY - GAS
TEST ACTION APPLICABILITY
3 Wi th the DRBI I I ௡ i n Sensors, read the MAP Sensor vol tage wi th the Sensor harness
connector di sconnected.
I s the vol tage above 4.5 vol ts?
Al l
Yes → Repl ace the MAP Sensor.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 7
4 Measure the vol tage on the (K7) 5-vol t Suppl y ci rcui t i n the MAP Sensor harness
connector whi l e di sconnecti ng the remai ni ng Sensors that share the (K7) 5-vol t
Suppl y ci rcui t.
Does the vol tage return to approxi matel y 5.0 vol ts wi th any Sensor di sconnected?
Al l
Yes → Repl ace the Sensor that pul l ed the (K7) 5-vol t Suppl y ci rcui t l ow.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 5
5 Turn the i gni ti on off.
Di sconnect the PCM harness connector.
Measure the resi stance of the (K7) 5-vol t Suppl y ci rcui t from the MAP Sensor
harness connector to the PCM harness connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 6
No → Repai r the excessi ve resi stance i n the (K7) 5-vol t Suppl y ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
6 Measure the resi stance between ground and the (K7) 5-vol t Suppl y ci rcui t i n the
MAP Sensor harness connector.
I s the resi stance bel ow 100 ohms?
Al l
Yes → Repai r the short to ground i n the (K7) 5-vol t Suppl y ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 7
7 NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Usi ng the schemati cs as a gui de, i nspect the wi re harness and connectors. Pay
parti cul ar attenti on to al l Power and Ground ci rcui ts.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace and program the Powertrai n Control Modul e per Servi ce
I nformati on.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
146
DRIVEABILITY - GAS
P1296-NO 5-VOLTS TO MAP SENSOR — Continued
Symptom:
P1297-NO CHANGE IN MAP FROM START TO RUN
When Monitored and Set Condition:
P1297-NO CHANGE IN MAP FROM START TO RUN
When Moni tored: Wi th engi ne RPM +/- 64 of target i dl e and the throttl e bl ade at cl osed
throttl e.
Set Condi ti on: Too smal l of a di fference i s seen between barometri c pressure wi th i gni ti on
on (engi ne runni ng) and mani fol d vacuum for 8.80 seconds.
POSSIBLE CAUSES
GOOD TRI P EQUAL TO ZERO
MAP SENSOR VACUUM PORT
MAP SENSOR VOLTAGE BELOW 3.19 VOLTS
(K7) 5-VOLT SUPPLY CI RCUI T OPEN
(K7) 5-VOLT SUPPLY CI RCUI T SHORTED TO GROUND
MAP SENSOR
(K1) MAP SENSOR SI GNAL CI RCUI T SHORTED TO GROUND
(K1) MAP SENSOR SI GNAL CI RCUI T SHORTED TO (K4) SENSOR GROUND CI RCUI T
PCM
TEST ACTION APPLICABILITY
1 NOTE: If a MAP high or Low DTC set along with P1297, diagnose the High
or Low DTC first before continuing.
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, read DTCs and record the rel ated Freeze Frame data.
I s the Good Tri p Counter di spl ayed and equal to zero?
Al l
Yes → Go To 2
No → Refer to the I NTERMI TTENT CONDI TI ON Symptom (Di agnos-
ti c Procedure).
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
2 Turn the i gni ti on off.
Remove the MAP Sensor.
I nspect the vacuum port, check for restri cti ons or any forei gn materi al s.
Were any restri cti on found?
Al l
Yes → Repai r as necessary.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 3
NOTE: Reinstall the MAP Sensor before continuing.
147
DRIVEABILITY - GAS
TEST ACTION APPLICABILITY
3 I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, read the MAP Sensor vol tage.
NOTE: If a MAP High or Low DTC was set along with P1297, diagnose the
High or Low DTC first.
I s the vol tage bel ow 3.19 vol ts?
Al l
Yes → Go To 4
No → Refer to the I NTERMI TTENT CONDI TI ON Symptom (Di agnos-
ti c Procedure).
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
4 Turn the i gni ti on off.
Di sconnect the MAP Sensor harness connector.
I gni ti on on, engi ne not runni ng.
Measure the vol tage on the (K7) 5-vol t Suppl y ci rcui t at the MAP Sensor harness
connector.
I s the vol tage between 4.5 to 5.2 vol ts?
Al l
Yes → Go To 5
No → Go To 8
5 Wi th the DRBI I I ௡, moni tor the MAP Sensor vol tage wi th the Sensor harness
connector di sconnected.
I s the vol tage above 1.2 vol ts?
Al l
Yes → Repl ace the MAP Sensor.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 6
6 Turn the i gni ti on off.
Di sconnect the PCM harness connectors.
Measure the resi stance between ground and the (K1) MAP Sensor Si gnal ci rcui t at
the MAP Sensor harness connector.
I s the resi stance bel ow 100 ohms?
Al l
Yes → Repai r the short to ground i n the (K1) MAP Sensor Si gnal ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 7
7 Measure the resi stance between the (K1) MAP Sensor Si gnal ci rcui t and the (K4)
Sensor ground ci rcui t at the MAP Sensor harness connector.
I s the resi stance bel ow 100 ohms?
Al l
Yes → Repai r the short between the (K4) Sensor ground and the (K1)
MAP Sensor Si gnal ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 10
8 Turn the i gni ti on off.
Di sconnect the PCM harness connectors.
Measure the resi stance of the (K7) 5-vol t Suppl y ci rcui t from the MAP Sensor
harness connector to the PCM harness connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 9
No → Repai r the open i n the (K7) 5-vol t Suppl y ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
148
DRIVEABILITY - GAS
P1297-NO CHANGE IN MAP FROM START TO RUN — Continued
TEST ACTION APPLICABILITY
9 Measure the resi stance between ground and the (K7) 5-vol t Suppl y ci rcui t i n the
MAP Sensor harness connector.
I s the resi stance bel ow 100 ohms?
Al l
Yes → Repai r the short to ground i n the (K7) 5-vol t Suppl y ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 10
10 NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Usi ng the schemati cs as a gui de, i nspect the wi re harness and connectors. Pay
parti cul ar attenti on to al l Power and Ground ci rcui ts.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace and program the Powertrai n Control Modul e per Servi ce
I nformati on.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
149
DRIVEABILITY - GAS
P1297-NO CHANGE IN MAP FROM START TO RUN — Continued
Symptom:
P1388-AUTO SHUTDOWN RELAY CONTROL CIRCUIT
When Monitored and Set Condition:
P1388-AUTO SHUTDOWN RELAY CONTROL CIRCUIT
When Moni tored: Wi th i gni ti on key on and battery vol tage above 10.4 vol ts.
Set Condi ti on: An open or shorted condi ti on i s detected i n the ASD Rel ay control ci rcui t.
POSSIBLE CAUSES
GOOD TRI P EQUAL TO ZERO
ASD RELAY
(F15) FUSED I GNI TI ON SWI TCH OUTPUT CI RCUI T
(K51) ASD RELAY CONTROL CI RCUI T OPEN
(K51) ASD RELAY CONTROL CI RCUI T SHORTED TO GROUND
PCM
TEST ACTION APPLICABILITY
1 Check for any rel ated TSBs.
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, read DTCs and record the rel ated Freeze Frame data.
I s the Good Tri p Counter di spl ayed and equal to zero?
Al l
Yes → Go To 2
No → Refer to the I NTERMI TTENT CONDI TI ON Symptom (Di agnos-
ti c Procedure).
Perform POWERTRAI N VERI FI CATI ON TEST VER - 2.
2 Turn the i gni ti on off.
Remove the ASD Rel ay.
Measure the resi stance between termi nal s 85 and 86 of the ASD Rel ay.
I s the resi stance between 50 and 80 ohms?
Al l
Yes → Go To 3
No → Repl ace the ASD Rel ay.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 2.
3 I gni ti on on, engi ne not runni ng.
Usi ng a 12-vol t test l i ght connected to ground, probe the (F15) Fused I gni ti on Swi tch
Output ci rcui t at the ASD Rel ay connector i n the PDC.
Does the test l i ght i l l umi nate bri ghtl y?
Al l
Yes → Go To 4
No → Repai r the open or short to ground i n the (F15) Fused I gni ti on
Output. I nspect the rel ated fuse and repai r as necessary.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 2.
150
DRIVEABILITY - GAS
TEST ACTION APPLICABILITY
4 Turn the i gni ti on off.
Di sconnect the PCM harness connectors.
Measure the resi stance of the (K51) ASD Rel ay Control ci rcui t from the ASD Rel ay
cavi ty i n the PDC to the PCM harness connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 5
No → Repai r the open i n the (K51) ASD Rel ay Control ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 2.
5 Measure the resi stance between ground and the (K51) ASD Rel ay Control ci rcui t at
the PDC.
I s the resi stance bel ow 100 ohms?
Al l
Yes → Repai r the short to ground i n the (K51)ASD Rel ay Control ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 2.
No → Go To 6
6 NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Usi ng the schemati cs as a gui de, i nspect the wi re harness and connectors. Pay
parti cul ar attenti on to al l Power and Ground ci rcui ts.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace and program the Powertrai n Control Modul e per Servi ce
I nformati on.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 2.
151
DRIVEABILITY - GAS
P1388-AUTO SHUTDOWN RELAY CONTROL CIRCUIT — Continued
Symptom:
P1389-NO ASD RELAY OUTPUT VOLTAGE AT PCM
When Monitored and Set Condition:
P1389-NO ASD RELAY OUTPUT VOLTAGE AT PCM
When Moni tored: Wi th i gni ti on key on, battery vol tage above 10.4 vol ts, and engi ne RPM
greater than 400.
Set Condi ti on: No vol tage sensed at the PCM when the ASD Rel ay i s energi zed.
POSSIBLE CAUSES
GOOD TRI P EQUAL TO ZERO
(A142) ASD RELAY OUTPUT CI RCUI T OPEN
(A14) FUSED B+ CI RCUI T OPEN
(A142) ASD OUTPUT CI RCUI T OPEN
PCM
TEST ACTION APPLICABILITY
1 Check for any rel ated TSBs.
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, read DTCs and record the rel ated Freeze Frame data.
I s the Good Tri p Counter di spl ayed and equal to zero?
Al l
Yes → Go To 2
No → Refer to the I NTERMI TTENT CONDI TI ON Symptom (Di agnos-
ti c Procedure).
Perform POWERTRAI N VERI FI CATI ON TEST VER - 2.
2 Attempt to start the engi ne.
Di d the engi ne start?
Al l
Yes → Go To 3
No → Go To 4
3 Turn the i gni ti on off.
Remove the ASD Rel ay from the PDC.
Di sconnect the PCM harness connectors.
Measure the resi stance of the (A142) ASD Rel ay Output ci rcui t from the ASD Rel ay
cavi ty i n the PDC to the PCM harness connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 6
No → Repai r the open i n the (A142) ASD Rel ay Output ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 2.
152
DRIVEABILITY - GAS
TEST ACTION APPLICABILITY
4 Turn the i gni ti on off.
Remove the ASD Rel ay from the PDC.
Di sconnect the PCM harness connectors.
Measure the resi stance of the (A142) ASD Rel ay Output ci rcui t from the ASD Rel ay
cavi ty i n the PDC to the PCM harness connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 5
No → Repai r the open i n the (A142) ASD Rel ay Output ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 2.
5 Turn the i gni ti on off.
Remove the ASD Rel ay from the PDC.
Usi ng a 12-vol t test l i ght, probe the (A14) Fused B+ ci rcui t at the ASD Rel ay
connector.
Does the test l i ght i l l umi nate bri ghtl y?
Al l
Yes → Go To 6
No → Repai r the open or short to ground i n the (A14) Fused B+ ci rcui t.
I nspect and repl ace fuses as necessary.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 2.
6 NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Usi ng the schemati cs as a gui de, i nspect the wi re harness and connectors. Pay
parti cul ar attenti on to al l Power and Ground ci rcui ts.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace and program the Powertrai n Control Modul e per Servi ce
I nformati on.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 2.
153
DRIVEABILITY - GAS
P1389-NO ASD RELAY OUTPUT VOLTAGE AT PCM — Continued
Symptom:
P1391-INTERMITTENT LOSS OF CMP OR CKP
When Monitored and Set Condition:
P1391-INTERMITTENT LOSS OF CMP OR CKP
When Moni tored: Engi ne runni ng or cranki ng.
Set Condi ti on: When the fai l ure counter reaches 20 for 2 consecuti ve tri ps.
POSSIBLE CAUSES
I NTERMI TTENT CONDI TI ON
CHECKI NG I NTERMI TTENT CMP SI GNAL WI TH A LAB SCOPE
CMP WI RE HARNESS I NSPECTI ON
TONE WHEEL/PULSE RI NG I NSPECTI ON
CKP WI RE HARNESS I NSPECTI ON
TONE WHEEL/PULSE RI NG I NSPECTI ON
CHECKI NG I NTERMI TTENT CKP SI GNAL WI TH A LAB SCOPE
CAMSHAFT POSI TI ON SENSOR
CRANKSHAFT POSI TI ON SENSOR
TEST ACTION APPLICABILITY
1 I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, read DTCs and record the rel ated Freeze Frame data.
Wi th the DRBI I I ௡, erase DTCs.
Start the engi ne and run unti l operati ng temp i s reached. (Cl osed Loop)
I f the DTC does not set ri ght away i t may be necessary to test dri ve the vehi cl e.
Does the DTC reset?
Al l
Yes → Go To 2
No → Refer to the I NTERMI TTENT CONDI TI ON Symptom (Di agnos-
ti c Procedure).
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
2 Turn the i gni ti on off.
Wi th the DRBI I I ௡ l ab scope probe and the Mi l l er speci al tool #6801, backprobe the
(K44) CMP Si gnal ci rcui t i n the CMP harness connector.
WARNING: 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.
Start the engi ne.
Observe the l ab scope screen.
Are there any i rregul ar or mi ssi ng si gnal s?
Al l
Yes → Go To 3
No → Go To 6
154
DRIVEABILITY - GAS
TEST ACTION APPLICABILITY
3 Turn the i gni ti on off.
Vi sual l y i nspect the rel ated wi re harness. Look for any chafed, pi erced, pi nched, or
parti al l y broken wi res.
Vi sual l y i nspect the rel ated wi re harness connectors. Look for broken, bent, pushed
out, or corroded termi nal s.
Ensure the Crankshaft Posi ti on Sensor and the Camshaft Posi ti on Sensor are
properl y i nstal l ed and the mounti ng bol t(s) ti ght.
Refer to any TSBs that may appl y.
Were any of the above condi ti ons present?
Al l
Yes → Repai r as necessary
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 4
4 Turn the i gni ti on off.
Remove the Camshaft Posi ti on Sensor.
I nspect the Tone Wheel /Pul se Ri ng for damage, forei gn materi al , or excessi ve
movement.
Were any probl ems found?
Al l
Yes → Repai r or repl ace the Tone Wheel /Pul se Ri ng as necessary.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 5
5 I f there are no possi bl e causes remai ni ng, vi ew repai r. Al l
Repai r
Repl ace the Camshaft Posi ti on Sensor.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
6 Turn the i gni ti on off.
Wi th the DRBI I I ௡ as a Dual Channel Lab Scope and the Mi l l er speci al tool #6801,
backprobe the (K44) CMP Si gnal ci rcui t i n the PCM harness connector and i n the
CMP harness connector.
WARNING: 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.
Start the engi ne.
Observe the l ab scope screen.
Wi ggl e the rel ated wi re harness and gentl y tap on the Cam Posi ti on Sensor.
Look for any di fferences between the Channel 1 and Channel 2 patterns, generated
by the CMP Sensor.
Does the DRBI I I ௡ screen di spl ay any mi ssi ng or i rregul ar patterns?
Al l
Yes → Repl ace the Camshaft Posi ti on Sensor or repai r the wi ri ng/
connecti on concern.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 7
155
DRIVEABILITY - GAS
P1391-INTERMITTENT LOSS OF CMP OR CKP — Continued
TEST ACTION APPLICABILITY
7 Turn the i gni ti on off.
Wi th the DRBI I I ௡ l ab scope probe and the Mi l l er speci al tool #6801, backprobe the
(K24) CKP Si gnal ci rcui t i n the CKP harness connector.
WARNING: 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.
Start the engi ne.
Observe the l ab scope screen.
Are there any i rregul ar or mi ssi ng si gnal s?
Al l
Yes → Go To 8
No → Go To 11
8 Turn the i gni ti on off.
Vi sual l y i nspect the rel ated wi re harness. Look for any chafed, pi erced, pi nched, or
parti al l y broken wi res.
Vi sual l y i nspect the rel ated wi re harness connectors. Look for broken, bent, pushed
out, or corroded termi nal s.
Ensure the Crankshaft Posi ti on Sensor and the Camshaft Posi ti on Sensor are
properl y i nstal l ed and the mounti ng bol t(s) ti ght.
Refer to any TSBs that may appl y.
Were any of the above condi ti ons present?
Al l
Yes → Repai r as necessary
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 9
9 Turn the i gni ti on off.
Remove the Crankshaft Posi ti on Sensor.
I nspect the Tone Wheel /Fl ex Pl ate sl ots for damage, forei gn materi al , or excessi ve
movement.
Were any probl ems found?
Al l
Yes → Repai r or repl ace the Tone Wheel /Fl ex Pl ate as necessary.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 10
10 I f there are no possi bl e causes remai ni ng, vi ew repai r. Al l
Repai r
Repl ace the Crankshaft Posi ti on Sensor.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
156
DRIVEABILITY - GAS
P1391-INTERMITTENT LOSS OF CMP OR CKP — Continued
TEST ACTION APPLICABILITY
11 NOTE: The conditions that set this DTC are not present at this time. The
following test may help in identifying the intermittent condition.
Turn the i gni ti on off.
Wi th the DRBI I I ௡ as a Dual Channel Lab Scope and the Mi l l er speci al tool #6801,
backprobe the (K24) CKP Si gnal ci rcui t i n the PCM harness connector and CKP
harness connector. Both of the graphs shoul d be i denti cal .
WARNING: 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.
Start the engi ne.
Moni tor the DRBI I I ௡ l ab scope screen, both patterns shoul d be the same.
Wi ggl e the rel ated wi re harness and gentl y tap on the Crank Posi ti on Sensor.
Look for any di fferences between Channel 1 and Channel 2 patterns generated by the
CKP Sensor.
Were any errati c or mi ssi ng si gnal s noti ced?
Al l
Yes → Repl ace the Crankshaft Posi ti on Sensor or repai r the wi ri ng/
connecti on concern.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Test Compl ete.
157
DRIVEABILITY - GAS
P1391-INTERMITTENT LOSS OF CMP OR CKP — Continued
Symptom:
P1398-MIS-FIRE ADAPTIVE NUMERATOR AT LIMIT
When Monitored and Set Condition:
P1398-MIS-FIRE ADAPTIVE NUMERATOR AT LIMIT
When Moni tored: Under cl osed throttl e decel and Fuel Pul se Wi dth equal to zero for 30
seconds.
Set Condi ti on: One of the CKP sensor target wi ndows has more than 2.86%vari ance from
the reference wi ndow.
POSSIBLE CAUSES
ADAPTI VE NUMERATOR RELEARN
CMP SENSOR CONNECTOR/WI RI NG
CKP SENSOR CONNECTOR/WI RI NG
DAMAGED TONE WHEEL/FLEX PLATE (CRANKSHAFT)
CRANKSHAFT POSI TI ON SENSOR
PCM
TEST ACTION APPLICABILITY
1 Note: Check for any TSB’s that may apply to this symptom.
Read and record the Freeze Frame Data. Use thi s i nformati on to hel p you dupl i cate
the condi ti ons that set the DTC. Pay parti cul ar attenti on to the DTC set condi ti ons,
such as, VSS, MAP, ECT, and Load.
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡ i n the mi scel l aneous menu, choose ЉCl ear PCM (battery di scon-
nect)Љ to reset the PCM.
Wi th the DRBI I I ௡, choose the ЉMi sfi re Pretest screen.
Road test the vehi cl e and re-l earn the adapti ve numerator.
The adapti ve numerator i s l earned when the ЉAdapti ve Numerator Done Learni ngЉ
l i ne on the Mi s-fi re Pre-test screen changes to ЉYesЉ.
Di d the adapti ve numerator re-l earn?
Al l
Yes → Refer to the I NTERMI TTENT CONDI TI ON Symptom (Di agnos-
ti c Procedure).
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 2
158
DRIVEABILITY - GAS
TEST ACTION APPLICABILITY
2 Visuallyinspect therelatedwireharnessconnectors. Look for broken, bent,
pushed out, or corroded terminals.
NOTE: Visually inspect the related wire harness. Look for any chafed,
pierced, pinched, or partially broken wires.
NOTE: Verify the Camshaft Position Sensor is properly installed.
Note: Refer to any technical service bulletins that may apply.
Were any probl ems found?
Al l
Yes → Repai r as necessary.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 3
3 Note: Visually inspect the Crankshaft Position Sensor and related wire
harness connectors. Look for broken, bent, pushed out, or corroded termi-
nals.
NOTE: Visually inspect the related wire harness. Look for any chafed,
pierced, pinched, or partially broken wires.
NOTE: Verify the Crank Position Sensor is properly installed.
Were any probl ems found?
Al l
Yes → Repai r as necessary.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 4
4 Di sconnect and remove the Crankshaft Posi ti on Sensor.
I nspect the tone wheel /fl expl ate sl ots for damage, forei gn materi al , or excessi ve
movement.
I s the tone wheel /fl expl ate free from defects?
Al l
Yes → Go To 5
No → Repai r/repl ace tone wheel /fl ex pl ate as necessary.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
5 Wi th the DRBI I I ௡ l ab scope probe and the Mi l l er speci al tool #6801, back probe the
(K24) CKP Si gnal ci rcui t i n the PCM harness connector.
WARNING: 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..
Start the engi ne and observe the l ab scope screen for any errati c CKP Sensor pul ses.
Were any errati c Crank Posi ti on si gnal s detected?
Al l
Yes.
Repl ace the Crankshaft Posi ti on Sensor.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No.
Go To 6
6 NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Usi ng the schemati cs as a gui de, i nspect the wi re harness and connectors. Pay
parti cul ar attenti on to al l Power and Ground ci rcui ts.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace and program the Powertrai n Control Modul e per Servi ce
I nformati on.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
159
DRIVEABILITY - GAS
P1398-MIS-FIRE ADAPTIVE NUMERATOR AT LIMIT — Continued
Symptom:
P1486-EVAP LEAK MONITOR PINCHED HOSE FOUND
When Monitored and Set Condition:
P1486-EVAP LEAK MONITOR PINCHED HOSE FOUND
When Moni tored: I mmedi atel y after a col d start, wi th battery/ambi ent temperature
between 40 deg. F and 90 deg. F and cool ant temperature wi thi n 10 deg. F of battery/
ambi ent.
Set Condi ti on: LDP test must pass fi rst. I f the PCM suspects a pi nched hose i t wi l l not set
a faul t unti l i t runs the evap purge fl ow moni tor. I f the purge moni tor does not pass then
the pi nched hose faul t wi l l be set.
POSSIBLE CAUSES
GOOD TRI P EQUAL TO ZERO
EVAP CANI STER OBSTRUCTED
OBSTRUCTI ON I N HOSE/TUBE BETWEEN EVAP CANI STER AND PURGE SOLENOI D
LDP PRESSURE HOSE OBSTRUCTED
LEAK DETECTI ON PUMP
TEST ACTION APPLICABILITY
1 Check for any rel ated TSBs.
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, read DTCs and record the rel ated Freeze Frame data.
I s the Good Tri p Counter di spl ayed and equal to zero?
Al l
Yes → Go To 2
No → Refer to the I NTERMI TTENT CONDI TI ON Symptom (Di agnos-
ti c Procedure).
Perform POWERTRAI N VERI FI CATI ON TEST VER - 6.
2 Pressuri ze the EVAP System. On Mi l l er Tool #8404, set the Pressure/Hol d swi tch to
Open and set the Vent swi tch to Cl osed. Turn the pump ti mer On and watch the
gauge.
The fl ow meter gauge on the EELD reads 0 LPM the EVAP system compl etel y
pressuri zed.
Di sconnect the LDP Pressure hose at the EVAP Cani ster. The LDP Pressure hose i s
the hose that connects the Evap Cani ster to the Leak Detecti on Pump.
Di d the pressure drop when the hose was di sconnected?
Al l
Yes → Go To 3
No → Repl ace the EVAP Cani ster.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 6.
160
DRIVEABILITY - GAS
TEST ACTION APPLICABILITY
3 Note: All previously disconnected hose(s) reconnected.
Re-pressuri ze the EVAP System. On Mi l l er Tool #8404A, set the Pressure/Hol d
swi tch to Open and set the Vent swi tch to Cl osed. Turn the pump ti mer On and watch
the gauge.
The fl ow meter gauge on the EELD reads 0 LPM the EVAP system compl etel y
pressuri zed.
Di sconnect the EVAP hoses at the Purge Sol enoi d.
Di d the pressure drop when the hose was di sconnected?
Al l
Yes → Go To 4
No → Repai r or repl ace hose/tube as necessary.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 6.
4 Di sconnect and remove the LDP pressure hose. The LDP pressure hose i s the hose
that connects the EVAP Cani ster to the Leak Detecti on Pump.
I nspect the LDP pressure hose for any obstructi ons or physi cal damage.
I s the LDP pressure hose free from defects?
Al l
Yes → Repl ace the Leak Detecti on Pump.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 6.
No → Repai r/repl ace hose as necessary.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 6.
161
DRIVEABILITY - GAS
P1486-EVAP LEAK MONITOR PINCHED HOSE FOUND — Continued
Symptom:
P1489-HIGH SPEED FAN RELAY CONTROL CIRCUIT
When Monitored and Set Condition:
P1489-HIGH SPEED FAN RELAY CONTROL CIRCUIT
When Moni tored: Wi th the i gni ti on on. Battery vol tage greater than 10 vol ts.
Set Condi ti on: An open or shorted ci rcui t i s detected i n the hi gh speed radi ator fan rel ay
control ci rcui t. One Tri p Faul t.
POSSIBLE CAUSES
HI GH SPEED RADI ATOR FAN RELAY OPERATI ON
HI GH SPEED RADI ATOR FAN RELAY
(F20) FUSED I GNI TI ON SWI TCH OUTPUT CI RCUI T
(A16) FUSED B+ CI RCUI T
(C27) HI GH SPEED RAD FAN RELAY CONTROL CI RCUI T OPEN
(C27) HI GH SPEED RAD FAN RELAY CONTROL CI RCUI T SHORT TO GROUND
PCM
TEST ACTION APPLICABILITY
1 I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, actuate the Hi gh Speed Radi ator Fan Rel ay.
I s the Hi gh Speed Radi ator Fan Rel ay operati ng?
Al l
Yes → Refer to the I NTERMI TTENT CONDI TI ON Symptom (Di agnos-
ti c Procedure).
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 2
2 Turn the i gni ti on off.
Remove the Hi gh Speed Radi ator Fan Rel ay from the PDC.
Measure the resi stance of the Hi gh Speed Radi ator Fan Rel ay between the Fused
I gni ti on Swi tch Output termi nal and the Hi gh Speed Rad Fan Rel ay Control
termi nal .
I s the resi stance between 60 to 85 ohms?
Al l
Yes → Go To 3
No → Repl ace the Hi gh Speed Radi ator Fan Rel ay.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
162
DRIVEABILITY - GAS
TEST ACTION APPLICABILITY
3 I gni ti on on, engi ne not runni ng.
Usi ng a 12-vol t test l i ght connected to ground, probe the (F22) Fused I gni ti on Swi tch
Output ci rcui t at the Rel ay connector i n the PDC.
Does the test l i ght i l l umi nate bri ghtl y?
Al l
Yes → Go To 4
No → Repai r the open or short to ground i n the (F20) Fused I gni ti on
Output. I nspect the rel ated fuse and repai r as necessary.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
4 Usi ng a 12-vol t test l i ght connected to ground probe the (A16) Fused B+ ci rcui t i n the
PDC.
Does the test l i ght i l l umi nate bri ghtl y?
Al l
Yes → Go To 5
No → Repai r the open or short to ground (A16) Fused B+ ci rcui t. I nspect
the rel ated fuse and repai r as necessary.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
5 Turn the i gni ti on off.
Di sconnect the PCM harness connectors.
Measure the resi stance of the (C27) Hi gh Speed Rad Fan Rel ay Control ci rcui t from
the PDC to the PCM harness connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 6
No → Repai r the open i n the (C27) Hi gh Speed Rad Fan Rel ay Control
ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
6 Measure the resi stance between ground and the (C27) Hi gh Speed Rad Fan Rel ay
Control ci rcui t i n the PDC.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Repai r the short to ground i n the (C27) Hi gh Speed Rad Fan
Rel ay Control ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 7
7 NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Usi ng the schemati cs as a gui de, i nspect the wi re harness and connectors. Pay
parti cul ar attenti on to al l Power and Ground ci rcui ts.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace and program the Powertrai n Control Modul e per Servi ce
I nformati on.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
163
DRIVEABILITY - GAS
P1489-HIGH SPEED FAN RELAY CONTROL CIRCUIT — Continued
Symptom:
P1490-LOWSPEED FAN RELAY CONTROL CIRCUIT
When Monitored and Set Condition:
P1490-LOWSPEED FAN RELAY CONTROL CIRCUIT
When Moni tored: Wi th the i gni ti on on. Battery vol tage greater than 10 vol ts.
Set Condi ti on: An open or shorted ci rcui t i s detected i n the l ow speed radi ator fan rel ay
control ci rcui t. One tri p Faul t.
POSSIBLE CAUSES
LOW SPEED RADI ATOR FAN RELAY OPERATI ON
LOW SPEED RADI ATOR FAN RELAY
(F20) FUSED I GNI TI ON SWI TCH OUTPUT CI RCUI T
(A16) FUSED B+ CI RCUI T
(C23) LOW SPEED RAD FAN RELAY CONTROL CI RCUI T OPEN
(C23) LOW SPEED RAD FAN RELAY CONTROL CI RCUI T SHORT TO GROUND
PCM
TEST ACTION APPLICABILITY
1 I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, actuate the Low Speed Radi ator Fan Rel ay.
I s the Low Speed Radi ator Fan Rel ay operati ng?
Al l
Yes → Refer to the I NTERMI TTENT CONDI TI ON Symptom (Di agnos-
ti c Procedure).
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 2
2 Turn the i gni ti on off.
Remove the Low Speed Radi ator Fan Rel ay from the PDC.
Measure the resi stance of the Low Speed Radi ator Fan Rel ay between the Fused
I gni ti on Swi tch Output termi nal and the Low Speed Rad Fan Rel ay Control
termi nal .
I s the resi stance between 60 to 85 ohms?
Al l
Yes → Go To 3
No → Repl ace the Low Speed Radi ator Fan Rel ay.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
164
DRIVEABILITY - GAS
TEST ACTION APPLICABILITY
3 I gni ti on on, engi ne not runni ng.
Usi ng a 12-vol t test l i ght connected to ground, probe the (F20) Fused I gni ti on Swi tch
Output ci rcui t at the Rel ay connector i n the PDC.
Does the test l i ght i l l umi nate bri ghtl y?
Al l
Yes → Go To 4
No → Repai r the open or short to ground i n the (F20) Fused I gni ti on
Output. I nspect the rel ated fuse and repai r as necessary.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
4 Usi ng a 12-vol t test l i ght connected to ground probe the (A16) Fused B+ ci rcui t i n the
PDC.
Does the test l i ght i l l umi nate bri ghtl y?
Al l
Yes → Go To 5
No → Repai r the open or short to ground i n the (A16) Fused B+ ci rcui t.
I nspect the rel ated fuse and repai r as necessary.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
5 Turn the i gni ti on off.
Di sconnect the PCM harness connectors.
Measure the resi stance of the (C23) Low Speed Rad Fan Rel ay Control ci rcui t from
the PDC to the PCM harness connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 6
No → Repai r the open i n the (C23) Low Speed Rad Fan Rel ay Control
ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
6 Measure the resi stance between ground and the (C23) Low Speed Rad Fan Control
ci rcui t at the PDC.
I s the resi stance bel ow 100 ohms?
Al l
Yes → Repai r the short to ground i n the (C23) Low Speed Rad Fan Rel ay
Control ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 7
7 NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Usi ng the schemati cs as a gui de, i nspect the wi re harness and connectors. Pay
parti cul ar attenti on to al l Power and Ground ci rcui ts.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace and program the Powertrai n Control Modul e per Servi ce
I nformati on.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
165
DRIVEABILITY - GAS
P1490-LOWSPEED FAN RELAY CONTROL CIRCUIT — Continued
Symptom:
P1491-COOLING FAN RELAY CONTROL CIRCUIT
POSSIBLE CAUSES
COOLI NG FAN RELAY OPERATI ON
FUSED B+ OUTPUT CI RCUI T
GROUND CI RCUI T
(K173) COOLI NG FAN RELAY CONTROL CI RCUI T OPEN
(K173) COOLI NG FAN RELAY CONTROL CI RCUI T SHORTED TO GROUND
PCM
TEST ACTION APPLICABILITY
1 I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, read DTCs and record the rel ated Freeze Frame data.
Wi th the DRBI I I ௡, actuate the Cool i ng Fan Rel ay.
I s the Cool i ng Fan operati ng?
Al l
Yes → Refer to the I NTERI TTENT CONDI TI ON Symptom (Di agnosti c
Procedure).
Perform POWERTRAI N VERI FI CATI ON TEST VER - 2.
No → Go To 2
2 Turn the i gni ti on off.
Remove the Cool i ng Fan Rel ay.
Usi ng a 12-vol t test l i ght connected to ground, probe the Fused B+ ci rcui t of the
Cool i ng Fan Rel ay connector.
I s the vol tage above 11.0 vol ts?
Al l
Yes → Go To 3
No → Repai r the open or short to ground i n the Fused B+ ci rcui t. Check
and repl ace any open fuses.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 2.
3 Usi ng a 12-vol t test l i ght connected to 12-vol ts, probe the Ground ci rcui t i n the
Cool i ng Fan Rel ay harness connector.
Does the test l i ght i l l umi nate bri ghtl y?
Al l
Yes → Go To 4
No → Repai r the open i n the Ground ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 2.
4 Di sconnect the PCM harness connectors.
Measure the resi stance of the (K173) Cool i ng Fan Rel ay Control ci rcui t between the
Cool i ng Fan Rel ay connector and the PCM harness connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Repai r the open i n the (K173) Cool i ng Fan Rel ay Control ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 2.
No → Go To 5
166
DRIVEABILITY - GAS
TEST ACTION APPLICABILITY
5 Measure the resi stance between ground and the (K173) Cool i ng Fan Rel ay Control
ci rcui t at Rel ay connector.
I s the resi stance bel ow 100 ohms?
Al l
Yes → Go To 6
No → Repai r the short to ground i n the (K173) Cool i ng Fan Rel ay
control ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 2.
6 NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Usi ng the schemati cs as a gui de, i nspect the wi re harness and connectors. Pay
parti cul ar attenti on to al l Power and Ground ci rcui ts.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace and program the Powertrai n Control Modul e per Servi ce
I nformati on.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 2.
167
DRIVEABILITY - GAS
P1491-COOLING FAN RELAY CONTROL CIRCUIT — Continued
Symptom:
P1492-BATTERY TEMPERATURE SENSOR VOLTAGE TOO HIGH
When Monitored and Set Condition:
P1492-BATTERY TEMPERATURE SENSOR VOLTAGE TOO HIGH
When Moni tored: Wi th the i gni ti on key on.
Set Condi ti on: The PCM senses the vol tage from the Battery Temperature Sensor above
4.9 vol ts for 3 seconds.
POSSIBLE CAUSES
BATTERY TEMP SENSOR VOLTS ABOVE 4.8 VOLTS
BATTERY TEMPERATURE SENSOR
(K118) BATT TEMP SI GNAL CI RCUI T OPEN
(K118) BATT TEMP SI GNAL CI RCUI T SHORTED TO VOLTAGE
(K4) SENSOR GROUND CI RCUI T OPEN
PCM
TEST ACTION APPLICABILITY
1 I gni ti on on, engi ne not runni ng.
Record al l DTCs and the rel ated Freeze Frame data.
Check for any rel ated TSBs.
Wi th the DRBI I I ௡, moni tor the Battery Temperature Sensor vol tage.
I s the vol tage above 4.8 vol ts?
Al l
Yes → Go To 2
No → Refer to the I NTERMI TTENT CONDI TI ON Symptom (Di agnos-
ti c Procedure).
Perform POWERTRAI N VERI FI CATI ON TEST VER - 3.
2 Turn the i gni ti on off.
Di sconnect the Battery Temp Sensor connector.
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡ i n sensors, read the Battery Temperature vol tage val ue.
Connect a jumper wi re between the (K118) Batt Temp Si gnal ci rcui t and the (K4)
Sensor ground ci rcui t at the Battery Temp Sensor connector.
Di d the Battery Temp Sensor vol tage change from greater than 4.5 vol ts to l ess than
1.0 vol t?
Al l
Yes → Repl ace the Battery Temperature Sensor.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 3.
No → Go To 3
NOTE: Remove the jumper wire before continuing.
168
DRIVEABILITY - GAS
TEST ACTION APPLICABILITY
3 Turn the i gni ti on off.
Di sconnect the PCM harness connectors.
I gni ti on on, engi ne not runni ng.
Measure the vol tage on the (K118) Battery Temp Si gnal ci rcui t at the Sensor harness
connector.
I s the vol tage above 0 vol ts?
Al l
Yes → Repai r the short to vol tage i n the (K118) Batt Temp Si gnal ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 3.
No → Go To 4
4 Turn the i gni ti on off.
Measure the resi stance of the (K118) Battery Temp Si gnal ci rcui t from the Battery
Temp Sensor harness connector to the PCM harness connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 5
No → Repai r the open i n the (K118) Batt Temp Si gnal ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 3.
5 Measure the resi stance i n the (K4) Sensor ground ci rcui t from the PCM harness
connector to the Sensor connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 6
No → Repai r the open i n the (K4) Sensor ground ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 3.
6 NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Usi ng the schemati cs as a gui de, i nspect the wi re harness and connectors. Pay
parti cul ar attenti on to al l Power and Ground ci rcui ts.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace and program the Powertrai n Control Modul e per Servi ce
I nformati on.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 3.
169
DRIVEABILITY - GAS
P1492-BATTERY TEMPERATURE SENSOR VOLTAGE TOO HIGH —
Continued
Symptom:
P1493-BATTERY TEMPERATURE SENSOR VOLTAGE TOO LOW
When Monitored and Set Condition:
P1493-BATTERY TEMPERATURE SENSOR VOLTAGE TOO LOW
When Moni tored: Wi th the i gni ti on on.
Set Condi ti on: The PCM senses the vol tage from the Battery Temperature Sensor to be
bel ow 0.5 vol t for 3 seconds.
POSSIBLE CAUSES
BATTERY TEMP SENSOR VOLTS BELOW 0.5 OF A VOLT
BATTERY TEMPERATURE SENSOR
(K118) BATT TEMP SI GNAL CI RCUI T SHORTED TO GROUND
(K118) BATT TEMP SI GNAL CI RCUI T SHORTED TO THE (K4) SENSOR GROUND CI RCUI T
PCM
TEST ACTION APPLICABILITY
1 Check for any rel ated TSBs.
I gni ti on on, engi ne not runni ng.
Record al l DTCs and the rel ated Freeze Frame data.
Wi th DRBI I I ௡, moni tor the Ambi ent/Battery Temperature Sensor vol tage.
I s the vol tage bel ow 0.5 of a vol t?
Al l
Yes → Go To 2
No → Refer to the I NTERMI TTENT CONDI TI ON Symptom (Di agnos-
ti c Procedure).
Perform POWERTRAI N VERI FI CATI ON TEST VER - 3.
2 I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡ i n Sensors, read the Battery Temperature vol tage val ue.
Di sconnect the Battery Temperature Sensor harness connector.
Di d the Battery Temperature Sensor vol tage change from bel ow 1.0 vol t to above 4.5
vol ts?
Al l
Yes → Repl ace the Battery Temperature Sensor.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 3.
No → Go To 3
3 Turn the i gni ti on off.
Di sconnect the PCM harness connectors.
Measure the resi stance between ground and the (K118) Batt Temp Si gnal ci rcui t i n
the Battery Temp Sensor harness connector.
I s the resi stance bel ow 100 ohms?
Al l
Yes → Repai r the short to ground i n the (K118) Batt Temp Si gnal ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 3.
No → Go To 4
170
DRIVEABILITY - GAS
TEST ACTION APPLICABILITY
4 Measure the resi stance between the (K118) Batt Temp Si gnal ci rcui t and the (K4)
Sensor ground ci rcui t at the Battery Temp Sensor harness connector.
I s the resi stance bel ow 100 ohms?
Al l
Yes → Repai r the short between the (K4) Sensor ground and the (K118)
Batt Temp Si gnal ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 3.
No → Go To 5
5 NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Usi ng the schemati cs as a gui de, i nspect the wi re harness and connectors. Pay
parti cul ar attenti on to al l Power and Ground ci rcui ts.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace and program the Powertrai n Control Modul e per Servi ce
I nformati on.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 3.
171
DRIVEABILITY - GAS
P1493-BATTERY TEMPERATURE SENSOR VOLTAGE TOO LOW —
Continued
Symptom:
P1494-LEAK DETECTION PUMP SWOR MECHANICAL FAULT
When Monitored and Set Condition:
P1494-LEAK DETECTION PUMP SWOR MECHANICAL FAULT
When Moni tored: I mmedi atel y after a col d start, wi th battery/ambi ent temperature
between 40 deg. F and 90 deg. F and cool ant temperature wi thi n 10 deg. F of battery/
ambi ent.
Set Condi ti on: The state of the swi tch does not change when the sol enoi d i s energi zed.
POSSIBLE CAUSES
GOOD TRI P EQUAL TO ZERO
LDP VACUUM SUPPLY
LEAK DETECTI ON PUMP
(K107) LDP SWI TCH SI GNAL CI RCUI T OPEN
(K107) LDP SWI TCH SI GNAL CI RCUI T SHORTED TO GROUND
PCM
TEST ACTION APPLICABILITY
1 Check for any rel ated TSBs.
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, read DTCs and record the rel ated Freeze Frame data.
I s the Good Tri p Counter di spl ayed and equal to zero?
Al l
Yes → Go To 2
No → Refer to the I NTERMI TTENT CONDI TI ON Symptom (Di agnos-
ti c Procedure).
Perform POWERTRAI N VERI FI CATI ON TEST VER - 6.
2 Turn the i gni ti on off.
Di sconnect the vacuum suppl y hose at the Leak Detecti on Pump.
Connect a vacuum gauge to the di sconnected vacuum suppl y hose at the Leak
Detecti on Pump.
Start the engi ne and read the vacuum gauge.
Does the vacuum gauge read at l east 13Љ Hg?
Al l
Yes → Go To 3
No → Repai r l eak or obstructi on i n vacuum hose as necessary.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 6.
172
DRIVEABILITY - GAS
TEST ACTION APPLICABILITY
3 Turn the i gni ti on off.
Connect the vacuum suppl y hose at the LDP.
Di sconnect the Leak Detecti on Pump el ectri cal harness connector.
Start the engi ne.
Wi th the DRBI I I ௡ i n I nputs/Outputs, read the Leak Detect Pump Swi tch state.
Connect a jumper wi re between 12-vol ts and the (K107) LDP Swi tch Si gnal ci rcui t.
Di d the Leak Detect Pump Sw state change when the jumper was connected?
Al l
Yes → Repl ace the Leak Detecti on Pump.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 6.
No → Go To 4
NOTE: Remove the jumper wire before continuing.
4 Turn the i gni ti on off.
Di sconnect the PCM harness connectors.
Measure the resi stance of the (K107) LDP Swi tch Si gnal ci rcui t from the PCM
harness connector to LDP harness connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 5
No → Repai r the open i n the (K107) Leak Detecti on Pump Swi tch
Si gnal ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 6.
5 Measure the resi stance between ground and the (K107) LDP Swi tch Si gnal ci rcui t at
the LDP harness connector.
I s the resi stance bel ow 100 ohms?
Al l
Yes → Repai r the short to ground i n the (K107) LDP Swi tch Si gnal
ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 6.
No → Go To 6
6 NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Usi ng the schemati cs as a gui de, i nspect the wi re harness and connectors. Pay
parti cul ar attenti on to al l Power and Ground ci rcui ts.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace and program the Powertrai n Control Modul e per Servi ce
I nformati on.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 6.
173
DRIVEABILITY - GAS
P1494-LEAK DETECTION PUMP SW OR MECHANICAL FAULT —
Continued
Symptom:
P1495-LEAK DETECTION PUMP SOLENOID CIRCUIT
When Monitored and Set Condition:
P1495-LEAK DETECTION PUMP SOLENOID CIRCUIT
When Moni tored: Conti nuousl y when the i gni ti on i s on and battery vol tage i s greater
than 10.4 vol ts.
Set Condi ti on: The state of the sol enoi d ci rcui t does not match the PCM’s desi red state.
POSSIBLE CAUSES
GOOD TRI P EQUAL TO ZERO
(K125) GENERATOR SOURCE CI RCUI T OPEN
(K106) LDP SOLENOI D CONTROL CI RCUI T OPEN
(K106) LDP SOLENOI D CONTROL CI RCUI T SHORTED TO GROUND
LEAK DETECTI ON PUMP
PCM
TEST ACTION APPLICABILITY
1 Check for any rel ated TSBs.
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, read DTCs and record the rel ated Freeze Frame data.
I s the Good Tri p Counter di spl ayed and equal to zero?
Al l
Yes → Go To 2
No → Refer to the I NTERMI TTENT CONDI TI ON Symptom (Di agnos-
ti c Procedure).
Perform POWERTRAI N VERI FI CATI ON TEST VER - 6.
2 Turn the i gni ti on off.
Di sconnect the Leak Detecti on Pump el ectri cal harness connector.
Start the engi ne.
Wi th the DRBI I I ௡, actuate the LDP Sol enoi d.
Usi ng a 12-vol t test l i ght connected to ground, check the (K125) Generator Source
ci rcui t at the LDP connector.
Does the test l i ght i l l umi nate bri ghtl y?
Al l
Yes → Go To 3
No → Repai r the open i n the (K125) Generator Source ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 6.
174
DRIVEABILITY - GAS
TEST ACTION APPLICABILITY
3 Turn the i gni ti on off.
Connect a 12-vol t test l i ght to a good 12-vol t source.
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, actuate the LDP Sol enoi d.
Probe the (K106) LDP Sol enoi d Control ci rcui t wi th the test l i ght whi l e the Pump i s
actuati ng.
Does the test l i ght bl i nk?
Al l
Yes → Go To 4
No → Go To 5
4 I f there are no possi bl e causes remai ni ng, vi ew repai r. Al l
Repai r
Repl ace the Leak Detecti on Pump.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 6.
5 Turn the i gni ti on off.
Di sconnect the PCM harness connectors.
Measure the resi stance of the (K106) LDP Sol enoi d Control ci rcui t from the PCM
harness connector to the LDP harness connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 6
No → Repai r the open i n the (K106) Leak Detecti on Pump Sol enoi d
Control ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 6.
6 Measure the resi stance between ground and the (K106) LDP Sol enoi d Control ci rcui t
at the Sol enoi d harness connector.
I s the resi stance bel ow 100 ohms?
Al l
Yes → Repai r the short to ground i n the (K106) LDP Sol enoi d Control
ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 6.
No → Go To 7
7 NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Usi ng the schemati cs as a gui de, i nspect the wi re harness and connectors. Pay
parti cul ar attenti on to al l Power and Ground ci rcui ts.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace and program the Powertrai n Control Modul e per Servi ce
I nformati on.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 6.
175
DRIVEABILITY - GAS
P1495-LEAK DETECTION PUMP SOLENOID CIRCUIT — Continued
Symptom:
P1594-CHARGING SYSTEM VOLTAGE TOO HIGH
When Monitored and Set Condition:
P1594-CHARGING SYSTEM VOLTAGE TOO HIGH
When Moni tored: Wi th the i gni ti on key on and the engi ne speed greater than 0 RPM.
Set Condi ti on: When the PCM regul ates the generator fi el d and there are no detected
fi el d probl ems, but the vol tage output does not decrease.
POSSIBLE CAUSES
CHARGI NG SYSTEM OPERATI ON
(K20) GENERATOR FI ELD DRI VER CI RCUI T SHORTED TO GROUND
GENERATOR FI ELD COI L SHORTED TO GROUND
BATTERY TEMPERATURE SENSOR
PCM
TEST ACTION APPLICABILITY
1 NOTE: Battery must befully charged and becapableof passinga load test.
Note: Generator Belt tension and condition must be checked before con-
tinuing.
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, read DTCs and the rel ated Freeze Frame data then cl ear the
DTCs.
Start the engi ne.
Wi th the DRBI I I ௡, read DTCs.
Does the Generator l i ght i l l umi nate and i s a DTC set?
Al l
Yes → Go To 2
No → Refer to the I NTERMI TTENT CONDI TI ON Symptom (Di agnos-
ti c Procedure).
Perform POWERTRAI N VERI FI CATI ON TEST VER - 3.
2 Turn the i gni ti on off.
Di sconnect the PCM harness connectors.
Di sconnect the Generator Fi el d Harness connector.
Careful l y i nspect the rel ated connectors for corrosi on or spread termi nal s before
conti nui ng.
Measure the resi stance between Ground and the (K20) Gen Fi el d Control ci rcui t at
the Generator connector.
I s the resi stance bel ow 100 ohms?
Al l
Yes → Repai r the short to ground i n the (K20) Generator Fi el d Dri ver
ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 3.
No → Go To 3
176
DRIVEABILITY - GAS
TEST ACTION APPLICABILITY
3 Measure the resi stance between ground and the Generator Fi el d termi nal s on the
Generator.
I s the resi stance bel ow 100 ohms?
Al l
Yes → Repl ace or repai r the Generator.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 3.
No → Go To 4
4 Connect the PCM harness connectors and the Generator harness connector.
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡ i n I nputs/Outputs, read the Batt Temp Sensor val ue.
Usi ng a thermometer to measure under hood temperature near Battery tray.
I s the thermometer temperature wi thi n 10 deg of DRBI I I ௡ Battery temperature?
Al l
Yes → Go To 5
No → Repl ace the Battery Temperature Sensor.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 3.
5 NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Usi ng the schemati cs as a gui de, i nspect the wi re harness and connectors. Pay
parti cul ar attenti on to al l Power and Ground ci rcui ts.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace and program the Powertrai n Control Modul e per Servi ce
I nformati on.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 3.
177
DRIVEABILITY - GAS
P1594-CHARGING SYSTEM VOLTAGE TOO HIGH — Continued
SymptomList:
P1595-SPEED CONTROL SOLENOID CIRCUITS
P1683-SPD CTRL PWR RELAY; OR S/C 12V DRIVER CKT
Test Note: All symptomslistedabovearediagnosedusingthesametests.
Thetitlefor thetests will beP1595-SPEED CONTROL SOLE-
NOID CIRCUITS.
When Monitored and Set Condition:
P1595-SPEED CONTROL SOLENOID CIRCUITS
When Moni tored: Wi th the i gni ti on key on, the speed control swi tched on, the SETswi tch
pressed and the vehi cl e i n dri ve gear movi ng above 35 MPH.
Set Condi ti on: The powertrai n control modul e actuates the vacuum and vent sol enoi ds
but they do not respond.
P1683-SPD CTRL PWR RELAY; OR S/C 12V DRIVER CKT
When Moni tored: Wi th the i gni ti on key on and the speed control swi tched on.
Set Condi ti on: The speed control power suppl y ci rcui t i s ei ther open or shorted to ground.
POSSIBLE CAUSES
(Z1) GROUND CI RCUI T OPEN
I NTERMI TTENT CONDI TI ON
(V30) S/C BRAKE SWI TCH OUTPUT CI RCUI T
(V30) S/C BRAKE SWI TCH OUTPUT CI RCUI T OPEN
BRAKE LAMP SWI TCH
(V32) S/C POWER SUPPLY CI RCUI T OPEN
S/C VACUUM SOLENOI D
(V36) S/C VACUUM SOL CONTROL CI RCUI T OPEN
(V36) S/C VACUUM SOL CONTROL CI RCUI T SHORTED TO GROUND
S/C VENT SOLENOI D
(V35) S/C VENT SOL CONTROL CI RCUI T OPEN
(V35) S/C VENT SOL CONTROL CI RCUI T SHORTED TO GROUND
PCM
178
DRIVEABILITY - GAS
TEST ACTION APPLICABILITY
1 I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, read DTCs and record the rel ated Freeze Frame data.
NOTE: In the below step you will need to actuate both S/C solenoids
separately. Note the operation of the each solenoid when actuated.
Wi th the DRBI I I ௡, actuate the Speed Control Vacuum Sol enoi d and note operati on.
Wi th the DRBI I I ௡, actuate the Speed Control Vent Sol enoi d and note operati on.
Choose the concl usi on that best matches the sol enoi ds operati on.
Al l
Vacuum Sol enoi d not operati ng
Go To 2
Vent Sol enoi d not operati ng
Go To 5
Both S/C Sol enoi ds not operati ng
Go To 8
Both S/C Sol enoi ds operati ng
Go To 13
2 Turn the i gni ti on off.
Di sconnect the Speed Control Servo harness connector.
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, actuate the Speed Control Vacuum Sol enoi d.
Usi ng a 12-vol t test l i ght connected to 12-vol ts, probe the (V36) S/C Vacuum Sol
Control ci rcui t at the S/C Servo harness connector.
Does the test l i ght i l l umi nate bri ghtl y and fl ash?
Al l
Yes → Repl ace the Speed Control Servo.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 4.
No → Go To 3
3 Turn the i gni ti on off.
Di sconnect the PCM harness connectors.
Measure the resi stance of the (V36) S/C Vacuum Sol Control ci rcui t between the PCM
harness connector and Speed Control Servo harness connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 4
No → Repai r the open i n the (V36) S/C Vacuum Sol Control ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 4.
4 Measure the resi stance between ground and the (V36) S/C Vacuum Sol Control
ci rcui t at the PCM harness connector.
I s the resi stance bel ow 100 ohms?
Al l
Yes → Repai r the short to ground i n the (V36) S/C Vacuum Sol Control
ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 4.
No → Go To 12
179
DRIVEABILITY - GAS
P1595-SPEED CONTROL SOLENOID CIRCUITS — Continued
TEST ACTION APPLICABILITY
5 Turn the i gni ti on off.
Di sconnect the Speed Control Servo harness connector.
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, actuate the S/C Vent Sol enoi d.
Usi ng a 12-vol t test l i ght connected to 12-vol ts, probe the (V35) S/C Vent Sol Control
ci rcui t i n the Speed Control Servo harness connector.
Does the test l i ght i l l umi nate bri ghtl y and fl ash?
Al l
Yes → Repl ace the Speed Control Servo.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 4.
No → Go To 6
6 Turn the i gni ti on off.
Di sconnect the PCM harness connectors.
Measure the resi stance of the (V35) S/C Vent Sol Control ci rcui t between the PCM
harness connector and S/C Servo harness connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 7
No → Repai r the open i n the (V35) S/C Vent Sol enoi d Control ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 4.
7 Measure the resi stance between ground and the (V35) S/C Vent Sol Control ci rcui t at
the PCM harness connector.
I s the resi stance bel ow 100 ohms?
Al l
Yes → Repai r the short to ground i n the (V35) S/C Vent Sol Control
ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 4.
No → Go To 12
8 Turn the i gni ti on off.
Di sconnect the S/C Servo harness connector.
I gni ti on on, engi ne not runni ng.
Turn the Crui se Control on.
Usi ng a 12-vol t test l i ght connected to ground, probe the (V30) S/C Brake Swi tch
Output ci rcui t i n the S/C Servo harness connector.
Does the test l i ght i l l umi nate bri ghtl y?
Al l
Yes → Repl ace the Speed Control Servo.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 4.
No → Go To 9
9 Turn the i gni ti on off.
Measure the resi stance of the (V30) S/C Brake Swi tch Output ci rcui t from the S/C
Servo harness connector to the Brake Lamp Swi tch harness connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 10
No → Repai r the open i n the (V30) S/C Brake Swi tch Output ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 4.
180
DRIVEABILITY - GAS
P1595-SPEED CONTROL SOLENOID CIRCUITS — Continued
TEST ACTION APPLICABILITY
10 Di sconnect the Brake Lamp Swi tch harness connector.
I gni ti on on, engi ne not runni ng.
Turn the Crui se Control on, i t may be necessary to hol d the On button down whi l e
checki ng the fol l owi ng ci rcui t.
Usi ng a 12-vol t test l i ght connected to ground, probe the (V32) S/C Power Suppl y
ci rcui t i n the Brake Lamp Swi tch harness connector.
Does the test l i ght i l l umi nate bri ghtl y?
Al l
Yes → Repl ace the Brake Lamp Swi tch.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 4.
No → Go To 11
11 Turn the i gni ti on off.
Di sconnect the PCM harness connectors.
Measure the resi stance of the (V32) S/C Power Suppl y ci rcui t between the PCM
harness connector and the Brake Lamp Swi tch harness connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 12
No → Repai r the open i n the (V32) S/C Suppl y ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 4.
12 NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Usi ng the schemati cs as a gui de, i nspect the wi re harness and connectors. Pay
parti cul ar attenti on to al l Power and Ground ci rcui ts.
I f the there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace and program the Powertrai n Control Modul e per Servi ce
I nformati on.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 4.
13 Turn the i gni ti on off.
Di sconnect the S/C Servo harness connector.
Usi ng a 12-vol t test l i ght connected to 12-vol ts, probe the (Z1) Ground ci rcui t i n the
S/C Servo harness connector.
Does the test l i ght i l l umi nate bri ghtl y?
Al l
Yes → Refer to the I NTERMI TTENT CONDI TI ON Symptom (Di agnos-
ti c Procedure).
Perform POWERTRAI N VERI FI CATI ON TEST VER - 4.
No → Repai r the open i n the (Z1) Ground ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 4.
181
DRIVEABILITY - GAS
P1595-SPEED CONTROL SOLENOID CIRCUITS — Continued
Symptom:
P1596-SPEED CONTROL SWITCH ALWAYS HIGH
When Monitored and Set Condition:
P1596-SPEED CONTROL SWITCH ALWAYS HIGH
When Moni tored: Wi th the i gni ti on key on.
Set Condi ti on: An open ci rcui t i s detected i n the speed control on/off swi tch ci rcui t. The
ci rcui t must be above 4.8 vol ts for more than 2 mi nutes to set the DTC.
POSSIBLE CAUSES
SPEED CONTROL ON/OFF SWI TCH OPERATI ON
S/C ON/OFF SWI TCH
CLOCKSPRI NG
(V37) S/C SWI TCH SI GNAL CI RCUI T SHORTED TO VOLTAGE
(V37) S/C SWI TCH SI GNAL CI RCUI T OPEN BETWEEN PCM AND CLOCK SPRI NG
(K4) SENSOR GROUND CI RCUI T OPEN BETWEEN PCM AND CLOCKSPRI NG
(V37) S/C SWI TCH SI GNAL CI RCUI T OPEN BETWEEN CLOCKSPRI NG AND S/C SWI TCH
(K4) SENSOR GROUND CI RCUI T OPEN BETWEEN CLOCKSPRI NG AND S/C SWI TCH
PCM
TEST ACTION APPLICABILITY
1 Engi ne Runni ng.
Wi th the DRBI I I ௡, read DTCs and record the rel ated Freeze Frame data.
Wi th the DRBI I I ௡ i n Sensors, read the Speed Control i nputs state.
Whi l e moni tori ng the DRBI I I ௡, push the Speed Control On/Off Swi tch several ti mes,
then l eave i t on.
Di d the DRBI I I ௡ show Speed Control Swi tchi ng off and on?
Al l
Yes → Refer to the I NTERMI TTENT CONDI TI ON Symptom (Di agnos-
ti c Procedure).
Perform POWERTRAI N VERI FI CATI ON TEST VER - 4.
No → Go To 2
2 Turn the i gni ti on off.
Di sconnect the S/C On/Off Swi tch 2-way harness connector onl y.
Measure the resi stance across the S/C On/Off Swi tch.
I s the resi stance between 20.3K and 20.7K ohms?
Al l
Yes → Go To 3
No → Repl ace the On/Off Swi tch.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 4.
182
DRIVEABILITY - GAS
TEST ACTION APPLICABILITY
3 Di sconnect the upper and l ower 6-way cl ockspri ng harness connectors per Servi ce
I nformati on.
Measure the resi stance of the (K4) Sensor ground ci rcui t between the upper and
l ower 6-way cl ockspri ng harness connectors.
Measure the resi stance of the (V37) S/C Swi tch Si gnal ci rcui t between the upper and
l ower 6-way cl ockspri ng harness connectors.
Was the resi stance above 5.0 ohms for ei ther ci rcui t?
Al l
Yes → Repl ace the cl ockspri ng.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 4.
No → Go To 4
4 Connect the Cl ockspri ng harness connectors per Servi ce I nformati on.
Di sconnect the Speed Control On/Off Swi tch 2-way harness connector onl y.
I gni ti on on, engi ne not runni ng.
Measure the vol tage on the (V37) S/C Swi tch Si gnal ci rcui t i n the On/Off Swi tch
2-way connector.
I s the vol tage above 5.2 vol ts?
Al l
Yes → Repai r the short to vol tage i n the (V37) S/C Swi tch Si gnal ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 4.
No → Go To 5
5 Turn the i gni ti on off.
Di sconnect the l ower Cl ockspri ng 6-way harness connector per Servi ce I nformati on.
Di sconnect the PCM harness connectors.
Measure the resi stance of the (V37) S/C Swi tch Si gnal ci rcui t from the PCM harness
connector to the l ower Cl ockspri ng harness connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 6
No → Repai r the open i n the (V37) S/C Swi tch Si gnal ci rcui t between
the PCM and Cl ockspri ng.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 4.
6 Measure the resi stance of the (K4) Sensor ground ci rcui t from the PCM harness
connector to the l ower Cl ockspri ng harness connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 7
No → Repai r the open (K4) Sensor ground ci rcui t between the PCM and
Cl ockspri ng.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 4.
7 Di sconnect the upper cl ockspri ng harness connector per Servi ce I nformati on.
Measure the resi stance of the (V37) S/C Swi tch Si gnal ci rcui t from the upper
Cl ockspri ng harness connector to the On/Off swi tch harness connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 8
No → Repai r the open i n the (V37) S/C Swi tch Si gnal ci rcui t, Cl ock-
spri ng to S/C Swi tch.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 4.
183
DRIVEABILITY - GAS
P1596-SPEED CONTROL SWITCH ALWAYS HIGH — Continued
TEST ACTION APPLICABILITY
8 Measure the resi stance of the (K4) Sensor ground ci rcui t from the On/Off Swi tch
2-way harness connector to the upper Cl ockspri ng harness connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 9
No → Repai r the open i n the (K4) Sensor ground ci rcui t between the
Cl ockspri ng and S/C Swi tch.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 4.
9 NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Usi ng the schemati cs as a gui de, i nspect the wi re harness and connectors. Pay
parti cul ar attenti on to al l Power and Ground ci rcui ts.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace and program the Powertrai n Control Modul e per Servi ce
I nformati on.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 4.
184
DRIVEABILITY - GAS
P1596-SPEED CONTROL SWITCH ALWAYS HIGH — Continued
Symptom:
P1597-SPEED CONTROL SWITCH ALWAYS LOW
When Monitored and Set Condition:
P1597-SPEED CONTROL SWITCH ALWAYS LOW
When Moni tored: Wi th the i gni ti on key on and battery vol tage above 10.4 vol ts.
Set Condi ti on: When swi tch vol tage i s l ess than 0.39 of a vol t for 2 mi nutes.
POSSIBLE CAUSES
S/C SWI TCH VOLTAGE BELOW 1.0 VOLT
S/C ON/OFF SWI TCH
S/C RESUME/ACCEL SWI TCH
CLOCKSPRI NG SHORTED TO GROUND
(V37) S/C SWI TCH SI GNAL CI RCUI T SHORTED TO GROUND
(V37) S/C SWI TCH SI GNAL CI RCUI T SHORTED TO (K4) SENSOR GROUND
PCM
TEST ACTION APPLICABILITY
1 I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, read DTCs and record the rel ated Freeze Frame data.
Check for any rel ated TSBs.
Wi th the DRBI I I ௡, read the S/C Swi tch vol ts status.
I s the S/C Swi tch vol tage bel ow 1.0 vol t?
Al l
Yes → Go To 2
No → Refer to the I NTERMI TTENT CONDI TI ON Symptom (Di agnos-
ti c Procedure).
Perform POWERTRAI N VERI FI CATI ON TEST VER - 4.
2 Turn the i gni ti on off.
Di sconnect the S/C ON/OFF Swi tch harness connector.
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡ i n Sensors, read the S/C Swi tch vol ts.
Di d the S/C Swi tch vol ts change to 5.0 vol ts?
Al l
Yes → Repl ace the S/C ON/OFF Swi tch.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 4.
No → Go To 3
185
DRIVEABILITY - GAS
TEST ACTION APPLICABILITY
3 Turn the i gni ti on off.
Di sconnect the S/C RESUME/ACCEL Swi tch harness connector.
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡ i n Sensors, read the S/C Swi tch vol ts.
Di d the S/C Swi tch vol ts go above 4.0 vol ts?
Al l
Yes → Repl ace the Resume/Accel Swi tch.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 4.
No → Go To 4
4 Turn the i gni ti on off.
Di sconnect the l ower cl ockspri ng 6-way harness connector per Servi ce I nformati on.
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡ i n Sensors, read the S/C Swi tch vol tage.
Di d the S/C Swi tch vol ts change to 5.0 vol ts?
Al l
Yes → Repl ace the Cl ockspri ng.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 4.
No → Go To 5
5 Turn the i gni ti on off.
Connect the Cl ockspri ng harness connector per Servi ce I nformati on.
Di sconnect the PCM harness connectors.
Measure the resi stance between a known good ground and the (V37) S/C Swi tch
Si gnal ci rcui t at S/C ON/OFF Swi tch harness connector.
I s the resi stance bel ow 100 ohms?
Al l
Yes → Repai r the short to ground i n the (V37) S/C Swi tch Si gnal ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 4.
No → Go To 6
6 Measure the resi stance between the (V37) S/C Si gnal ci rcui t and the (K4) Sensor
ground ci rcui t at the ON/OFF Swi tch harness connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Repai r the short between the (K4) Sensor ground and the (V37)
S/C Swi tch Si gnal ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 4.
No → Go To 7
7 NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Usi ng the schemati cs as a gui de, i nspect the wi re harness and connectors. Pay
parti cul ar attenti on to al l Power and Ground ci rcui ts.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace and program the Powertrai n Control Modul e per Servi ce
I nformati on.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 4.
186
DRIVEABILITY - GAS
P1597-SPEED CONTROL SWITCH ALWAYS LOW— Continued
Symptom:
P1682-CHARGING SYSTEM VOLTAGE TOO LOW
When Monitored and Set Condition:
P1682-CHARGING SYSTEM VOLTAGE TOO LOW
When Moni tored: Wi th the i gni ti on key on and the engi ne runni ng over 1500 RPM after
25 seconds.
Set Condi ti on: When the PCM regul ates the generator fi el d and there are no detected
fi el d probl ems, but the vol tage output does not i ncrease.
POSSIBLE CAUSES
CHARGI NG VOLTAGE BELOW 15.1 VOLTS
BATTERY TEMPERATURE SENSOR
RESI STANCE I N THE BATTERY POSI TI VE CI RCUI T
RESI STANCE I N THE GENERATOR GROUND
(K125) GEN FI ELD SOURCE CI RCUI T OPEN
(K125) GEN FI ELD SOURCE CI RCUI T SHORTED TO GROUND
(K20) GEN FI ELD CONTROL CI RCUI T OPEN
GENERATOR FI ELD COI L HI GH RESI STANCE
PCM
TEST ACTION APPLICABILITY
1 Turn the i gni ti on off.
NOTE: Battery must befully charged and capableof passinga battery load
test.
NOTE: Generator Belt tension and condition must be checked before
continuing.
NOTE: Inspect thevehiclefor any aftermarket accessories that may exceed
the maximumGenerator output.
WARNING: 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.
Start the engi ne.
Record al l DTCs and the rel ated Freeze Frame data.
Wi th the DRBI I I ௡, read the target chargi ng vol tage.
I s the target chargi ng vol tage above 15.1 vol ts?
Al l
Yes → Refer to the I NTERMI TTENT CONDI TI ON Symptom (Di agnos-
ti c Procedure).
Perform POWERTRAI N VERI FI CATI ON TEST VER - 3.
No → Go To 2
187
DRIVEABILITY - GAS
TEST ACTION APPLICABILITY
2 Start the engi ne.
Al l ow the engi ne to reach normal operati ng temperature.
Wi th the DRBI I I ௡ i n sensors, read the Battery Temp Sensor val ue.
Usi ng a Thermometer, measure under hood temperature.
I s the temperature wi thi n 10° F of Battery temperature?
Al l
Yes → Go To 3
No → Repl ace the Battery Temperature Sensor.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 3.
3 I gni ti on on, engi ne not runni ng.
Measure the vol tage between the Generator B+ Termi nal and the Battery Posi ti ve
Post.
WARNING: 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.
CAUTION: Ensure all wires are clear of the engine’s moving parts.
Start the engi ne.
I s the vol tage above 0.4 of a vol t?
Al l
Yes → Repai r the excessi ve resi stance i n the Battery Posi ti ve ci rcui t
between the Generator and Battery.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 3.
No → Go To 4
4 Start the engi ne.
WARNING: 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.
Warm the engi ne to operati ng temperature.
Caution: Ensure all wires are clear of the engine’s moving parts.
Measure the vol tage between the Generator case and Battery Negati ve Post.
I s the vol tage above 0.1 of a vol t?
Al l
Yes → Repai r the excessi ve resi stance i n the Generator Ground ci rcui t
between the Generator Case and Battery Negati ve si de.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 3.
No → Go To 5
5 I gni ti on on, engi ne not runni ng.
Careful l y i nspect al l connectors for corrosi on or spread termi nal s before conti nui ng.
Wi th the DRBI I I ௡ actuate the Generator Fi el d Dri ver.
Whi l e backprobi ng, measure the vol tage on the (K125) Gen Fi el d Source ci rcui t at
back of Generator.
I s the vol tage above 10.0 vol ts?
Al l
Yes → Go To 6
No → Repai r the open i n the (K125) Gen Fi el d Source ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 3.
188
DRIVEABILITY - GAS
P1682-CHARGING SYSTEM VOLTAGE TOO LOW— Continued
TEST ACTION APPLICABILITY
6 Turn the i gni ti on off.
Di sconnect the Generator Fi el d harness connector at back of the Generator.
Measure resi stance across the Generator Fi el d Termi nal s at the Generator.
I s the resi stance above 15 ohms?
Al l
Yes → Repl ace or repai r the Generator as necessary.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 3.
No → Go To 7
7 Measure the resi stance between ground and the (K125) Gen Fi el d Source ci rcui t i n
the PCM harness connector.
I s the resi stance bel ow 100 ohms?
Al l
Yes → Repai r the short to ground i n the (K125) Gen Fi el d Source ci rcui t
and repl ace the PCM.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 3.
No → Go To 8
8 Measure the resi stance of the (K20) Gen Fi el d Control ci rcui t from the Generator
harness connector to the PCM harness connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 9
No → Repai r the open i n the (K20) Gen Fi el d Control ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 3.
9 NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Usi ng the schemati cs as a gui de, i nspect the wi re harness and connectors. Pay
parti cul ar attenti on to al l Power and Ground ci rcui ts.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace and program the Powertrai n Control Modul e per Servi ce
I nformati on.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 3.
189
DRIVEABILITY - GAS
P1682-CHARGING SYSTEM VOLTAGE TOO LOW— Continued
Symptom:
P1685 WRONG OR INVALID KEY MSG RECEIVED FROM SKIM
POSSIBLE CAUSES
NO COMMUNI CATI ON WI TH SKI M
SKI M TROUBLE CODES SET
NO VI N PROGRAMMED I N THE PCM
I NCORRECT VI N I N PCM
I NVALI D SKI M KEY NOT PRESENT
PCM
TEST ACTION APPLICABILITY
1 Check for any rel ated TSBs.
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, read the PCM DTCs and record the rel ated Freeze Frame data.
I s the Good Tri p Counter di spl ayed and equal to zero?
Al l
Yes → Go To 2
No → Go To 7
2 Wi th the DRBI I I ௡, attempt to communi cate wi th the SKI M.
Can the DRB I I I ௡ communi cate wi th the SKI M?
Al l
Yes → Go To 3
No → Refer to symptom BUS +/- SI GNAL OPEN FROM SKI M i n the
COMMUNI CATI ON category.
Perform SKI S VERI FI CATI ON.
3 Wi th the DRB I I I ௡, check for SKI M DTCs.
Are any DTCs present i n the SKI M?
Al l
Yes → Repai r al l SKI M DTCs.
Perform SKI S VERI FI CATI ON.
No → Go To 4
4 Wi th the DRB I I I ௡, di spl ay the VI N that i s programmed i n the PCM.
Has a VI N been programmed i nto the PCM?
Al l
Yes → Go To 5
No → Program the correct VI N i nto the PCM and retest.
Perform SKI S VERI FI CATI ON.
5 Wi th the DRB I I I ௡, di spl ay the VI N that i s programmed i n the PCM.
Was the correct VI N programmed i nto the PCM?
Al l
Yes → Go To 6
No → Go to SKI M and perform the PCM repl aced functi on to wri te i n
the correct VI N.
Perform SKI S VERI FI CATI ON.
190
DRIVEABILITY - GAS
TEST ACTION APPLICABILITY
6 Turn the i gni ti on off.
Repl ace and program the Sentry Key I mmobi l i zer Modul e per wi th the Servi ce
I nformati on.
I gni ti on on, engi ne not runni ng.
Wi th the DRB I I I ௡, erase al l SKI M and PCM DTCs.
Attempt to start and i dl e the engi ne.
Wi th the DRB I I I ௡, read the PCM DTCs.
Does the DRB I I I ௡ di spl ay thi s code?
Al l
Yes → Go to SKI M and perform functi on to wri te i n correct VI N.
Perform SKI S VERI FI CATI ON.
No → Test Compl ete.
7 NOTE: This DTC could have been set if the SKIM harness connector was
disconnected, or if the SKIM was replaced recently.
NOTE: All keys that the customer uses for this vehicle must be tested to
verify they are operating properly.
NOTE: Ensurethecustomer is not attemptingto usea non-SKIM duplicate
key.
I gni ti on on, engi ne not runni ng.
Veri fy the correct VI N i s programmed i nto the PCM and SKI M.
Turn the i gni ti on off.
Wi th the next customer key turn the i gni ti on key on and crank the engi ne to start.
Wi th the DRB I I I ௡, read the PCM DTCs. Look for P1685
Does the DTC return?
Al l
Yes → Repl ace the I gni ti on Key.
Perform SKI S VERI FI CATI ON.
No → Test Compl ete.
NOTE: If this DTC cannot be reset, it could have been an actual theft
attempt.
191
DRIVEABILITY - GAS
P1685 WRONG OR INVALID KEY MSG RECEIVED FROM SKIM —
Continued
Symptom:
P1686 NO SKIM BUS MESSAGE RECEIVED
POSSIBLE CAUSES
NO SKI M BUS MESSAGES
LOSS OF SKI M COMMUNI CATI ON
PCI BUS CI RCUI T OPEN FROM PCM TO SKI M
SKI M/PCM
TEST ACTION APPLICABILITY
1 I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, read the PCM DTCs and record the rel ated Freeze Frame data.
Check for any rel ated TSBs.
I s the Good Tri p Counter di spl ayed and equal to zero?
Al l
Yes → Go To 2
No → Refer to the I NTERMI TTENT CONDI TI ON Symptom (Di agnos-
ti c Procedure).
Perform SKI S VERI FI CATI ON.
2 Wi th the DRBI I I ௡, attempt to communi cate wi th the SKI M.
NOTE: This test will indicate if the Bus is operational fromthe DLC to the
SKIM.
Was the DRBI I I ௡ abl e to communi cate wi th the SKI M?
Al l
Yes → Go To 3
No → Refer to symptom BUS +/- SI GNAL OPEN FROM SKI M i n the
COMMUNI CATI ON category.
Perform SKI S VERI FI CATI ON.
3 Turn the i gni ti on off.
Di sconnect the PCM harness connectors.
Di sconnect the SKI M harness connector.
Measure the resi stance of the PCI Bus ci rcui t between the PCM harness connector
and the SKI M harness connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 4
No → Repai r the PCI Bus ci rcui t between the PCM and the SKI M for an
open.
Perform SKI S VERI FI CATI ON.
4 Repl ace the Sentry Key I mmobi l i zer Modul e per Servi ce I nformati on.
I gni ti on on, engi ne not runni ng.
Di spl ay and erase al l PCM and SKI M DTCs.
Perform 5 i gni ti on key cycl es l eavi ng the i gni ti on key on for 90 seconds per cycl e.
Wi th the DRBI I I ௡, di spl ay PCM DTCs.
Does the DRBI I I ௡ di spl ay the same DTC?
Al l
Yes → Repl ace and program the Powertrai n Control Modul e per Servi ce
I nformati on.
Perform SKI S VERI FI CATI ON.
No → Test Compl ete.
192
DRIVEABILITY - GAS
Symptom:
P1687-NO CLUSTER BUS MESSAGE
When Monitored and Set Condition:
P1687-NO CLUSTER BUS MESSAGE
When Moni tored: I gni ti on key on.
Set Condi ti on: No messages recei ved from the MI C (I nstrument Cl uster) for 20 seconds.
POSSIBLE CAUSES
NO CLUSTER BUS MESSAGE
COMMUNI CATE WI TH CLUSTER
I NSTRUMENT CLUSTER OPERATI ON
PCM
TEST ACTION APPLICABILITY
1 I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, erase DTCs.
Cycl e the i gni ti on key on for 20 seconds then turn off. Perform thi s several ti mes.
Wi th the DRBI I I ௡, read DTC’s.
Does the DTC reset?
Al l
Yes → Go To 2
No → Refer to the I NTERMI TTENT CONDI TI ON Symptom (Di agnos-
ti c Procedure).
Perform POWERTRAI N VERI FI CATI ON TEST VER - 1.
2 Wi th the DRBI I I ௡, attempt to communi cate wi th the I nstrument cl uster.
Can communi cati on be establ i shed wi th the I nstrument Cl uster?
Al l
Yes → Go To 3
No → Refer to the Communi cati on Category and perform the appropri -
ate symptom (Di agnosti c test) rel ated to no communi cati on wi th
cl uster.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 1.
3 Start the engi ne
Al l ow the engi ne to i dl e.
I s the correct engi ne speed di spl ay i n the i nstrument cl uster (Tach)?
Al l
Yes → Repl ace and program the Powertrai n Control Modul e per Servi ce
I nformati on.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 1.
No → Refer to the I nstrument Cl uster Category and perform the appro-
pri ate symptom.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 1.
193
DRIVEABILITY - GAS
Symptom:
P1692-CLUSTER SOFTWARE MISMATCH
When Monitored and Set Condition:
P1692-CLUSTER SOFTWARE MISMATCH
When Moni tored: I gni ti on on.
Set Condi ti on: When the PCM i s i ni ti al i zed, i t sends out a request to the cl uster for Ti re
Si ze, Axl e Rati o and T-case data. The PCM does thi s 3 ti mes, once every 1.87 seconds. I f the
Cl uster does not respond wi th the correct i nformati on after the thi rd ti me, thi s faul t wi l l
set i n the PCM. The PCM wi l l onl y request thi s data upon a NAVRAM reset, i ni ti al modul e
power-up, battery di sconnect/reconnect cycl e, or manual reset of the modul e performed
wi th a di agnosti c tool .
POSSIBLE CAUSES
I NCORRECT CLUSTER I NSTALLED
I NCORRECT AXLE RATI O,TI RE SI ZE, OR T/CASE I NFO
TEST ACTION APPLICABILITY
1 I f the cl uster was previ ousl y repl ace wi th the wrong part number thi s faul t wi l l set.
Was the cl uster previ ousl y repl aced?
Al l
Yes → I nstal l correct Rubi con Cl uster.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 2
2 Veri fy that the proper transfer case, ti re si ze, and axl e rati o are programmed i n the
PCM.
Was the proper i nformati on programmed i n the PCM?
Al l
Yes → Set the correct axl e rati o, ti re si ze, or transfer case i nformati on i n
the PCM.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Test Compl ete.
194
DRIVEABILITY - GAS
Symptom:
P1696-PCM FAILURE EEPROM WRITE DENIED
POSSIBLE CAUSES
PCM FAI LURE
Repair Instructions:
PCM FAILURE
Repl ace and program the Powertrai n Control Modul e per Servi ce I nformati on.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
195
DRIVEABILITY - GAS
Symptom:
P1698-NO BUS MESSAGE FROM TRANS CONTROL MODULE
POSSIBLE CAUSES
NO BUS MESSAGE FROM TRANS I NTERMI TTENT
PCM PCI BUS CI RCUI T OPEN
NO BUS MESSAGE FROM TRANS
TEST ACTION APPLICABILITY
1 I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, erase DTCs.
Cycl e the i gni ti on key on and off several ti mes.
Wi th the DRBI I I ௡, read DTCs.
Does the DTC reset?
Al l
Yes → Go To 2
No → Refer to the I NTERMI TTENT CONDI TI ON Symptom (Di agnos-
ti c Procedure).
Perform POWERTRAI N VERI FI CATI ON TEST VER - 1.
NOTE: This DTC could have been set when the TCM was disconnected
during transmission Diagnostics.
2 I gni ti on on, engi ne not runni ng.
Connect the DRBI I I ௡ and access Powertrai n Control Modul e.
Note: This test checks for other PCI BUS codes. That indicates different
circuits in the BUS.
Wi th the DRBI I I ௡, read DTCs.
I s a DTC al so set for NO SKI M BUS MESSAGE and/or No MI C BUS MESSAGE?
Al l
Yes → Go To 3
No → Refer to the Communi cati on Category and perform the appropri -
ate symptom rel ated to the no communi cati on wi th TCM.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 1.
196
DRIVEABILITY - GAS
TEST ACTION APPLICABILITY
3 Wi th the DRBI I I ௡, read DTCs. Thi s i s to ensure power and grounds to the PCM are
operati onal .
NOTE: If the DRBIII௡ will not read PCM DTC’s, followthe ؆NO RESPONSE
TO PCM (SCI only)؆ symptom path, if vehicle will start. For NO START
Conditions follow symptom؆NO RESPONSE؆ in Starting category .
Turn the i gni ti on off.
Di sconnect the PCM harness connector(s).
Connect the DRBI I I ௡ to the Data Li nk connector
Use Scope i nput cabl e CH7058, Cabl e to Probe adapter CH7062, and the red and
bl ack test probes.
Connect the scope i nput cabl e to the channel one connector on the DRBI I I ௡. Attach
the red and bl ack l eads and the cabl e to probe adapter to the scope i nput cabl e.
Sel ect DRBI I I ௡ Standal one.
Sel ect l ab scope.
Sel ect Li ve.
Sel ect 12 vol t square wave.
Press F2 for Scope.
Press F2 and use the down arrow to set vol tage range to 20 vol ts. Press F2 agai n
when compl ete.
Connect the Bl ack l ead to the PCM ground. Connect the Red l ead to the PCM PCI
Bus ci rcui t
I gni ti on on, engi ne not runni ng.
Observe the vol tage di spl ayed on the DRBI I I ௡ Lab Scope.
What i s the vol tage di spl ayed on the scope?
Al l
Pul se from 0 to approxi matel y 7.5 vol ts
Test Compl ete.
Steady 0 vol ts
Repai r the open PCI Bus ci rcui t to PCM.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 1.
197
DRIVEABILITY - GAS
P1698-NO BUS MESSAGE FROMTRANS CONTROL MODULE — Continued
Symptom:
P1899-P/N SWITCH PERFORMANCE
POSSIBLE CAUSES
DRBI I I ௡ DI SPLAYS P/N & D/R NOT I N CORRECT POSI TI ON
TRS T41 SENSE (P/N SENSE) CI RCUI T SHORTED TO GROUND
TRS T41 (P/N SENSE) CI RCUI T OPEN
TRS (P/N SWI TCH)
PCM
TEST ACTION APPLICABILITY
1 Check for any rel ated TSBs.
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, read the PNP swi tch i nput state.
Whi l e movi ng the gear sel ector through al l gear posi ti ons Park to 1st and back to
Park, watch the DRBI I I ௡ di spl ay.
Di d the DRBI I I ௡ di spl ay P/N and D/R i n the correct gear posi ti ons?
Al l
Yes → Refer to the I NTERMI TTENT CONDI TI ON Symptom (Di agnos-
ti c Procedure).
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 2
2 Turn the i gni ti on off.
Di sconnect the PCM harness connectors.
Di sconnect the TRS P/N swi tch harness connector.
Check connectors - Clean/repair as necessary
Measure the resi stance between ground and the TRS T41 (P/N Sense) ci rcui t.
I s the resi stance bel ow 100 ohms?
Al l
Yes → Repai r the short to ground i n the TRS T41 Sense (P/N Sense)
ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 3
3 Measure the resi stance of the TRS T41 (P/N Sense) ci rcui t between the PCM C1
harness connector and the TRS harness connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 4
No → Repai r the open i n the TRS T41 (P/N Sense) ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
198
DRIVEABILITY - GAS
TEST ACTION APPLICABILITY
4 Turn the i gni ti on off.
Connect the TRS (P/N) harness connector.
Move the gear sel ector through al l gear posi ti ons, from Park to 1st and back.
Whi l e movi ng the gear sel ector through the gear posi ti ons, measure the resi stance
between ground and the TRS T41 (P/N) Sense ci rcui t i n the PCM C1 harness
connector.
NOTE: The circuit is grounded in Park and Neutral and open in the other
positions.
Di d the di spl ay change from above 100 kohms (open) to bel ow 10.0 ohms (grounded)?
Al l
Yes → Go To 5
No → Repl ace the TRS Assembl y (P/N Swi tch) per Servi ce I nformati on.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
5 NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Usi ng the schemati cs as a gui de, i nspect the wi re harness and connectors. Pay
parti cul ar attenti on to al l Power and Ground ci rcui ts.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace and program the Powertrai n Control Modul e per Servi ce
I nformati on.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
199
DRIVEABILITY - GAS
P1899-P/N SWITCH PERFORMANCE — Continued
Symptom:
*BRAKE SWITCH SENSE STATUSDOESNOT CHANGE ONDRBIII௡
POSSIBLE CAUSES
DRBI I I ௡ DOES NOT SHOW BRAKE SW PRESSED OR RELEASED
(F32) FUSED B+ CI RCUI T OPEN
(Z1) GROUND CI RCUI T OPEN
(K29) BRAKE LAMP SWI TCH SI GNAL CI RCUI T
(K29) BRAKE LAMP SWI TCH SI GNAL CI RCUI T OPEN
(K29) BRAKE LAMP SWI TCH SI GNAL CI RCUI T SHORT TO GROUND
(K29) BRAKE LAMP SWI TCH SI GNAL LESS THAN 10.0 VOLTS
(V32) S/C POWER SUPPLY CI RCUI T BELOW 10 VOLTS AT BRAKE SWI TCH CONN
PCM
TEST ACTION APPLICABILITY
1 Check for any rel ated TSBs.
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡ i n I nputs/Outputs, read the Brake Swi tch state.
Press and rel ease the brake pedal several ti mes.
Does the DRBI I I ௡ di spl ay Brake Swi tch PRESSED and RELEASED?
Al l
Yes → The Brake Lamp Swi tch i s operati ng properl y at thi s ti me.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 4.
No → Go To 2
2 Turn the i gni ti on off.
Di sconnect the Brake Lamp Swi tch harness connector.
Usi ng a 12-vol t test l i ght connected to ground, probe the (F32) Fused B+ci rcui t at the
Brake Lamp Swi tch harness connector.
Does the test l i ght i l l umi nate bri ghtl y?
Al l
Yes → Go To 3
No → Repai r the excessi ve resi stance or short to ground i n the (F32)
Fused B+ ci rcui t. I nspect the rel ated fuse and repai r as necessary.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 4.
3 Usi ng a 12-vol t test l i ght connect to 12-vol ts, probe the Brake Lamp Swi tch ground
ci rcui t.
Does the test l i ght i l l umi nate bri ghtl y?
Al l
Yes → Go To 4
No → Repai r the open i n the (Z1) Brake Lamp Swi tch Ground ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 4.
200
DRIVEABILITY - GAS
TEST ACTION APPLICABILITY
4 Measure the resi stance across the Brake Lamp Swi tch Si gnal termi nal and the
Ground termi nal (measurement taken across the swi tch).
Appl y and rel ease the Brake Pedal whi l e moni tori ng the ohmmeter.
Does the resi stance change from bel ow 5.0 ohms to open ci rcui t?
Al l
Yes → Go To 5
No → Repl ace the Brake Lamp Swi tch.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 4.
5 Di sconnect the PCM harness connectors.
Measure the resi stance of the (K29) Brake Lamp Swi tch Si gnal ci rcui t.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 6
No → Repai r the open i n the (K29) Brake Lamp Swi tch Si gnal ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 4.
6 Di sconnect the CAB harness connector.
Measure the resi stance between ground and the (K29) Brake Lamp Swi tch Si gnal
ci rcui t.
I s the resi stance bel ow 100 ohms?
Al l
Yes → Repai r the short to ground i n the (K29) Brake Lamp Swi tch
Si gnal ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 4.
No → Go To 7
7 Turn the i gni ti on off.
Connect the PCM harness connectors.
Connect the CAB harness connector.
Connect the Brake Lamp Swi tch harness connector.
Brake pedal must be depressed i n the next step.
I gni ti on on, engi ne not runni ng.
Usi ng a 12-vol t test l i ght connected to ground, probe the (K29) Brake Lamp Swi tch
Si gnal ci rcui t at the Brake Lamp Swi tch harness connector.
I s the test l i ght i l l umi nated and bri ght?
Al l
Yes → Go To 8
No → Repl ace or adjust the brake swi tch.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 4.
8 Turn the i gni ti on off.
Di sconnect the Brake Swi tch harness connector.
Note: Check connectors - Clean/repair as necessary.
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, actuate the S/C Vacuum Sol enoi d.
Usi ng a 12-vol t test l i ght connected to ground, backprobe the S/C Power Suppl y
Ci rcui t i n the Brake Swi tch harness connector.
Di d the test l i ght i l l umi nate bri ghtl y?
Al l
Yes → Go To 9
No → Repai r the excesssi ve resi stance i n the (V32) S/C Power Suppl y
ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 4.
201
DRIVEABILITY - GAS
*BRAKE SWITCH SENSE STATUS DOES NOT CHANGE ON DRBIII௡ —
Continued
TEST ACTION APPLICABILITY
9 NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Usi ng the schemati cs as a gui de, i nspect the wi re harness and connectors. Pay
parti cul ar attenti on to al l Power and Ground ci rcui ts.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace and program the Powertrai n Control Modul e per Servi ce
I nformati on.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 4.
202
DRIVEABILITY - GAS
*BRAKE SWITCH SENSE STATUS DOES NOT CHANGE ON DRBIII௡ —
Continued
Symptom:
*CHECKING A/C SYSTEM OPERATION WITH NO DTCS
POSSIBLE CAUSES
A/C CLUTCH RELAY DTC PRESENT
REFRI GERATI ON SYSTEM NOT PROPERLY CHARGED
HI GH PRESS CUT-OFF SWI TCH
LOW PRESSURE SWI TCH
A/C REQUEST CI RCUI T OPEN
A/C SELECT CI RCUI T OPEN
A/C CLUTCH COI L
A/C COMPRESSOR CLUTCH GROUND CI RCUI T OPEN
(C3) A/C CLUTCH RELAY OUTPUT CI RCUI T OPEN
(A17) FUSED B+ CI RCUI T
A/C CLUTCH RELAY
TEST ACTION APPLICABILITY
1 I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, read DTCs.
I s there an A/C Cl utch Rel ay DTC present?
Al l
Yes → Di agnose the rel ated DTC(s) before conti nui ng.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 2
2 Turn the i gni ti on off.
Veri fy that the Refri gerant System i s properl y charged per Servi ce Procedure.
I s the Refri gerant System properl y charged?
Al l
Yes → Go To 3
No → Properl y charge the Refri gerant System per Servi ce I nformati on.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
3 Veri fy the Hi gh Pressure Cut-Off Swi tch operati on per Servi ce I nformati on.
I s the Hi gh Pressure Cut-Off Swi tch OK?
Al l
Yes → Go To 4
No → Repl ace the Hi gh Pressure Cut-Off Swi tch.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
4 Veri fy the Low Pressure Swi tch operati on per Servi ce I nformati on.
I s the Low Pressure Swi tch OK?
Al l
Yes → Go To 5
No → Repl ace the Low Pressure Swi tch.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
203
DRIVEABILITY - GAS
TEST ACTION APPLICABILITY
5 Engi ne Runni ng.
Turn the A/C system on and the fan on hi gh.
Wi th the DRBI I I ௡ i n I nputs/Outputs, read the A/C request state.
Does the A/C request state change?
Al l
Yes → Go To 6
No → Repai r the open i n the A/C Request ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
6 Wi th the DRBI I I ௡, read the A/C Sel ect status.
Turn the A/C Swi tch on and off a few ti mes.
Does the A/C Sel ect state change?
Al l
Yes → Go To 7
No → Repai r the open i n the A/C Sel ect ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
7 I gni ti on on, engi ne not runni ng.
Di sconnect the A/C Compressor Cl utch harness connector.
Connect a test l i ght between the ground ci rcui t and the A/C Cl utch Rel ay Output
ci rcui t.
Wi th the DRBI I I ௡, actuate the A/C Cl utch Rel ay.
Does the test l i ght i l l umi nate bri ghtl y on and off wi th the rel ay actuati on?
Al l
Yes → Repl ace the A/C Cl utch Coi l .
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 8
8 Turn the i gni ti on off.
Di sconnect the A/C Cl utch harness connector.
NOTE: Check connectors - Clean/repair as necessary.
Measure the resi stance between ground and the A/C Compressor Cl utch Ground
Ci rcui t.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 9
No → Repai r the A/C compressor cl utch ground ci rcui t for an open.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
9 Remove the A/C Cl utch Rel ay.
Note: Check connectors - Clean/repair as necessary.
Measure the resi stance of the A/C Cl utch Rel ay Output ci rcui t between the Rel ay and
the A/C Cl utch Coi l connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 10
No → Repai r the open i n the (C3) A/C Cl utch Rel ay Output ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
10 Measure the vol tage on the (A17) Fused B+ ci rcui t i n the A/C Cl utch Rel ay connector.
I s the vol tage above 11.0 vol ts?
Al l
Yes → Go To 11
No → Repai r the open or short to ground i n the (A17) Fused B+ ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
204
DRIVEABILITY - GAS
*CHECKING A/C SYSTEM OPERATION WITH NO DTCS — Continued
TEST ACTION APPLICABILITY
11 I f there are no possi bl e causes remai ni ng, vi ew repai r. Al l
Repai r
Repl ace the A/C Cl utch Rel ay.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
205
DRIVEABILITY - GAS
*CHECKING A/C SYSTEM OPERATION WITH NO DTCS — Continued
Symptom:
*CHECKING EVAPORATIVE EMISSION OPERATION WITH NO
DTCS
POSSIBLE CAUSES
FUEL TANK VENT
WI RE HARNESS I NSPECTI ON
VACUUM HARNESS I NSPECTI ON
PURGE SYSTEM CONTAMI NATED
TEST ACTION APPLICABILITY
1 Start the engi ne.
Al l ow the engi ne to reach normal operati ng temperature.
Note: Engine must be in closed loop.
Wi th the DRBI I I ௡, go to Purge Vapors Test. Press 3 to fl ow.
Note: Short TermAdaptive should change.
Di d Short Term Adapti ve change?
Al l
Yes → Test Compl ete.
No → Go To 2
2 Turn the i gni ti on off.
Remove the Purge Sol enoi d.
I nspect the l i ne from rol l over val ve to the sol enoi d.
I s l i qui d fuel i n the l i ne?
Al l
Yes → Repl ace the Fuel Tank Vent.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 1.
No → Go To 3
3 Note: Use the Freeze Frame Data to help you duplicate the conditions that
set the DTC. Pay particular attention to the DTC set conditions, such as,
VSS, MAP, ECT, and Load.
NOTE: Visually inspect the related wire harness. Look for any chafed,
pierced, pinched, or partially broken wires.
Note:Visuallyinspect therelatedwireharnessconnectors. Look for broken,
bent, pushed out, or corroded terminals.
Note: Refer to any technical service bulletins that may apply.
Perform a wi ggl e test of the Evap Purge Sol enoi d wi ri ng whi l e the ci rcui t i s actuated
wi th the DRBI I I ௡. Li sten for the sol enoi d to qui t actuati ng. Al so watch for the Good
Tri p Counter to change to 0.
Were any probl ems found?
Al l
Yes → Repai r wi re harness/connectors as necessary.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 1.
No → Go To 4
206
DRIVEABILITY - GAS
TEST ACTION APPLICABILITY
4 Note: Visually inspect the Evap Purge Solenoid and vacuumharness. Look
for any chafed, pierced, pinched, or partially broken hoses.
Note: Refer to any technical service bulletins that may apply.
Were any probl ems found?
Al l
Yes → Repai r vacuum harness/connecti ons as necessary.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 1.
No → Go To 5
5 Turn the i gni ti on off.
Remove the Purge sol enoi d and tap the ports agai nst a cl ean sol i d surface.
Di d any forei gn materi al fal l out?
Al l
Yes → Repl ace the purge sol enoi d and cl ean or repl ace the vacuum and
purge l i nes and Evap cani ster.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 1.
No → Test Compl ete.
207
DRIVEABILITY - GAS
*CHECKING EVAPORATIVE EMISSION OPERATION WITH NO DTCS —
Continued
Symptom:
*CHECKING HARD TO FILL WITH FUEL
POSSIBLE CAUSES
NVLD FI LTER PLUGGED
Repair Instructions:
NVLD FILTER PLUGGED
Repl ace the NVLD fi l ter and cl ean out the Hoses.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 2.
208
DRIVEABILITY - GAS
Symptom:
*CHECKING THE PCM POWER AND GROUNDS
POSSIBLE CAUSES
PCM FUSED B+ CI RCUI T
PCM FUSED I GNI TI ON SWI TCH OUTPUT CI RCUI T
PCM GROUND CI RCUI TS
TEST ACTION APPLICABILITY
1 Turn the i gni ti on off.
Di sconnect the PCM harness connectors.
Usi ng a 12-vol t test l i ght connected to ground, probe the PCM Fused B+ ci rcui t i n the
PCM harness connector.
Does the test l i ght i l l umi nate bri ghtl y?
Al l
Yes → Go To 2
No → Repai r the open i n the Fused B+ ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 1.
2 I gni ti on on, engi ne not runni ng.
Usi ng a 12-vol t test l i ght connected to ground, probe the PCM Fused I gni ti on Swi tch
Output ci rcui t i n the PCM harness connector.
Does the test l i ght i l l umi nate bri ghtl y?
Al l
Yes → Go To 3
No → Repai r the open i n the I gni ti on Swi tch Output ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 1.
3 Turn the i gni ti on off.
Usi ng a 12-vol t test l i ght connected to battery vol tage, probe the PCM ground ci rcui ts
i n the PCM harness connector.
Does the test l i ght i l l umi nate bri ghtl y?
Al l
Yes → Test Compl ete.
No → Repai r the open i n the PCM ground ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 1.
209
DRIVEABILITY - GAS
Symptom:
*CHECKING FUEL DELIVERY
POSSIBLE CAUSES
FUEL PUMP RELAY
FUEL PRESSURE OUT OF SPECI FI CATI ON
RESTRI CTED FUEL SUPPLY LI NE
FUEL PUMP I NLET STRAI NER PLUGGED
FUEL PUMP
(A61) FUSED B+ CI RCUI T
(A141) FUEL PUMP RELAY OUTPUT CI RCUI T OPEN
(Z1) FUEL PUMP GROUND CI RCUI T EXCESSI VE RESI STANCE
FUEL PUMP MODULE
TEST ACTION APPLICABILITY
1 I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, actuate the ASD Fuel System test.
Note: It may be necessary to use a mechanics stethoscope in the next step.
Li sten for fuel pump operati on at the fuel tank.
Does the Fuel Pump operate?
Al l
Yes → Go To 2
No → Go To 5
Caution: Stop All Actuations.
2 Turn the i gni ti on off.
WARNING: The fuel system is under a constant pressure even with the
engine off. Before testing or servicing any fuel systemhose, fitting or line,
the fuel systempressure must be released.
I nstal l a fuel pressure gauge to the fuel rai l test port.
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, actuate the ASD Fuel System test and observe the fuel pressure
gauge.
NOTE: Fuel pressure specification is 400 KPa +/- 34 KPa (58 psi +/- 5 psi).
Choose a concl usi on that best matches your fuel pressure readi ng.
Al l
Bel ow Speci fi cati on
Go To 3
Wi thi n Speci fi cati on
Test Compl ete.
Above Speci fi cati on
Repl ace the fuel fi l ter/fuel pressure regul ator.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 1.
Caution: Stop All Actuations.
210
STARTING
TEST ACTION APPLICABILITY
3 Turn the i gni ti on off.
WARNING: The fuel system is under a constant pressure even with the
engine off. Before testing or servicing any fuel systemhose, fitting or line,
the fuel systempressure must be released.
Rai se vehi cl e on hoi st, and di sconnect the fuel pressure l i ne at the fuel pump modul e.
I nstal l speci al 5/16Љ fuel l i ne adapter tool #6539 between di sconnected fuel l i ne and
the fuel pump modul e.
Attach a fuel pressure test gauge to the ЉTЉ fi tti ng on tool #6539.
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, actuate the ASD Fuel System test and observe the fuel pressure
gauge.
NOTE: Fuel pressure specification is 400 KPa +/- 34 KPa (58 psi +/- 5 psi).
I s the fuel pressure wi thi n speci fi cati on now?
Al l
Yes → Repai r/repl ace fuel suppl y l i ne as necessary.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 1.
No → Go To 4
Caution: Stop All Actuations.
4 Turn the i gni ti on off.
WARNING: The fuel system is under a constant pressure even with the
engine off. Before testing or servicing any fuel system hose,fitting or line,
the fuel systempressure must be released.
Remove the Fuel Pump Modul e and i nspect the Fuel I nl et Strai ner.
I s the Fuel I nl et Strai ner pl ugged?
Al l
Yes → Repl ace the Fuel Pump I nl et Strai ner.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 1.
No → Repl ace the Fuel Pump Modul e.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 1.
5 Turn the i gni ti on off.
Di sconnect the fuel pump modul e harness connector.
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, actuate the ASD Fuel System test.
Usi ng a 12-vol t test l i ght connected to ground, probe the (A141) Fuel Pump Rel ay
Output ci rcui t at the Fuel Pump Modul e harness connector.
Does the test l i ght i l l umi nate bri ghtl y?
Al l
Yes → Go To 6
No → Go To 8
Caution: Stop All Actuations.
6 Turn the i gni ti on off.
Di sconnect the Fuel Pump Modul e harness connector.
Usi ng a test l i ght connected to 12-vol ts, backprobe the (Z1) Fuel Pump ground ci rcui t
at the Fuel Pump Modul e harness connector.
Does the test l i ght i l l umi nate bri ghtl y?
Al l
Yes → Go To 7
No → Repai r the excessi ve resi stance i n the (Z1) Fuel Pump Ground
ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 1.
211
STARTING
*CHECKING FUEL DELIVERY — Continued
TEST ACTION APPLICABILITY
7 I f there are no possi bl e causes remai ni ng, vi ew repai r. Al l
Repai r
Repl ace the Fuel Pump Modul e.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 1.
8 Turn the i gni ti on off.
Remove the Fuel Pump Rel ay from the PDC.
Usi ng a 12-vol t test l i ght connected to ground, backprobe the Fuel Pump Rel ay Fused
B+ ci rcui t at the PDC.
Does the test l i ght i l l umi nate?
Al l
Yes → Go To 9
No → Repai r the open or short to ground i n the (A61) Fuel Pump Real y
Fused B+ ci rcui t. I nspect the fuse and repai r as necessary.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 1.
9 Di sconnect the Fuel Pump Modul e harness connector.
Measure the resi stance of the (A141) Fuel Pump Rel ay Output ci rcui t from the rel ay
connector to the Fuel Pump Modul e connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Repl ace the Fuel Pump Rel ay.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 1.
No → Repai r the open i n the (A141) Fuel Pump Rel ay Output ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 1.
212
STARTING
*CHECKING FUEL DELIVERY — Continued
Symptom:
*CHECKING HARD START (FUEL DELIVERY SYSTEM)
POSSIBLE CAUSES
RESTRI CTED FUEL SUPPLY LI NE
FUEL PUMP MODULE
FUEL PUMP I NLET STRAI NER PLUGGED
FAULTY FUEL PUMP MODULE
FUEL I NJECTORS
FUEL CONTAMI NATI ON
TEST ACTION APPLICABILITY
1 Turn the i gni ti on off.
WARNING: The fuel system is under a constant pressure even with the
engine off. Before testing or servicing any fuel systemhose, fitting or line,
the fuel systempressure must be released.
I nstal l the fuel pressure gauge at the engi ne. Refer to the Servi ce I nformati on FUEL
DELI VERY Secti on.
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, actuate the ASD Fuel System test and observe the fuel pressure
gauge.
NOTE: Fuel pressure specification is 400 KPa +/- 34 KPa (58 psi +/- 5 psi).
Choose a concl usi on that best matches your fuel pressure readi ng.
Al l
Bel ow Speci fi cati on
Go To 2
Wi thi n Speci fi cati on
Go To 4
2 Turn the i gni ti on off.
WARNING: The fuel system is under a constant pressure even with the
engine off. Before testing or servicing any fuel systemhose, fitting or line,
the fuel systempressure must be released.
Rai se vehi cl e on hoi st, and di sconnect the fuel suppl y l i ne at the fuel pump modul e.
I nstal l speci al tool #6539 (5/16Љ) fuel l i ne adapter fuel pressure gauge between the
fuel suppl y l i ne and the fuel pump modul e.
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, actuate the ASD Fuel System test and observe the fuel pressure
gauge.
NOTE: Fuel pressure specification is 400 KPa +/- 34 KPa (58 psi +/- 5 psi).
I s the fuel pressure wi thi n speci fi cati on?
Al l
Yes → Vi sual l y and physi cal l y i nspect the fuel suppl y l i nes between the
fuel tank and the fuel rai l . Repai r/repl ace as necessary.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 2.
No → Go To 3
213
STARTING
TEST ACTION APPLICABILITY
3 Turn the i gni ti on off.
WARNING: The fuel system is under a constant pressure even with the
engine off. Before testing or servicing any fuel system hose,fitting or line,
the fuel systempressure must be released.
Remove the Fuel Pump Modul e and i nspect the Fuel I nl et Strai ner.
I s the Fuel I nl et Strai ner pl ugged?
Al l
Yes → Repl ace the Fuel Pump I nl et Strai ner.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 2.
No → Test Compl ete.
4 NOTE: Before continuing visually and physically inspect the fuel delivery
systemfor external leaks or damage. Repair /replace as necessary.
Turn the i gni ti on off.
WARNING: The fuel system is under a constant pressure even with the
engine off. Before testing or servicing any fuel systemhose, fitting or line,
the fuel systempressure must be released.
I nstal l speci al tool #6539 (5/16Љ) fuel l i ne adapter.
I nstal l the fuel pressure gauge.
Start the engi ne and al l ow the fuel system to reach maxi mum pressure.
Turn the i gni ti on off.
NOTE: Fuel specification is 400 KPa +/- 34 KPa (58 psi +/- 5 psi).
Usi ng speci al tool #C4390, Hose Cl amp Pl i ers, pi nch the rubber fuel l i ne between the
fuel pressure gauge and the engi ne.
Moni tor the fuel pressure gauge for a mi ni mum of 5 mi nutes.
NOTE: The pressure should not fall below 241 KPa (35 psi)
Does the fuel pressure drop?
Al l
Yes → Repl ace fuel pump modul e.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 2.
No → Go To 5
5 WARNING: The fuel system is under a constant pressure even with the
engine off. Before testing or servicing any fuel systemhose, fitting or line,
the fuel systempressure must be released.
Remove speci al tool #C4390.
Start the engi ne and al l ow the fuel system to reach maxi mum pressure.
Turn the i gni ti on off.
NOTE: Fuel specification is 400 KPa +/- 34 KPa (58 psi +/- 5 psi).
I nstal l speci al tool #C4390, Hose Cl amp Pl i ers, pi nch the rubber fuel l i ne between the
fuel pressure gauge and the fuel pump modul e.
Moni tor the fuel pressure gauge for a mi ni mum of 5 mi nutes.
NOTE: The pressure should not fall below 241 KPa (35 psi)
Does the fuel pressure drop?
Al l
Yes → Repl ace l eaki ng fuel i njectors.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 2.
No → Check the fuel for contami nants.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 2.
214
STARTING
*CHECKING HARD START (FUEL DELIVERY SYSTEM) — Continued
Symptom:
*ENGINE CRANKS DOES NOT START
POSSIBLE CAUSES
NO START PRE-TEST
POWERTRAI N FUSES OPEN
SECONDARY I NDI CATORS PRESENT
NO CKP SENSOR SI GNAL WHEN CRANKI NG ENGI NE
NO CMP SENSOR SI GNAL WHEN CRANKI NG ENGI NE
ENGI NE MECHANI CAL PROBLEM
(A142) ASD RELAY OUTPUT CI RCUI T OPEN
FUEL CONTAMI NATI ON
TEST ACTION APPLICABILITY
1 Note: The following list of items must be checked before continuing with
any no start tests.
The battery must be ful l y charged and i n good condi ti on. A l ow charged battery may
produce i nval i d test resul ts. I f the battery i s l ow, charge the battery and then attempt
to start the vehi cl e by cranki ng the engi ne for 15 seconds, 3 consecuti ve ti mes.
Thi s wi l l al l ow any DTCs to set that may have been erased due to a dead battery.
Try to communi cate wi th PCM, i f not abl e to communi cate check fuses.
Make sure the Powers and Ground to the PCM are ok.
Make sure the PCM communi cates wi th the DRBI I I ௡ and that there are no DTCs
stored i n the PCM memory. I f the PCM reports a No Response condi ti on, refer to the
Communi cati on category for the proper tests.
Read the PCM DTCs wi th the DRBI I I ௡. I f any DTCs are present, they must be
repai red before conti nui ng wi th any other No Start di agnosti c tests. Refer to the
Symptom l i st for the rel ated P-code that i s reported by the PCM.
Make sure that the PCI bus i s functi onal . Attempt to communi cate wi th the
I nstrument Cl uster and VTSS. I f you are unabl e to establ i sh communi cate refer to
the Communi cati on category for the proper symptoms.
The Sentry Key I mmobi l i zer System must be operati ng properl y. Check for proper
communi cati on wi th the DRBI I I ௡ and check for DTCs that may be stored i n the
Sentry Key I mmobi l i zer Modul e (SKI M). Repai r the DTC(s) before conti nui ng.
I f no DTCs are found, usi ng the DRBI I I ௡, sel ect Cl ear PCM (BATT Di sconnect).
Crank the engi ne several ti mes. Usi ng the DRBI I I ௡, read DTCs. I f a DTC i s present
perform the DTC di agnosti cs before conti nui ng.
Were any probl ems found?
Al l
Yes → Repai r as necessary.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 2
2 Check for any open fuses i n the PDC or Juncti on Bl ock that may be rel ated to the No
Start condi ti on.
Are any of the fuses open?
Al l
Yes → Repl ace the open fuse and check the rel ated ci rcui t(s) for a short
to ground.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 3
215
STARTING
TEST ACTION APPLICABILITY
3 I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, under DTCs & Rel ated Functi ons, read the Secondary I ndi cators
whi l e cranki ng the engi ne.
Are there any Secondary I ndi cators present whi l e cranki ng the engi ne?
Al l
Yes → Refer to symptom l i st and perform tests rel ated to the secondary
i ndi cator that i s reported by the DRBI I I ௡.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 4
4 Wi th the DRBI I I ௡ i n Sensors, check the Current CKP Count whi l e cranki ng the
engi ne.
Does the CKP Counter change whi l e cranki ng the engi ne?
Al l
Yes → Go To 5
No → Refer to Dri veabi l i ty Symptom P0320-NO CRANK REFERENCE
SI GNAL AT PCM.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
5 Wi th the DRBI I I ௡ i n Sensors, check the Current CMP Count whi l e cranki ng the
engi ne.
Does the Current CMP Count change whi l e cranki ng the engi ne?
Al l
Yes → Go To 6
No → Refer to Dri veabi l i ty Symptom P0340-NO CAM SI GNAL ATPCM
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
6 Check for any of the fol l owi ng condi ti ons/mechani cal probl ems.
ENGI NE VALVE TI MI NG - must be wi thi n speci fi cati ons
ENGI NE COMPRESSI ON - must be wi thi n speci fi cati ons
ENGI NE EXHAUST SYSTEM - must be free of any restri cti ons or l eaks.
FUEL - must be free of contami nati on
FUEL I NJECTOR - pl ugged or restri cted i njector; control wi re not connected to
correct i njector
Are there any engi ne mechani cal probl ems?
Al l
Yes → Repai r as necessary.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
No → Go To 7
7 Turn the i gni ti on off.
Remove the ASD rel ay from the PDC.
Di sconnect the PCM harness connectors.
Veri fy the ASD Rel ay i s getti ng Fused B+ vol tage before conti nui ng.
Measure the resi stance of the (A142) ASD Rel ay output ci rcui t from the ASD Rel ay
connector to the PCM harness connector, I gni ti on coi l , and the fuel i njectors.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 8
No → Repai r the open ASD Rel ay output ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
216
STARTING
*ENGINE CRANKS DOES NOT START — Continued
TEST ACTION APPLICABILITY
8 Veri fy that the Fuel tank i s not empty before conti nui ng.
Fol l ow the di agnosti cs for Checki ng Fuel Del i very under the Dri veabi l i ty secti on of
thi s manual .
Was the No Start condi ti on sol ved after fol l owi ng the above di agnosti c procedure?
Al l
Yes → Test Compl ete.
No → Check for contami nati on/water i n the fuel . Ensure the fuel bei ng
used i n thi s vehi cl e meets manufactures Fuel Requi rement, refer
to the servi ce manual .
Perform POWERTRAI N VERI FI CATI ON TEST VER - 5.
217
STARTING
*ENGINE CRANKS DOES NOT START — Continued
Symptom:
*FUEL PRESSURE LEAK DOWN
POSSIBLE CAUSES
CHECKI NG FUEL LEAK DOWN
FUEL I NJECTORS
TEST ACTION APPLICABILITY
1 NOTE: Before continuing visually and physically inspect the fuel delivery
systemfor external leaks or damage. Repair /replace as necessary.
Turn the i gni ti on off.
WARNING: The fuel system is under a constant pressure even with the
engine off. Before testing or servicing any fuel systemhose, fitting or line,
the fuel systempressure must be released.
I nstal l speci al tool #6539 (5/16Љ) fuel l i ne adapter.
I nstal l the fuel pressure gauge.
Start the engi ne and al l ow the fuel system to reach maxi mum pressure.
Turn the i gni ti on off.
NOTE: Fuel specification is 400 KPa +/- 34 KPa (58 psi +/- 5 psi).
Usi ng speci al tool #C4390, Hose Cl amp Pl i ers, pi nch the rubber fuel l i ne between the
fuel pressure gauge and the engi ne.
Moni tor the fuel pressure gauge for a mi ni mum of 5 mi nutes.
NOTE: The pressure should not fall below 241 KPa (35 psi).
Does the fuel pressure drop?
Al l
Yes → Repl ace the fuel pump modul e.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 2.
No → Go To 2
2 WARNING: The fuel system is under a constant pressure even with the
engine off. Before testing or servicing any fuel systemhose, fitting or line,
the fuel systempressure must be released.
Remove speci al tool #C4390.
Start the engi ne and al l ow the fuel system to reach maxi mum pressure.
Turn the i gni ti on off.
NOTE: Fuel specification is 400 KPa +/- 34 KPa (58 psi +/- 5 psi).
I nstal l speci al tool #C4390, Hose Cl amp Pl i ers, pi nch the rubber fuel l i ne between the
fuel pressure gauge and the fuel pump modul e.
Moni tor the fuel pressure gauge for a mi ni mum of 5 mi nutes.
NOTE: The pressure should not fall below 241 KPa (35 psi)
Does the fuel pressure drop?
Al l
Yes → Repl ace l eaki ng fuel i njectors.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 2.
No → Test Compl ete.
218
STARTING
Symptom:
*NO CRANK CONDITION
POSSIBLE CAUSES
MECHANI CAL CONDI TI ON
TRANSMI SSI ON RANGE SENSOR
BATTERY CI RCUI T RESI STANCE TOO HI GH
CLUTCH PEDAL POSI TI ON SWI TCH
(T141) FUSED I GNI TI ON SWI TCH OUTPUT CI RCUI T OPEN
TRS T41 SENSE (P/N SENSE) CI RCUI T OPEN
(T40) STARTER RELAY OUTPUT CI RCUI T OPEN
(A2) FUSED B+ CI RCUI T OPEN
STARTER
STARTER RELAY
TEST ACTION APPLICABILITY
1 NOTE: Check all fusesandverify thebattery isfully chargedandcapableof
passing a load test before continuing.
WARNING: MAKE SURE THE BATTERY IS DISCONNECTED, THEN WAIT
TWO MINUTES BEFORE PROCEEDING.
Turn the engi ne over by hand to ensure the engi ne i s not sei zed.
I s the engi ne abl e to turn over?
Al l
Yes → Go To 2
No → Repai r the mechani cal condi ti on preventi ng the starter motor
from cranki ng.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 1.
2 Turn the i gni ti on off.
Di sconnect the PCM harness connectors.
Move the Gear sel ector through al l gear posi ti ons, from Park to 1st and back.
Whi l e movi ng the gear sel ector through each gear, measure the resi stance between
ground and the TRS T41 Sense (P/N Sense) ci rcui t.
Di d the resi stance change from above 10.0 ohms to bel ow 10.0 ohms?
Al l
Yes → Go To 3
No → Repl ace the Transmi ssi on Range Sensor.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 1.
3 Check the Battery Cabl es for hi gh resi stance usi ng the servi ce i nformati on proce-
dure.
Di d ei ther Battery Cabl e have a vol tage drop greater than 0.2 of a vol t?
Al l
Yes → Repai r the Battery ci rcui t for hi gh resi stance.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 1.
No → Go To 4
219
STARTING
TEST ACTION APPLICABILITY
4 Di sconnect the Cl utch Pedal Posi ti on Swi tch.
I f thi s vehi cl e i s not equi pped wi th a manual transmi ssi on answer NO to thi s test and
conti nue.
Connect a jumper wi re between the two termi nal s of the Cl utch Pedal Posi ti on
Swi tch and attempt to start the engi ne.
Does the engi ne crank?
Al l
Yes → Repl ace the Cl utch Pedal Posi ti on Swi tch.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 1.
No → Go To 5
5 Turn i gni ti on off.
Remove the Starter Rel ay from PDC.
WARNING: TheParkingBrakemust beon and theTransmission must bein
park for a vehicle equipped with an automatic transmission or Neutral on
a Manual transmission.
WARNING: The engine may be cranked in the next step. Keep away from
moving engine parts.
Bri efl y connect a jumper wi re between Starter Rel ay B+ ci rcui t and the (T40) Starter
Rel ay Output ci rcui ts.
Di d the Starter Motor crank the engi ne?
Al l
Yes → Go To 6
No → Go To 8
NOTE: Remove the jumper wire before continuing.
6 I gni ti on on, engi ne not runni ng.
Usi ng a 12-vol t test l i ght connected to ground, probe the (T141) Fused I gni ti on
Swi tch Output ci rcui t i n the Starter Rel ay connector.
Whi l e observi ng 12-vol t test l i ght, hol d i gni ti on key i n the start posi ti on.
Does the test l i ght i l l umi nate bri ghtl y?
Al l
Yes → Go To 7
No → Repai r the open or hi gh resi stance i n the (T141) Fused I gni ti on
Swi tch Output ci rcui t. I nspect rel ated fuses and repai r as neces-
sary.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 1.
7 Turn the i gni ti on off.
Di sconnect the PCM harness connectors.
Measure the resi stance of the Starter Rel ay Control ci rcui t between the Rel ay
termi nal and the PCM harness connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Repl ace the Starter Motor Rel ay.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 1.
No → Repai r the open i n the TRS T41 Sense (P/N Sense) ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 1.
220
STARTING
*NO CRANK CONDITION — Continued
TEST ACTION APPLICABILITY
8 Di sconnect the Starter Rel ay Output connector from the Starter Sol enoi d.
Measure the resi stance of the (T40) Starter Rel ay Output ci rcui t between the Rel ay
and the Sol enoi d harness connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 9
No → Repai r the open i n the (T40) Starter Rel ay Output ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 1.
9 Usi ng a 12-vol t test l i ght connected to ground, backprobe the (A2) Fused B+ ci rcui t
at the Starter Rel ay termi nal .
Does the test l i ght i l l umi nate bri ghtl y?
Al l
Yes → Go To 10
No → Repai r the open or hi gh resi stance i n the (A2) Fused B+ ci rcui t.
I nspect rel ated fuses and repai r as necessary.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 1.
10 I f there are no other possi bl e causes remai ni ng, revi ew repai r. Al l
Repai r
Repl ace the Starter.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 1.
221
STARTING
*NO CRANK CONDITION — Continued
Symptom:
*NO RESPONSE FROM PCM WITH A NO START CONDITION
POSSIBLE CAUSES
PCM FUSED B+ CI RCUI T
PCM NO RESPONCE
PCM FUSED I GNI TI ON SWI TCH OUTPUT CI RCUI T
PCM GROUND CI RCUI TS
TP SENSOR
5-VOLT SENSOR OPEN OR SHORTED
(K7) 5-VOLT SUPPLY CKT SHORT TO GROUND
(K6) 5-VOLT CI RCUI T SUPPLY SHORTED TO GROUND
PCM
TEST ACTION APPLICABILITY
1 NOTE: TheDRBIII௡ and cablemust beoperatingproperly for theresults of
this test to be valid.
NOTE: Ensuretheignition switch wason whiletryingtocommunicatewith
the PCM.
Turn the i gni ti on off.
Di sconnect the PCM harness connectors.
Usi ng a 12-vol t test l i ght connected to ground, backprobe the PCM Fused B+ ci rcui t
i n the PCM harness connector.
Does the test l i ght i l l umi nate bri ghtl y?
Al l
Yes → Go To 2
No → Repai r the open i n the Fused B+ ci rcui t. I nspect and repl ace fuses
as necessary.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 1.
2 I gni ti on on, engi ne not runni ng.
Usi ng a 12-vol t test l i ght connected to ground, backprobe the PCM Fused I gni ti on
Swi tch Output ci rcui t i n the PCM harness connector.
Does the test l i ght i l l umi nate bri ghtl y?
Al l
Yes → Go To 3
No → Repai r the open i n the I gni ti on Swi tch Output ci rcui t. I nspect and
repl ace fuses as necessary.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 1.
3 Turn the i gni ti on off.
Usi ng a 12-vol t test l i ght connected to 12-vol ts, backprobe the PCM ground ci rcui ts
i n the PCM harness connector.
Does the test l i ght i l l umi nate bri ghtl y?
Al l
Yes → Go To 4
No → Repai r the opens i n the PCM ground ci rcui ts.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 1.
222
STARTING
TEST ACTION APPLICABILITY
4 Connect the PCM harness connectors.
Di sconnect the TP Sensor harness connector.
I gni ti on on, engi ne not runni ng.
Measure the vol tage on the (K7) 5-vol t Suppl y ci rcui t.
I s the vol tage between 4.5 and 5.2 vol ts?
Al l
Yes → Go To 5
No → Go To 6
5 Turn the i gni ti on off.
Di sconnect the MAP Sensor harness connector.
NOTE: Connect the TP Sensor harness connector.
I gni ti on on, engi ne not runni ng.
Measure the vol tage on the (K7) 5-vol t Suppl y ci rcui t i n the MAP Sensor harness
connector.
I s the vol tage between 4.5 and 5.2 vol ts?
Al l
Yes → I f communi cati on i s avai l abl e wi th a PCM on a l i ke vehi cl e,
repl ace and program the Powertrai n Control Modul e i n accor-
dance wi th Servi ce I nformati on.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 1.
No → Repl ace the Throttl e Posi ti on Sensor.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 1.
6 Measure the vol tage on the (K7) 5-vol t Suppl y ci rcui t.
Di sconnect al l the sensors that use a 5-vol t Suppl y ci rcui t.
Di d the vol tage return to 4.5 to 5.2 vol ts when di sconnecti ng any of the sensors.
Al l
Yes → Repl ace the sensor that i s pul l i ng down the 5-vol t suppl y.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 1.
No → Go To 7
7 Turn the i gni ti on off.
Di sconnect PCM harness connectors.
Measure the resi stance between ground and the (K7) 5-vol t Suppl y ci rcui t wi th al l
the Sensor harness connectors di sconnected.
I s the resi stance bel ow 100 ohms?
Al l
Yes → Repai r the short to ground i n the (K7) 5-vol t Suppl y ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 1.
No → Go To 8
8 Di sconnect al l sensors that use the (K6) 5-vol t Suppl y.
Measure the resi stance between ground and the (K6) 5-vol t Suppl y ci rcui t at the
PCM harness connector.
I s the resi stance bel ow 100 ohms?
Al l
Yes → Repai r the short to ground i n the (K6) 5-vol t Suppl y ci rcui t.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 1.
No → Go To 9
223
STARTING
*NO RESPONSE FROM PCM WITH ANO START CONDITION — Continued
TEST ACTION APPLICABILITY
9 NOTE: Before continuing, check the PCM harness connector terminals for
corrosion, damage, or terminal push out. Repair as necessary.
Usi ng the schemati cs as a gui de, i nspect the wi re harness and connectors. Pay
parti cul ar attenti on to al l Power and Ground ci rcui ts.
I f there i s no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace and program the Powertrai n Control Modul e per Servi ce
I nformati on.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 1.
224
STARTING
*NO RESPONSE FROM PCM WITH ANO START CONDITION — Continued
Symptom:
*START AND STALL CONDITION
POSSIBLE CAUSES
CHECKI NG DTCS
CHECKI NG SKI M DTCS
TP SENSOR SWEEP
TP SENSOR VOLTAGE GREATER THAN 0.92 VOLTS WI TH THROTTLE CLOSED
ECT SENSOR OPERATI ON
OTHER POSSI BLE CAUSES FOR START & STALL
FUEL CONTAMI NATI ON
TEST ACTION APPLICABILITY
1 I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, read engi ne DTCs.
Are any DTCs present?
Al l
Yes → Refer to the Dri veabi l i ty Category and perform the appropri ate
symptom.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 1.
No → Go To 2
2 NOTE: If you are unable to communicate with the SKIM, refer to the
Communication Category and performthe appropriate symptom.
Wi th the DRBI I I ௡, read the SKI M codes.
Are there any SKI M DTCs?
Al l
Yes → Refer to the Vehi cl e Theft category and perform the appropri ate
symptom.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 1.
No → Go To 3
3 Wi th the DRBI I I ௡, read TP Sensor vol tage.
Whi l e moni tori ng the DRBI I I ௡, sl owl y open and cl ose the Throttl e.
I s the vol tage change smooth?
Al l
Yes → Go To 4
No → Repl ace the Throttl e Posi ti on Sensor.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 1.
4 Wi th the DRBI I I ௡, read TP Sensor vol tage. Throttl e must be agai nst stop.
I s the vol tage 0.92 or l ess wi th the Throttl e cl osed?
Al l
Yes → Go To 5
No → Check for a bi ndi ng throttl e condi ti on. I f OK, repl ace the Throttl e
Posi ti on Sensor.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 1.
225
STARTING
TEST ACTION APPLICABILITY
5 Note: For this test to be valid, the thermostat must be operating correctly.
Note: This test works best if performed on a cold engine (cold soaked).
NOTE: If the vehicle was allowed to sit over night with no engine start,
coolant temperature should be near ambient temperatures.
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, read the ECT val ue.
Note: If enginecoolant temperatureisabove82° C (180° F), allowtheengine
to cool until 65° C (150° F) is reached.
Start the engi ne.
Duri ng engi ne warm-up, moni tor the ECT Sensor val ue. The temperature val ue
change shoul d be a smooth transi ti on from start up to normal operati ng temp 82° C
(180° F). The val ue shoul d reach at l east 82° C (180° F).
Di d the Engi ne Temperature val ue i ncrease smoothl y and di d i t reach at l east 82° C
(180° F)?
Al l
Yes → Go To 6
No → Repl ace the Engi ne Cool ant Temperature Sensor.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 1.
6 The fol l owi ng addi ti onal i tems shoul d be checked as a possi bl e cause for a start and
stal l condi ti on.
Refer to any Techni cal Servi ce Bul l eti ns (TSB’s) that may appl y to the symptom.
The exhaust system must be free of any restri cti ons.
The engi ne compressi on must be wi thi n speci fi cati ons.
The engi ne val ve ti mi ng must be wi thi n speci fi cati ons.
The engi ne must be free from vacuum l eaks.
The throttl e body must be free of carbon bui l dup and di rt.
Do any of the above condi ti ons exi st?
Al l
Yes → Repai r as necessary.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 1.
No → Go To 7
7 Veri fy that the Fuel tank i s not empty before conti nui ng.
Fol l ow the di agnosti cs for Checki ng Fuel Del i very under the Dri veabi l i ty secti on of
thi s manual .
Was the Start and Stal l condi ti on sol ved after fol l owi ng the above di agnosti c test?
Al l
Yes → Test Compl ete.
No → Check for contami nati on/water i n the fuel . Ensure the fuel bei ng
used i n thi s vehi cl e meets manufactures Fuel Requi rement, refer
to the servi ce manual .
Perform POWERTRAI N VERI FI CATI ON TEST VER - 1.
226
STARTING
*START AND STALL CONDITION — Continued
Verification Tests
BODY VERIFICATION TEST - VER 1 APPLICABILITY
1. Di sconnect al l jumper wi res and reconnect al l previ ousl y di sconnected components and
connectors.
2. NOTE: If the SKIM or PCM was replaced, refer to the service information for
proper programming procedures.
3. NOTE: If theMIC was replaced, configurenewcluster with TireSize, Axle, T-Case
Type, and EQ Setting.
4. Ensure al l accessori es are turned off and the battery i s ful l y charged.
5. Wi th the DRBI I I ௡, record and erase al l DTC’s from ALL modul es. Start and run the engi ne
for 2 mi nutes. Operate al l functi ons of the system that caused the ori gi nal concern.
6. Turn the i gni ti on off and wai t 5 seconds. Turn the i gni ti on on and usi ng the DRBI I I ௡, read
DTC’s from ALL modul es.
Are any DTCs present or i s the ori gi nal condi ti on sti l l present?
Al l
Yes → Repai r i s not compl ete, refer to the appropri ate symptom.
No → Repai r i s compl ete.
POWERTRAIN VERIFICATION TEST VER - 1 APPLICABILITY
1. I nspect the vehi cl e to ensure that al l engi ne components are properl y i nstal l ed and
connected. Reassembl e and reconnect components as necessary.
2. I nspect the engi ne oi l for contami nati on. I f oi l contami nati on i s suspected, change the oi l and
fi l ter.
3. I f the PCM was not repl aced ski p steps 4 through 6 and conti nue wi th the veri fi cati on.
4. I f the PCM was repl aced the correct VI N and mi l eage must be programmed or a DTC wi l l set
i n the ABS and Ai r Bag modul es. I n addi ti on, i f the vehi cl e i s equi pped wi th Sentry Key
I mmobi l i zer Modul e (SKI M), Secret Key data must be updated to enabl e start.
5. For ABS and Ai r Bag systems: Enter correct VI N and Mi l eage i n PCM. Erase codes i n ABS
and Ai r Bag modul es.
6. For SKI M theft al arm: Connect DRBI I I ௡ to data l i nk conn. Go to Theft Al arm, SKI M, Mi sc.
and pl ace SKI M i n secured access mode, by usi ng the appropri ate PI N code for thi s vehi cl e.
Sel ect Update the Secret Key data. Data wi l l be transferred from SKI M to PCM
7. Attempt to start the engi ne.
8. I f the condi ti ons cannot be dupl i cated, erase al l DTCs.
I s the vehi cl e sti l l unabl e to start and/or are there any DTCs or symptoms remai ni ng?
Al l
Yes → Check for any rel ated Techni cal Servi ce Bul l eti ns and/or refer to the
appropri ate Symptom l i st (Di agnosti c Procedure).
No → Repai r i s compl ete.
227
VERIFICATION TESTS
POWERTRAIN VERIFICATION TEST VER - 2 APPLICABILITY
1. I nspect the vehi cl e to ensure that al l engi ne components are properl y i nstal l ed and
connected. Reassembl e and reconnect components as necessary.
2. I f thi s veri fi cati on procedure i s bei ng performed after a NO TROUBLE CODE repai r, perform
steps 3 and 4.
3. Check to see i f the i ni ti al symptom sti l l exi sts. I f there are no troubl e codes or the symptom
no l onger exi sts, the repai r was successful and testi ng i s compl ete.
4. I f the i ni ti al or another symptom exi sts, the repai r i s not compl ete. Check al l techni cal
servi ce bul l eti ns or fl ash updates and return to Symptoms i f necessary.
5. I f thi s veri fi cati on procedure i s bei ng performed after a DTC repai r, perform steps 6 through
13.
6. Connect the DRBI I I ௡ to the data l i nk connector. Usi ng the DRBI I I ௡ erase any di agnosti c
troubl e codes and reset al l val ues.
7. I f the PCM was not repl aced, ski p steps 8 through 10, then proceed wi th the veri fi cati on.
8. I f the PCM was repl aced the correct VI N and mi l eage must be programmed or a DTC wi l l set
i n the ABS and Ai r Bag modul es. I n addi ti on, i f the vehi cl e i s equi pped wi th Sentry Key
I mmobi l i zer System (SKI S), Secret Key data must be updated to enabl e start.
9. For ABS and Ai r Bag systems: Enter correct VI N and Mi l eage i n PCM. Erase codes i n ABS
and Ai r Bag modul es.
10. For SKI S theft al arm: Connect DRBI I I ௡ to data l i nk conn. Go to Theft Al arm, SKI M, and
Mi sc. Pl ace SKI M i n secured access mode by usi ng the correct PI N code for thi s vehi cl e. Sel ect
Update the Secret Key data. Data wi l l be transferred from SKI M to PCM.
11. Road test the vehi cl e. I f the test i s for an A/C DTC, ensure i t i s operati ng duri ng the
fol l owi ng test.
12. Dri ve the vehi cl e for at l east 5 mi nutes at 64 Km/h (40 mph). Ensure the transmi ssi on shi fts
properl y through al l gears. At some poi nt stop the vehi cl e and turn off the engi ne for at l east
10 seconds.
13. Wi th the DRBI I I ௡, read DTCs.
Are any DTCs or symptoms remai ni ng?
Al l
Yes → Check for any rel ated Techni cal Servi ce Bul l eti ns and/or refer to the
appropri ate Symptom l i st (Di agnosti c Procedure).
No → Repai r i s compl ete.
POWERTRAIN VERIFICATION TEST VER - 3 APPLICABILITY
1. I nspect the vehi cl e to ensure that al l engi ne components are properl y i nstal l ed and
connected. Reassembl e and reconnect components as necessary.
2. Connect the DRBI I I ௡ to the Data Li nk Connector and erase the DTCs.
3. I f the PCM was not repl aced ski p steps 4 through 6 then conti nue the veri fi cati on.
4. I f the PCM was repl aced, the correct VI N and mi l eage must be programmed or a DTC wi l l
set i n the ABS and Ai r Bag modul es. I n addi ti on, i f the vehi cl e i s equi pped wi th Sentry Key
I mmobi l i zer Modul e (SKI M), Secret Key data must be updated to enabl e start.
5. For ABS and Ai r Bag systems: Enter correct VI N and Mi l eage i n PCM. Erase codes i n ABS
and Ai r Bag modul es.
6. For SKI M theft al arm: Connect DRBI I I ௡ to data l i nk conn. Go to Theft Al arm, SKI M, Mi sc.
and pl ace SKI M i n secured access mode, by usi ng the appropri ate PI N code for thi s vehi cl e.
Sel ect Update the Secret Key data. Data wi l l be transferred from SKI M to PCM
7. Perform the generator output test per servi ce manual i nformati on.
8. Start the engi ne and set the engi ne speed to 2000 rpm for at l east 30 seconds.
9. Al l ow the engi ne to return to i dl e.
10. Cycl e the i gni ti on key off then on.
11. Wi th the DRBI I I ௡, read DTCs.
Are any DTCs or symptoms remai ni ng?
Al l
Yes → Check for any rel ated Techni cal Servi ce Bul l eti ns and/or refer to the
appropri ate Symptom l i st (Di agnosti c Procedure).
No → Repai r i s compl ete.
228
VERIFICATION TESTS
Verification Tests — Continued
POWERTRAIN VERIFICATION TEST VER - 4 APPLICABILITY
1. I nspect the vehi cl e to ensure that al l engi ne components are properl y i nstal l ed and
connected. Reassembl e and reconnect components as necessary.
2. Wi th the DRBI I I ௡, erase DTCs.
3. I f the PCM was not repl aced, ski p steps 4 through 6, then conti nue wi th the veri fi cati on.
4. I f the PCM was repl aced, the correct VI N and mi l eage must be programmed or a DTC wi l l
set i n the ABS and Ai r bag modul es. I n addi ti on, i f the vehi cl e i s equi pped wi th entry Key
I mmobi l i zer Modul e (SKI M), Secret Key data must be updated to enabl e start.
5. For ABS and Ai r Bag systems: Enter correct VI N and Mi l eage i n PCM. Erase codes i n ABS
and Ai r Bag modul es.
6. For SKI M theft al arm: Connect DRBI I I ௡ to data l i nk conn. Go to Theft Al arm, SKI M, Mi sc.
and pl ace SKI M i n secured access mode, by usi ng the appropri ate PI N code for thi s vehi cl e.
Sel ect Update the Secret Key data. Data wi l l be transferred from SKI M to PCM
7. Turn the speed control ON (i f equi pped, crui se l i ght wi l l be on).
8. Depress and rel ease the SET Swi tch when the vehi cl e speed i s greater than 35 MPH. The
speed control shoul d engage and mai ntai n the sel ected speed.
9. Depress and hol d the RESUME/ACCEL Swi tch. The vehi cl e speed shoul d i ncrease by at l east
2 mph.
10. Press and hol d the COAST swi tch. The vehi cl e speed shoul d decrease.
11. Usi ng cauti on, depress and rel ease the brake pedal . The speed control shoul d di sengage.
12. Bri ng the vehi cl e speed back up to 35 MPH.
13. Depress the RESUME/ACCEL swi tch. The speed control shoul d resume the previ ousl y set
speed.
14. Hol d down the SET swi tch. The vehi cl e shoul d decel erate.
15. Ensure vehi cl e speed i s greater than 35 mph and rel ease the SET Swi tch. The vehi cl e
shoul d adjust and set a new vehi cl e speed.
16. Depress and rel ease the CANCEL swi tch. The speed control shoul d di sengage.
17. Bri ng the vehi cl e speed back up above 35 mph and engage speed control .
18. Depress the OFF swi tch to turn OFF, (Crui se l i ght wi l l be off). The speed control shoul d
di sengage.
19. NOTE: OVERSHOOT/UNDERSHOOT FOLLOWI NG SPEED CONTROL SET.
20. I f the vehi cl e operator repeatedl y presses and rel eases the SET button wi th thei r foot off of
the accel erator (referred to as Љl i ft foot setЉ), the vehi cl e may accel erate and exceed the desi red
set speed by up to 5 mph (8 km/h).
21. I t may al so decel erate to l ess than the desi red set speed, before fi nal l y achi evi ng the desi red
set speed.
22. The Speed Control System has an adapti ve strategy that compensates for vehi cl e-to-vehi cl e
vari ati ons i n speed control cabl e l engths.
23. When the speed control i s set wi th the vehi cl es operators foot off of the accel erator pedal ,
the speed control thi nks there i s excessi ve speed control cabl e sl ack and adapts accordi ngl y.
24. I f the Љl i ft foot setsЉ are conti nual l y used, a speed control overshoot/undershoot condi ti on
wi l l devel op.
25. To Љunl earnЉ the overshoot/undershoot condi ti on, the vehi cl e operator has to press and
rel ease the set button whi l e mai ntai ni ng the desi red set speed usi ng the accel erator pedal (not
decel erati ng or accel erati ng).
26. Then turni ng the crui se control swi tch to the OFF posi ti on (or press the CANCEL button i f
equi pped) after wai ti ng 10 seconds.
27. Thi s procedure must be performed approxi matel y 10-15 ti mes to compl etel y unl earn the
overshoot/undershoot condi ti on.
Di d the Speed Control pass the above test?
Al l
Yes → Repai r i s compl ete.
No → Check for any rel ated Techni cal Servi ce Bul l eti ns and/or refer to the
appropri ate Symptom l i st (Di agnosti c Procedure).
229
VERIFICATION TESTS
Verification Tests — Continued
POWERTRAIN VERIFICATION TEST VER - 5 APPLICABILITY
1. I nspect the vehi cl e to ensure that al l engi ne components are properl y i nstal l ed and
connected. Reassembl e and reconnect components as necessary.
2. I f any exi sti ng di agnosti c troubl e codes have not been repai red, go to the appropri ate
Symptom Li st and fol l ow path speci fi ed.
3. Connect the DRBI I I ௡ to the data l i nk connector.
4. Ensure the fuel tank has at l east a quarter tank of fuel . Turn off al l accessori es.
5. I f the PCM was not repl aced ski p steps 6 through 8 and conti nue the veri fi cati on.
6. I f the PCM was repl aced, the correct VI N and mi l eage must be programmed or a DTC wi l l
set i n the ABS and Ai r Bag modul es. I n addi ti on, i f the vehi cl e i s equi pped wi th entry Key
I mmobi l i zer Modul e (SKI M), Secret Key data must be updated to enabl e start.
7. For ABS and Ai r Bag systems: Enter correct VI N and Mi l eage i n PCM. Erase codes i n ABS
and Ai r Bag modul es.
8. For SKI M theft al arm: Connect DRBI I I ௡ to data l i nk connectorto Theft Al arm, SKI M, Mi sc.
and pl ace SKI M i n secured access mode by usi ng the appropri ate PI N code for thi s vehi cl e.
Sel ect Update the Secret Key data. Data wi l l be transferred from SKI M to PCM.
9. I f the Catal yst was repl aced, wi th the DRBI I I ௡ go to the mi scel l aneous Menu Opti on
ЉCatal yst Repl acedЉ and press enter.
10. I f a Comprehensi ve Component DTC was repai red, perform steps 11 and 13. I f a Major OBD
I I Moni tor DTC was repai red ski p step 11 and conti nue veri fi cati on.
11. After the i gni ti on has been off for at l east 10 seconds, restart the vehi cl e and run 2 mi nutes.
12. Wi th the DRBI I I ௡, moni tor the appropri ate pre-test enabl i ng condi ti ons unti l al l condi ti ons
have been met. Once the condi ti ons have been met, swi tch screen to the appropri ate OBDI I
moni tor, (Audi bl e beeps when the moni tor i s runni ng).
13. I f the condi ti ons cannot be dupl i cated, erase al l DTC wi th the DRBI I I ௡.
Di d the OBD I I moni tor run successful l y and has the Good Tri p Counter changed to one or
more?
Al l
Yes → Repai r i s compl ete.
No → Check for any rel ated Techni cal Servi ce Bul l eti ns and/or refer to the
appropri ate Symptom l i st (Di agnosti c Procedure).
230
VERIFICATION TESTS
Verification Tests — Continued
POWERTRAIN VERIFICATION TEST VER - 6 APPLICABILITY
1. I nspect the vehi cl e to ensure that al l engi ne components are properl y i nstal l ed and
connected. Reassembl e and reconnect components as necessary.
2. I f al l DTCs have not been repai red, go to the symptom l i st and fol l ow the path speci fi ed. After
al l DTCs have been repai red, return to TEST VER-6 and, wi th the DRBI I I ௡ i n System Tests,
perform the LDP Moni tor Test.
3. I f the PCM was not repl aced, ski p steps 4 through 6 then conti nue wi th the veri fi cati on.
4. I f the PCM was repl aced, the correct VI N and mi l eage must be programmed or a DTC wi l l
set i n the ABS and Ai r Bag modul es. I n addi ti on, i f the vehi cl e i s equi pped wi th a Sentry Key
I mmobi l i zer Modul e (SKI M), Secret Key data must be updated to enabl e start.
5. For ABS and Ai rbag Systems: Enter correct VI N and Mi l eage i n PCM. Erase codes i n ABS
and Ai rbag modul es.
6. For SKI M theft al arm: Connect DRBI I I ௡ to data l i nk conn. Go to Theft Al arm, SKI M, Mi sc.
and pl ace SKI M i n secured access mode, by usi ng the appropri ate PI N code for thi s vehi cl e.
Sel ect Update the Secret Key data. Data wi l l be transferred from SKI M to PCM
7. The LDP Moni tor Test i s a useful way to run a total LDP system performance test. Use thi s
test to veri fy any type of LDP system repai r.
8. Connect the DRBI I I ௡ to the data l i nk connector. Engi ne runni ng, turn off al l accessori es.
Wi th the DRBI I I ௡ i n System Tests, perform the LDP Moni tor Test.
9. Note: Whi l e test i s bei ng performed, PCM must see RPM, mi ni mum MAP, No Vehi cl e speed
and mi ni mum Throttl e Posi ti on sensor (At i dl e, i n park.)
Di d the LDP Moni tor Test fai l and/or have any DTCs set?
Al l
Yes → Check for any rel ated Techni cal Servi ce Bul l eti ns and/or refer to the
apopropri ate Symptom l i st (Di agnosti c Procedure)
No → Repai r i s compl ete.
SKIS VERIFICATION APPLICABILITY
1. Reconnect al l previ ousl y di sconnected components and connectors.
2. Obtai n the vehi cl e’s uni que Personal I denti fi cati on Number (PI N) assi gned to i t’s ori gi nal
SKI M. Thi s number can be obtai ned from the vehi cl e’s i nvoi ce or Chrysl er’s Customer Center
(1-800-992-1997).
3. NOTE: When entering the PIN, care should be taken because the SKIM will only
allow3consecutiveattemptstoenter thecorrect PIN. If 3consecutiveincorrect PINs
are entered, the SKIM will Lock Out the DRB for 1 hour.
4. To exi t Lock Out mode, the i gni ti on key must remai n i n the Run posi ti on conti nual l y for 1
hour. Turn off al l accessori es and connect a battery charger i f necessary.
5. Wi th the DRB, sel ect Theft Al arm, SKI M and Mi scel l aneous. Then, sel ect the desi red
procedure and fol l ow the steps that wi l l be di spl ayed.
6. I f the SKI M has been repl aced, ensure al l of the vehi cl e i gni ti on keys are programmed to the
new SKI M.
7. NOTE:Prior toreturningvehicletothecustomer, performamodulescantobesure
that all DTCs are erased. Erase any DTCs that are found.
8. Wi th the DRB, erase al l DTCs. Perform 5 i gni ti on key cycl es l eavi ng the key on for at l east
90 seconds per cycl e.
9. Wi th the DRB, read the SKI M DTCs.
Are there any SKI M DTCs?
Al l
Yes → Repai r i s not compl ete, refer to appropri ate symptom.
No → Repai r i s compl ete.
231
VERIFICATION TESTS
Verification Tests — Continued
NOTES
232
8.0 COMPONENT LOCATIONS
8. 1 CONTROL MODULES AND PDC
8. 2 DATA LINK CONNECTOR
C
O
M
P
O
N
E
N
T
L
O
C
A
T
I
O
N
S
233
COMPONENT LOCATIONS
8. 3 SENSORS AND SOLENOIDS
4.0L
2.4L 4.0L
2.4L 4.0L
C
O
M
P
O
N
E
N
T
L
O
C
A
T
I
O
N
S
234
COMPONENT LOCATIONS
2.4L 2.4L
4.0L 2.4L
2.4L
2.4L
C
O
M
P
O
N
E
N
T
L
O
C
A
T
I
O
N
S
235
COMPONENT LOCATIONS
4.0L
1/1 Federal & BUX 1/2 Federal & BUX
1/1 and 2/1 Calif & EURO III 1/2 and 2/2 Calif. & EURO III
C
O
M
P
O
N
E
N
T
L
O
C
A
T
I
O
N
S
236
COMPONENT LOCATIONS
8. 3 SENSORS AND SOLENOIDS (Continued)
1.2 Calif. & EURO III
8. 4 FUEL SYSTEM
C
O
M
P
O
N
E
N
T
L
O
C
A
T
I
O
N
S
237
COMPONENT LOCATIONS
8. 5 SWITCHES
C
O
M
P
O
N
E
N
T
L
O
C
A
T
I
O
N
S
238
COMPONENT LOCATIONS
8. 4 FUEL SYSTEM (Continued)
9.0 CONNECTOR PINOUTS
A/C COMPRESSOR CLUTCH - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 C3 18DB/BK (2.4L) A/C CLUTCH RELAY OUTPUT
1 C3 20DB/BK (4.0L) A/C COMPRESSOR CLUTCH RELAY OUTPUT
2 Z246 18BK/OR (2.4L) GROUND
2 Z1 20BK (4.0L) GROUND
A/C HIGH PRESSURE SWITCH (4. 0L) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 C90 20LG A/C SELECT SIGNAL
2 C22 20DB/WT A/C SWITCH SIGNAL
A/C LOW PRESSURE SWITCH (2. 4L) - GREEN 2 WAY
CAV CIRCUIT FUNCTION
1 C21 18DB/OR A/C REQUEST SIGNAL
2 C90 20LG A/C SELECT SIGNAL
A/C LOW PRESSURE SWITCH (4. 0L) - GREEN 2 WAY
CAV CIRCUIT FUNCTION
1 C21 20DB/OR A/C REQUEST SIGNAL
2 C22 20DB/WT A/C SWITCH SIGNAL
C
O
N
N
E
C
T
O
R
P
I
N
O
U
T
S
239
CONNECTOR PINOUTS
A/C PRESSURE TRANSDUCER (2. 4L) - 4 WAY
CAV CIRCUIT FUNCTION
1 K4 20BK/LB SENSOR GROUND 1
2 K6 20VT/WT 5 VOLT SUPPLY
3 C18 18DB A/C PRESSURE SIGNAL
4 - -
BATTERY TEMPERATURE SENSOR - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 K118 18PK/YL BATTERY TEMPERATURE SENSOR SIGNAL
2 K4 20BK/LB SENSOR GROUND 1
BRAKE LAMP SWITCH - GRAY 6 WAY
CAV CIRCUIT FUNCTION
1 K29 20WT/PK BRAKE LAMP SWITCH SENSE
1 K29 20WT/PK BRAKE LAMP SWITCH SENSE
2 Z1 20BK/WT GROUND
3 V32 20YL/RD SPEED CONTROL ON/OFF SWITCH SENSE
4 V30 20DB/RD SPEED CONTROL BRAKE LAMP SWITCH OUTPUT
5 F32 18PK/DB FUSED B(+)
6 L50 18WT/TN BRAKE LAMP SWITCH OUTPUT
BRAKE TRANSMISSION SHIFT INTERLOCK SOLENOID - WHITE 2 WAY
CAV CIRCUIT FUNCTION
1 K29 20WT/PK BRAKE LAMP SWITCH SENSE
2 G5 20DB/WT FUSED IGNITION SWITCH OUTPUT (RUN-START)
CAMSHAFT POSITION SENSOR (2. 4L) - BLACK 3 WAY
CAV CIRCUIT FUNCTION
1 K7 18OR 5 VOLT SUPPLY
2 K4 18BK/LB SENSOR GROUND 1
3 K44 18TN/YL CMP SIGNAL
C
O
N
N
E
C
T
O
R
P
I
N
O
U
T
S
240
CONNECTOR PINOUTS
CAMSHAFT POSITION SENSOR (4. 0L) - 3 WAY
CAV CIRCUIT FUNCTION
1 K44 18TN/YL CMP SIGNAL
2 K4 20BK/LB SENSOR GROUND 1
3 K7 20OR 5V SUPPLY
CLOCKSPRING C1 - 4 WAY
CAV CIRCUIT FUNCTION
1 X3 20RD/YL HORN RELAY CONTROL
2 V37 20RD/LG (EXCEPT
RHD HARDTOP SUB-
WOOFER)
SPEED CONTROL SWITCH SIGNAL
2 V37 20RD/LB (RHD HARD-
TOP SUBWOOFER)
SPEED CONTROL SWITCH SIGNAL
3 K4 20BK/LB SENSOR GROUND 1
4 - -
CLUTCH PEDAL POSITION SWITCH (M/T) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 T141 18YL/RD FUSED IGNITION SWITCH OUTPUT (START)
2 A41 18YL FUSED IGNITION SWITCH OUTPUT (START)
CRANKSHAFT POSITION SENSOR (2. 4L/4. 0L A/T) - BLACK 3 WAY
CAV CIRCUIT FUNCTION
1 K24 18GY/BK (2.4L) CRANKSHAFT POSITION SENSOR SIGNAL
1 K7 20OR (4.0L) 5V SUPPLY
2 K4 20BK/LB SENSOR GROUND 1
2 K4 18BK/LB (2.4L) SENSOR GROUND 1
3 K7 18OR (2.4L) 5V SUPPLY
3 K24 18GY/BK (4.0L) CRANKSHAFT POSITION SENSOR SIGNAL
CRANKSHAFT POSITION SENSOR (4. 0L M/T) - 3 WAY
CAV CIRCUIT FUNCTION
1 K24 18GY/BK CRANKSHAFT POSITION SENSOR SIGNAL
2 K4 20BK/LB SENSOR GROUND 1
3 K7 20OR 5 VOLT SUPPLY
C
O
N
N
E
C
T
O
R
P
I
N
O
U
T
S
241
CONNECTOR PINOUTS
DATA LINK CONNECTOR - BLACK 16 WAY
CAV CIRCUIT FUNCTION
1 - -
2 D25 20VT/YL PCI BUS
3 - -
4 Z2 20BK/LG GROUND
5 Z12 20BK/TN GROUND
6 D32 20LG/WT SCI RECEIVE
7 D21 20PK SCI TRANSMIT
8 - -
9 D23 20WT/BR FLASH PROGRAM ENABLE
10 - -
11 - -
12 - -
13 - -
14 D20 20LG/PK SCI RECEIVE
15 - -
16 M1 20PK/WT FUSED B(+)
ENGINE COOLANT TEMPERATURE SENSOR - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 K4 18BK/LB (2.4L) SENSOR GROUND 1
1 K4 20BK/LB (4.0L) SENSOR GROUND 1
2 K2 18TN/BK ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
ENGINE OIL PRESSURE SWITCH - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 G60 18GY/YL OIL PRESSURE SIGNAL
2 - -
EVAP/PURGE SOLENOID - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 K52 18PK/BK EVAP/PURGE SOLENOID CONTROL
2 F12 20RD/LG FUSED IGNITION SWITCH OUTPUT (RUN-START)
C
O
N
N
E
C
T
O
R
P
I
N
O
U
T
S
242
CONNECTOR PINOUTS
FUEL INJECTOR NO. 1 (2. 4L) - 2 WAY
CAV CIRCUIT FUNCTION
1 F142 18OR/DG FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT
2 K11 18WT/DB FUEL INJ ECTOR NO. 1 DRIVER
FUEL INJECTOR NO. 1 (4. 0L) - 2 WAY
CAV CIRCUIT FUNCTION
1 F42 18DG/LG FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT
2 K11 18WT/DB FUEL INJ ECTOR NO. 1 DRIVER
FUEL INJECTOR NO. 2 (2. 4L) - 2 WAY
CAV CIRCUIT FUNCTION
1 F142 18OR/DG FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT
2 K12 18TN FUEL INJ ECTOR NO. 2 DRIVER
FUEL INJECTOR NO. 2 (4. 0L) - 2 WAY
CAV CIRCUIT FUNCTION
1 F42 18DG/LG FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT
2 K12 18TN FUEL INJ ECTOR NO. 2 DRIVER
FUEL INJECTOR NO. 3 (2. 4L) - 2 WAY
CAV CIRCUIT FUNCTION
1 F142 18OR/DG FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT
2 K13 18YL/WT FUEL INJ ECTOR NO. 3 DRIVER
FUEL INJECTOR NO. 3 (4. 0L) - 2 WAY
CAV CIRCUIT FUNCTION
1 F42 18DG/LG FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT
2 K13 18YL/WT FUEL INJ ECTOR NO. 3 DRIVER
C
O
N
N
E
C
T
O
R
P
I
N
O
U
T
S
243
CONNECTOR PINOUTS
FUEL INJECTOR NO. 4 (2. 4L) - 2 WAY
CAV CIRCUIT FUNCTION
1 F142 18OR/DG FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT
2 K14 18LB/BR FUEL INJ ECTOR NO. 4 DRIVER
FUEL INJECTOR NO. 4 (4. 0L) - 2 WAY
CAV CIRCUIT FUNCTION
1 F42 18DG/LG FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT
2 K14 18LB/BR FUEL INJ ECTOR NO. 4 DRIVER
FUEL INJECTOR NO. 5 (4. 0L) - 2 WAY
CAV CIRCUIT FUNCTION
1 F42 18DG/LG FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT
2 K38 18GY FUEL INJ ECTOR NO. 5 DRIVER
FUEL INJECTOR NO. 6 (4. 0L) - 2 WAY
CAV CIRCUIT FUNCTION
1 F42 18DG/LG FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT
2 K58 18BR/DB FUEL INJ ECTOR NO. 6 DRIVER
FUEL PUMP MODULE - 4 WAY
CAV CIRCUIT FUNCTION
1 A141 18DG/WT FUEL PUMP RELAY OUTPUT
2 K226 20DB/LG FUEL LEVEL SENSOR SIGNAL
3 K4 20BK/LB SENSOR GROUND 1
4 Z1 18BK GROUND
C
O
N
N
E
C
T
O
R
P
I
N
O
U
T
S
244
CONNECTOR PINOUTS
C
O
N
N
E
C
T
O
R
P
I
N
O
U
T
S
245
CONNECTOR PINOUTS
FUSES (FUSE/RELAY BLOCK)
FUSE
NO.
AMPS FUSED CIRCUIT FUNCTION
1 20A F33 18PK/RD FUSED B(+)
1 20A F33 20PK/RD FUSED B(+)
2 20A F32 18PK/DB FUSED B(+)
3 20A X13 16BK/RD (SUBWOOFER) FUSED B(+)
4 10A Z1 20BK DOOR AJ AR SWITCH OUTPUT
5 10A F23 18DB/YL FUSED IGNITION SWITCH OUTPUT (RUN)
6 20A V23 18BR/PK (HARD TOP) FUSED IGNITION SWITCH OUTPUT (RUN)
7 10A F20 20VT/WT FUSED IGNITION SWITCH OUTPUT (RUN)
8 10A F24 20RD/DG FUSED IGNITION SWITCH OUTPUT (RUN)
9 10A F14 18LG/YL FUSED IGNITION SWITCH OUTPUT (RUN)
9 10A F14 18LG/YL (PAD) FUSED IGNITION SWITCH OUTPUT (RUN)
10 10A G5 20DB/WT FUSED IGNITION SWITCH OUTPUT (RUN-START)
10 10A G5 20DB/WT FUSED IGNITION SWITCH OUTPUT (RUN-START)
11 10A F12 20RD/LG FUSED IGNITION SWITCH OUTPUT (RUN-START)
12 10A F15 20DB FUSED IGNITION SWITCH OUTPUT (RUN-START)
12 10A F15 20DB FUSED IGNITION SWITCH OUTPUT (RUN-START)
13 10A L5 20BK/GY FUSED IGNITION SWITCH OUTPUT (RUN-START)
14 10A X12 20PK FUSED IGNITION SWITCH OUTPUT (RUN-START)
15 10A F81 20DB/RD (HARD TOP) FUSED REAR WINDOW DEFOGGER RELAY OUTPUT
16 10A L22 20LG/DG (EXPORT) DIMMER SWITCH LOW BEAM OUTPUT
16 10A L22 20LG/DG (EXPORT) FUSED IGNITION SWITCH OUTPUT (RUN-START)
17 25A V6 16PK/BK FUSED IGNITION SWITCH OUTPUT (RUN-START)
17 25A V6 16PK/BK FUSED IGNITION SWITCH OUTPUT (RUN-START)
18 20A F38 16LB/WT FUSED IGNITION SWITCH OUTPUT (RUN)
19 20A - -
20 20A T141 18YL/RD FUSED IGNITION SWITCH OUTPUT (START)
20 20A T141 18YL/RD FUSED IGNITION SWITCH OUTPUT (START)
GENERATOR - 3 WAY
CAV CIRCUIT FUNCTION
1 - FIELD WIRES
2 - FIELD WIRE CONNECTOR
3 - B(+) (OUTPUT TERMINAL)
C
O
N
N
E
C
T
O
R
P
I
N
O
U
T
S
246
CONNECTOR PINOUTS
GENERATOR - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 K125 18WT/DB GENERATOR SOURCE
2 K20 18DG GENERATOR FIELD
IDLE AIR CONTROL MOTOR - BLACK 4 WAY
CAV CIRCUIT FUNCTION
1 K59 18VT/BK IDLE AIR CONTROL NO. 4 DRIVER
2 K40 18BR/WT IDLE AIR CONTROL NO. 3 DRIVER
3 K60 18YL/BK IDLE AIR CONTROL NO. 2 DRIVER
4 K39 18GY/RD IDLE AIR CONTROL NO. 1 DRIVER
IGNITION COIL PACK (2. 4L) - BLACK 3 WAY
CAV CIRCUIT FUNCTION
1 K17 18DB/TN IGNITION COIL NO. 2 DRIVER
2 F42 18DG/LG FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT
3 K19 18GY IGNITION COIL NO. 1 DRIVER
IGNITION COIL PACK (4. 0L) - BLACK 4 WAY
CAV CIRCUIT FUNCTION
1 K19 18BK/GY IGNITION COIL NO. 1 DRIVER
2 F42 18DG/LG FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT
3 K17 18DB/TN IGNITION COIL NO. 2 DRIVER
4 K18 18RD/YL IGNITION COIL NO. 3 DRIVER
C
O
N
N
E
C
T
O
R
P
I
N
O
U
T
S
247
CONNECTOR PINOUTS
IGNITION SWITCH - 10 WAY
CAV CIRCUIT FUNCTION
1 A1 18RD FUSED B(+)
2 A21 18DB IGNITION SWITCH OUTPUT (RUN-START)
3 F22 12WT/PK IGNITION SWITCH OUTPUT (RUN-ACC)
4 F30 12RD/PK FUSED B(+)
5 G26 20LB KEY-IN IGNITION SWITCH SENSE
6 A41 18YL IGNITION SWITCH OUTPUT (START)
7 A31 18BK/DG IGNITION SWITCH OUTPUT (RUN-ACC)
8 A22 14BK/OR IGNITION SWITCH OUTPUT (RUN)
9 A2 14PK/BK FUSED B(+)
10 Z1 16BK GROUND
INTAKE AIR TEMPERATURE SENSOR - GRAY 2 WAY
CAV CIRCUIT FUNCTION
1 K4 18BK/LB (2.4L) SENSOR GROUND 1
1 K4 20BK/LB (4.0L) SENSOR GROUND 1
2 K21 18BK/RD INTAKE AIR TEMPERATURE SENSOR SIGNAL
LEAK DETECTION PUMP - BLACK 4 WAY
CAV CIRCUIT FUNCTION
1 - -
2 K125 18WT/DB GENERATOR SOURCE
3 K106 18WT/DG LEAK DETECTION PUMP SOLENOID CONTROL
4 K107 18OR LEAK DETECTION PUMP SWITCH SENSE
MANIFOLD ABSOLUTE PRESSURE SENSOR (2. 4L) - BLACK 3 WAY
CAV CIRCUIT FUNCTION
1 K1 18DG/RD MAP SIGNAL
2 K4 18BK/LB SENSOR GROUND 1
3 K7 18OR 5 VOLT SUPPLY
C
O
N
N
E
C
T
O
R
P
I
N
O
U
T
S
248
CONNECTOR PINOUTS
MANIFOLD ABSOLUTE PRESSURE SENSOR (4. 0L) - 3 WAY
CAV CIRCUIT FUNCTION
1 K1 18DG/RD MAP SIGNAL
2 K4 20BK/LB SENSOR GROUND 1
3 K7 20OR 5V SUPPLY
OVERDRIVE OFF SWITCH - 4 WAY
CAV CIRCUIT FUNCTION
1 Z1 20BK GROUND
2 T6 18OR/WT OVERDRIVE OFF SWITCH SENSE
3 T56 18DG/LB OVERDRIVE OFF SWITCH INDICATOR
4 E2 20OR PANEL LAMPS FEED
OXYGEN SENSOR 1/1 UPSTREAM - 4 WAY
CAV CIRCUIT FUNCTION
1 F142 18OR/DG FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT
2 K99 18BR/OR OXYGEN SENSOR 1/1 HEATER CONTROL
3 K4 20BK/LB SENSOR GROUND 1
4 K41 18BK/DG OXYGEN SENSOR 1/1 SIGNAL
OXYGEN SENSOR 1/2 DOWNSTREAM - BLACK 4 WAY
0
CAV CIRCUIT FUNCTION
1 F142 18OR/DG (EXCEPT
EXPORT/J APAN LOW
EMISSION VEHICLE)
FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT
1 A242 18VT/OR (EXPORT/
J APAN LOW EMISSIONS
VEHICLE)
OXYGEN SENSOR DOWNSTREAM HEATER RELAY OUTPUT
2 K299 18BR/WT (EXCEPT
EXPORT/J APAN LOW
EMISSION VEHICLE)
OXYGEN SENSOR 1/2 HEATER CONTROL
2 Z1 18BK (EXPORT/J APAN
LOW EMISSIONS VEHI-
CLE)
GROUND
3 K4 20BK/LB SENSOR GROUND 1
4 K141 18TN/WT OXYGEN SENSOR 1/2 SIGNAL
C
O
N
N
E
C
T
O
R
P
I
N
O
U
T
S
249
CONNECTOR PINOUTS
OXYGEN SENSOR 2/1 UPSTREAM (EXCEPT EXPORT/JAPAN LOW EMISSION VEHICLE) - 4 WAY
CAV CIRCUIT FUNCTION
1 F142 18OR/DG FUSED AUTO SHUT DOWN RELAY OUTPUT
2 K299 18BR/WT O2 SENSOR 2/1 HEATER CONTROL
3 K4 20BK/LB SENSOR GROUND 1
4 K241 18LG/RD OXYGEN SENSOR 2/1 SIGNAL
OXYGEN SENSOR 2/2 DOWNSTREAM (EXCEPT EXPORT/JAPAN LOW EMISSION VEHICLE) - 4
WAY
CAV CIRCUIT FUNCTION
1 A242 18VT/OR OXYGEN SENSOR DOWNSTREAM HEATER RELAY OUTPUT
2 Z1 18BK GROUND
3 K4 20BK/LB SENSOR GROUND 1
4 K341 18TN/WT OXYGEN SENSOR 2/2 SIGNAL
C
O
N
N
E
C
T
O
R
P
I
N
O
U
T
S
250
CONNECTOR PINOUTS
C
O
N
N
E
C
T
O
R
P
I
N
O
U
T
S
251
CONNECTOR PINOUTS
FUSES (PDC)
FUSE
NO.
AMPS FUSED CIRCUIT FUNCTION
1 40A A111 12RD/LB FUSED B(+)
2 40A A4 12BK/PK FUSED B(+)
3 40A A6 12RD/BK FUSED B(+)
4 40A A16 12GY (2.4L) FUSED B(+)
5 20A A30 16RD/WT (A/T) FUSED B(+)
6 30A A2 14PK/BK FUSED B(+)
7 - - -
8 40A A10 12RD/DG (ABS) FUSED B(+)
9 30A A14 14RD/WT FUSED B(+)
9 30A A14 14RD/WT FUSED B(+)
10 40A A3 12RD/WT FUSED B(+)
11 - - -
12 30A A20 12RD/DB (ABS) FUSED B(+)
13 40A F30 12RD/PK FUSED B(+)
14 - - -
15 50A M1 16PK/WT FUSED B(+)
15 50A M1 20PK/WT (ABS) FUSED B(+)
16 15A A142 14DG/PK AUTOMATIC SHUT DOWN RELAY OUTPUT
16 15A F142 18OR/DG AUTOMATIC SHUT DOWN RELAY OUTPUT
17 20A F70 16PK/BK FUSED B(+)
18 20A F31 18VT FUSED B(+)
18 20A F31 18VT FUSED B(+)
19 20A F39 16PK/LG (FRONT FOG LAMPS) FUSED B(+)
20 15A F60 16RD/WT FUSED B(+)
21 10A A17 20RD/GY FUSED B(+)
22 20A A1 18RD FUSED B(+)
23 20A A61 18DG/BK FUSED B(+)
24 20A A88 18RD/DB (OFF-ROAD PACKAGE) FUSED B(+)
25 - - -
26 10A M1 20PK/WT FUSED B(+)
27 20A L9 18BK/WT FUSED B(+)
28 20A F42 18DG/LG AUTOMATIC SHUT DOWN RELAY OUTPUT
28 20A A142 14DG/PK AUTOMATIC SHUT DOWN RELAY OUTPUT
A/C COMPRESSOR CLUTCH RELAY (IN PDC)
CAV CIRCUIT FUNCTION
A6 F12 20RD/LG FUSED IGNITION SWITCH OUTPUT (RUN-START)
A7 - -
A8 C13 18DB/OR A/C COMPRESSOR CLUTCH RELAY CONTROL
A9 C3 20DB/BK A/C COMPRESSOR CLUTCH RELAY OUTPUT
A10 A17 20RD/GY FUSED B(+)
AUTOMATIC SHUT DOWN RELAY (IN PDC)
CAV CIRCUIT FUNCTION
A11 K51 18DB/YL AUTOMATIC SHUT DOWN RELAY CONTROL
A12 - -
A13 F15 20DB FUSED IGNITION SWITCH OUTPUT (RUN-START)
A13 F15 20DB FUSED IGNITION SWITCH OUTPUT (RUN-START)
A14 A142 14DG/PK AUTOMATIC SHUT DOWN RELAY OUTPUT
A15 A14 14RD/WT FUSED B(+)
C
O
N
N
E
C
T
O
R
P
I
N
O
U
T
S
252
CONNECTOR PINOUTS
ENGINE STARTER MOTOR RELAY (IN PDC)
CAV CIRCUIT FUNCTION
B1 A2 14PK/BK FUSED B(+)
B2 T40 12BR (ABS) ENGINE STARTER MOTOR RELAY OUTPUT
B2 T40 14BR (EXCEPT ABS) ENGINE STARTER MOTOR RELAY OUTPUT
B3 T41 20BR/LB PARK/NEUTRAL POSITION SWITCH SENSE
B4 - -
B5 T141 18YL/RD FUSED IGNITION SWITCH OUTPUT (START)
FUEL PUMP RELAY (IN PDC)
CAV CIRCUIT FUNCTION
C6 F15 20DB FUSED IGNITION SWITCH OUTPUT (RUN-START)
C6 F15 20DB FUSED IGNITION SWITCH OUTPUT (RUN-START)
C7 - -
C8 K31 18BR FUEL PUMP RELAY CONTROL
C9 A141 18DG/WT FUEL PUMP RELAY OUTPUT
C10 A61 18DG/BK FUSED B(+)
HIGH SPEED RADIATOR FAN RELAY (2. 4L)
CAV CIRCUIT FUNCTION
D10 A16 12GY FUSED B(+)
D11 C27 18DB HIGH SPEED RADIATOR FAN RELAY CONTROL
D13 F20 20VT/WT FUSED IGNITION SWITCH OUTPUT (RUN-START)
D14 C25 12YL HIGH SPEED RADIATOR FAN RELAY OUTPUT
LOW SPEED RADIATOR FAN RELAY (2. 4L)
CAV CIRCUIT FUNCTION
D2 A16 12GY FUSED B(+)
D4 F20 20VT/WT FUSED IGNITION SWITCH OUTPUT (RUN-START)
D4 F20 20VT/WT FUSED IGNITION SWITCH OUTPUT (RUN-START)
D6 C24 18DB/PK LOW SPEED RADIATOR FAN RELAY CONTROL
D8 C23 12DG LOW SPEED RADIATOR FAN RELAY OUTPUT
OXYGEN SENSOR DOWNSTREAM HEATER RELAY
CAV CIRCUIT FUNCTION
B11 F142 18OR/DG FUSED ASD RELAY OUTPUT
B11 F142 18OR/DG FUSED ASD RELAY OUTPUT
B12 A242 18VT/OR OXYGEN SENSOR DOWNSTREAM HEATER RELAY OUTPUT
B13 F142 18OR/DG FUSED ASD RELAY OUTPUT
B13 F142 18OR/DG FUSED ASD RELAY OUTPUT
B14 - -
B15 K512 18RD/YL OXYGEN SENSOR DOWNSTREAM HEATER RELAY OUTPUT
C
O
N
N
E
C
T
O
R
P
I
N
O
U
T
S
253
CONNECTOR PINOUTS
POWER STEERING PRESSURE SWITCH (2. 4L) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 K10 18DB/OR POWER STEERING PRESSURE SWITCH SENSE
2 Z1 20BK GROUND
POWERTRAIN CONTROL MODULE C1 - BLACK 32 WAY
CAV CIRCUIT FUNCTION
1 K18 18RD/YL (4.0L) IGNITION COIL NO. 3 DRIVER
2 F15 18DB/WT FUSED IGNITION SWITCH OUTPUT (RUN-START)
3 - -
4 K4 18BK/LB SENSOR GROUND 1
5 - -
6 T41 18BK/WT PARK/NEUTRAL POSITION SWITCH SENSE
7 K19 18BK/GY IGNITION COIL NO. 1 DRIVER
8 K24 18GY/BK CRANKSHAFT POSITION SENSOR SIGNAL
9 - -
10 K60 18YL/BK IDLE AIR CONTROL NO. 2 DRIVER
11 K40 18BR/WT IDLE AIR CONTROL NO. 3 DRIVER
12 K10 18DB/OR (2.4L) POWER STEERING PRESSURE SWITCH SENSE
13 T141 18YL/RD FUSED IGNITION SWITCH OUTPUT (START)
14 - -
15 K21 18BK/RD INTAKE AIR TEMPERATURE SENSOR SIGNAL
16 K2 18TN/BK ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
17 K7 18OR 5V SUPPLY
18 K44 18TN/YL CMP SIGNAL
19 K39 18GY/RD IDLE AIR CONTROL NO. 1 DRIVER
20 K59 18VT/BK IDLE AIR CONTROL NO. 4 DRIVER
21 - -
22 A14 14RD/WT FUSED B(+)
23 K22 18OR/DB THROTTLE POSITION SENSOR SIGNAL
24 K41 18BK/DG OXYGEN SENSOR 1/1 SIGNAL
25 K141 18TN/WT OXYGEN SENSOR 1/2 SIGNAL
26 K241 18LG/RD (4.0L EX-
CEPT EXPORT/4.0L J APAN
LOW EMISSION VEHICLE)
OXYGEN SENSOR 2/1 SIGNAL
27 K1 18DG/RD MAP SIGNAL
28 - -
29 K341 18TN/WT (4.0L EX-
CEPT EXPORT/4.0L J APAN
LOW EMISSION VEHICLE)
OXYGEN SENSOR 2/2 SIGNAL
30 - -
31 Z12 14BK/TN GROUND
32 Z12 14BK/TN GROUND
C
O
N
N
E
C
T
O
R
P
I
N
O
U
T
S
254
CONNECTOR PINOUTS
POWERTRAIN CONTROL MODULE C2 - WHITE 32 WAY
CAV CIRCUIT FUNCTION
1 - -
2 - -
3 - -
4 K11 18WT/DB FUEL INJ ECTOR NO. 1 DRIVER
5 K13 18YL/WT FUEL INJ ECTOR NO. 3 DRIVER
6 K38 18GY (4.0L) FUEL INJ ECTOR NO. 5 DRIVER
7 - -
8 - -
9 K17 18DB/TN IGNITION COIL NO. 2 DRIVER
10 K20 18DG GENERATOR FIELD
11 - -
12 K58 18BR/DB (4.0L) FUEL INJ ECTOR NO. 6 DRIVER
13 - -
14 - -
15 K12 18TN FUEL INJ ECTOR NO. 2 DRIVER
16 K14 18LB/BR FUEL INJ ECTOR NO. 4 DRIVER
17 - -
18 - -
19 C18 18DB (2.4L) A/C PRESSURE SIGNAL
20 - -
21 - -
22 - -
23 G60 18GY/YL ENGINE OIL PRESSURE SIGNAL
24 - -
25 - -
26 - -
27 G7 18WT/OR VEHICLE SPEED SENSOR SIGNAL
28 - -
29 - -
30 - -
31 K6 18VT/WT 5V SUPPLY
32 - -
C
O
N
N
E
C
T
O
R
P
I
N
O
U
T
S
255
CONNECTOR PINOUTS
POWERTRAIN CONTROL MODULE C3 - GRAY 32 WAY
CAV CIRCUIT FUNCTION
1 C13 18DB/OR (A/C) A/C COMPRESSOR CLUTCH RELAY CONTROL
2 C24 18DB/PK (2.4L) LOW SPEED RADIATOR FAN RELAY CONTROL
3 K51 18DB/YL AUTOMATIC SHUT DOWN RELAY CONTROL
4 V36 18TN/RD (SPEED
CONTROL)
SPEED CONTROL VACUUM SOLENOID CONTROL
5 V35 18LG/RD (SPEED
CONTROL)
SPEED CONTROL VENT SOLENOID CONTROL
6 - -
7 - -
8 K99 18BR/OR OXYGEN SENSOR 1/1 HEATER CONTROL
9 K512 18RD/YL (4.0L) OXYGEN SENSOR DOWNSTREAM HEATER RELAY CONTROL
10 K106 18WT/DG LEAK DETECTION PUMP SOLENOID CONTROL
11 V32 18YL/RD (SPEED
CONTROL)
SPEED CONTROL ON/OFF SWITCH SENSE
12 A142 14DG/PK AUTOMATIC SHUT DOWN RELAY OUTPUT
13 T10 18YL/DG (A/T) TORQUE MANAGEMENT REQUEST SENSE
14 K107 18OR LEAK DETECTION PUMP SWITCH SENSE
15 K118 18PK/YL BATTERY TEMPERATURE SENSOR SIGNAL
16 K299 18BR/WT OXYGEN SENSOR HEATER CONTROL
17 - -
18 - -
19 K31 18BR FUEL PUMP RELAY CONTROL
20 K52 18PK/BK EVAP/PURGE SOLENOID CONTROL
21 C27 18DB (2.4L) HIGH SPEED RADIATOR FAN RELAY CONTROL
22 C21 18DB/OR (A/C) A/C SWITCH SENSE
23 C90 18LG (A/C) A/C SELECT INPUT
24 K29 18WT/PK BRAKE LAMP SWITCH SENSE
25 K125 18WT/DB GENERATOR SOURCE
26 K226 18DB/LG (4.0L) FUEL LEVEL SENSOR SIGNAL
27 D21 18PK SCI TRANSMIT
28 - -
29 D32 18LG/WT SCI RECEIVE
30 D25 18VT/YL PCI BUS
31 - -
32 V37 18RD/LB (SPEED
CONTROL)
SPEED CONTROL SWITCH SIGNAL
SENTRY KEY IMMOBILIZER MODULE - BLACK 6 WAY
CAV CIRCUIT FUNCTION
1 - -
2 D25 20VT/YL PCI BUS
3 - -
4 F15 20DB FUSED IGNITION SWITCH OUTPUT (RUN-START)
5 Z1 20BK GROUND
6 F33 20PK/RD FUSED B(+)
C
O
N
N
E
C
T
O
R
P
I
N
O
U
T
S
256
CONNECTOR PINOUTS
SPEED CONTROL SERVO - BLACK 4 WAY
CAV CIRCUIT FUNCTION
1 V36 18TN/RD SPEED CONTROL VACUUM SOLENOID CONTROL
2 V35 18LG/RD SPEED CONTROL VENT SOLENOID CONTROL
3 V30 20DB/RD SPEED CONTROL BRAKE LAMP SWITCH OUTPUT
4 Z1 18BK GROUND
THROTTLE POSITION SENSOR (2. 4L) - WHITE/BLUE 3 WAY
CAV CIRCUIT FUNCTION
1 K7 18OR 5 VOLT SUPPLY
2 K4 18BK/LB SENSOR GROUND 1
3 K22 18OR/DB THROTTLE POSITION SENSOR NO.1 SIGNAL
THROTTLE POSITION SENSOR (4. 0L) - 3 WAY
CAV CIRCUIT FUNCTION
1 K7 20OR 5-VOLT SUPPLY
2 K4 20BK/LB SENSOR GROUND 1
3 K22 18OR/DB THROTTLE POSITION SENSOR NO.1 SIGNAL
VEHICLE SPEED SENSOR - BLACK 3 WAY
CAV CIRCUIT FUNCTION
1 K6 18VT/WT 5V SUPPLY
2 K4 20BK/LB SENSOR GROUND 1
3 G7 18WT/OR VEHICLE SPEED SENSOR SIGNAL
C
O
N
N
E
C
T
O
R
P
I
N
O
U
T
S
257
CONNECTOR PINOUTS
NOTES
258
10.0 SCHEMATIC DIAGRAMS
S
C
H
E
M
A
T
I
C
D
I
A
G
R
A
M
S
259
SCHEMATIC DIAGRAMS
S
C
H
E
M
A
T
I
C
D
I
A
G
R
A
M
S
260
SCHEMATIC DIAGRAMS
S
C
H
E
M
A
T
I
C
D
I
A
G
R
A
M
S
261
SCHEMATIC DIAGRAMS
NOTES
262
11.0 CHARTS AND GRAPHS
2.4L 4.0L
C
H
A
R
T
S
A
N
D
G
R
A
P
H
S
263
CHARTS AND GRAPHS
C
H
A
R
T
S
A
N
D
G
R
A
P
H
S
264
CHARTS AND GRAPHS
C
H
A
R
T
S
A
N
D
G
R
A
P
H
S
265
CHARTS AND GRAPHS
NOTES
266
TABLE OF CONTENTS
1.0 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.1 SYSTEM COVERAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.2 SIX-STEP TROUBLESHOOTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . .1
2.0 IDENTIFICATION OF SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
3.0 SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION . . . . . . . . . . . . . . . . . . . . . .1
3.1 AIRBAG SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
3.1.1 PASSENGER AIRBAG ON-OFF SWITCH. . . . . . . . . . . . . . . . . . . . . . . .2
3.1.2 SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
3.1.3 DIAGNOSTIC TROUBLE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
3.1.3.1 ACTIVE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
3.1.3.2 STORED CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
3.2 AUDIO SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
3.3 ELECTROCHROMIC COMPASS/TEMPERATURE MIRROR WITH LIGHTS . . . .4
3.4 ELECTRICALLY HEATED SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
3.4.1 REAR WINDOW DEFOGGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
3.5 ELECTRO/MECHANICAL INSTRUMENT CLUSTER (EMIC). . . . . . . . . . . . . . . . .7
3.5.1 SMART CLUSTER FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
3.5.2 INSTRUMENT CLUSTER SELF TEST. . . . . . . . . . . . . . . . . . . . . . . . . . .8
3.6 VEHICLE COMMUNICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
3.7 USING THE DRBIIIா . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
3.7.1 DRBIIIா ERROR MESSAGES AND BLANK SCREEN . . . . . . . . . . . . . .9
3.7.2 DRBIIIா DOES NOT POWER UP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
3.7.3 DISPLAY IS NOT VISIBLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
4.0 DISCLAIMERS, SAFETY, WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
4.1 DISCLAIMERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
4.2 SAFETY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
4.2.1 TECHNICIAN SAFETY INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . .10
4.2.2 VEHICLE PREPARATION FOR TESTING. . . . . . . . . . . . . . . . . . . . . . .10
4.2.3 SERVICING SUB-ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
4.2.4 DRBIIIா SAFETY INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
4.3 WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
4.3.1 VEHICLE DAMAGE WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
4.3.2 ROAD TESTING A COMPLAINT VEHICLE . . . . . . . . . . . . . . . . . . . . . .11
5.0 REQUIRED TOOLS AND EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
6.0 GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
7.0 DIAGNOSTIC INFORMATION AND PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . .13
AIRBAG
ACCELEROMETER 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
INTERNAL 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
OUTPUT DRIVER 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
SAFING SENSOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
STORED ENERGY FIRING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
STORED ENERGY LOGIC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
AIRBAG WARNING INDICATOR OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
i
TABLE OF CONTENTS - Continued
AIRBAG WARNING INDICATOR SHORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
CLUSTER MESSAGE MISMATCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
DRIVER SQUIB 1 CIRCUIT OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
DRIVER SQUIB 1 CIRCUIT SHORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
DRIVER SQUIB 1 SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
DRIVER SQUIB 1 SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
LOSS OF IGNITION RUN - START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
LOSS OF IGNITION RUN ONLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
MODULE NOT CONFIGURED FOR PAB OFF SWITCH . . . . . . . . . . . . . . . . . . . . . . . .40
NO CLUSTER MESSAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
NO PCI TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
PASSENGER AIRBAG ON - OFF SWITCH OPEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
PASSENGER AIRBAG ON - OFF SWITCH SHORT TO BATTERY. . . . . . . . . . . . . . . .50
PASSENGER AIRBAG ON - OFF SWITCH SHORT TO GROUND. . . . . . . . . . . . . . . .53
PASSENGER OFF INDICATOR CIRCUIT SHORT TO BATTERY . . . . . . . . . . . . . . . . .56
PASSENGER OFF INDICATOR CIRCUIT SHORT TO GROUND . . . . . . . . . . . . . . . . .59
PASSENGER SQUIB 1 CIRCUIT OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
PASSENGER SQUIB 1 CIRCUIT SHORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
PASSENGER SQUIB 1 SHORT TO BATTERY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
PASSENGER SQUIB 1 SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
*AIRBAG INDICATOR ON WITHOUT ACTIVE TROUBLE CODES. . . . . . . . . . . . . . . .74
AUDIO
ALL OUTPUTS SHORT - BASE AUDIO SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
ALL OUTPUTS SHORT - PREMIUM AUDIO SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . .77
CASSETTE PLAYER INOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
CD MECHANICAL FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
NO PCI TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
*AM/FM SWITCH INOPERATIVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
*ANY STATION PRESET SWITCH INOPERATIVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
*BALANCE INOPERATIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
*CD EJECT SWITCH INOPERATIVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
*EQUALIZER INOPERATIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
*FADER INOPERATIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
*FF/RW SWITCH INOPERATIVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
*HOUR/MINUTE SWITCHES INOPERATIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
*PAUSE/PLAY SWITCH INOPERATIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
*PWR SWITCH INOPERATIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
*SCAN SWITCH INOPERATIVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
*SEEK SWITCH INOPERATIVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
*SET SWITCH INOPERATIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
*TAPE EJECT SWITCH INOPERATIVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
*TIME SWITCH INOPERATIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
*TUNE SWITCH INOPERATIVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
CD PLAY FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
CD READ FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
CD TEMPERATURE HIGH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
LOW VOLTAGE LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
NO ANTENNA CONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
POWER AMP SHUTDOWN - BASE AUDIO SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . .87
POWER AMP SHUTDOWN - PREMIUM AUDIO SYSTEM . . . . . . . . . . . . . . . . . . . . . .89
*POOR SOUND QUALITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
ii
TABLE OF CONTENTS - Continued
CHIME
*CHIME INOPERATIVE AT ALL TIMES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
*CHIME INOPERATIVE WITH DRIVER SEAT BELT UNFASTENED. . . . . . . . . . . . . . .94
*CHIME INOPERATIVE WITH EXTERIOR LAMPS ON AND DRIVER DOOR OPEN .95
*CHIME INOPERATIVE WITH KEY IN IGNITION, DRIVER’S DOOR OPEN . . . . . . . .96
*CHIME SOUNDS WITH DRIVER SEAT BELT FASTENED. . . . . . . . . . . . . . . . . . . . . .99
*CHIME SOUNDS WITH DRIVER’S DOOR OPEN, KEY REMOVED. . . . . . . . . . . . .101
COMMUNICATION
*NO RESPONSE FROM AIRBAG CONTROL MODULE . . . . . . . . . . . . . . . . . . . . . . .102
*NO RESPONSE FROM CONTROLLER ANTILOCK BRAKE . . . . . . . . . . . . . . . . . . .104
*NO RESPONSE FROM INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . .106
*NO RESPONSE FROM PCM (PCI BUS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
*NO RESPONSE FROM PCM (SCI ONLY). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
*NO RESPONSE FROM RADIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
*NO RESPONSE FROM SENTRY KEY IMMOBILIZER MODULE. . . . . . . . . . . . . . . .114
*NO RESPONSE FROM TRANSMISSION CONTROL MODULE . . . . . . . . . . . . . . . .116
*PCI BUS COMMUNICATION FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
COMPASS/MINI-TRIP COMPUTER
*COMPASS/TEMP MODULE WILL NOT CALIBRATE . . . . . . . . . . . . . . . . . . . . . . . . .121
*COMPASS/TEMPERATURE MODULE INOPERATIVE. . . . . . . . . . . . . . . . . . . . . . . .122
*TEMPERATURE DISPLAY INACCURATE OR INOPERATIVE. . . . . . . . . . . . . . . . . .123
ELECTRICALLY HEATED SYSTEMS
*REAR WINDOW DEFOGGER INOPERATIVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125
*REAR WINDOW DEFOGGER SWITCH INDICATOR LAMP INOPERATIVE. . . . . . .128
INSTRUMENT CLUSTER
ACM MESSAGE NOT REC’D BY MIC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129
AIR BAG LAMP CIRCUIT OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130
AIR BAG LAMP CIRCUIT SHORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
CHECKSUM FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132
PANEL DIMMER OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133
PCM MESSAGE NOT REC’D BY MIC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135
SKIM MESSAGE NOT REC’D BY MIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136
*ЉNO BUSЉ IN VF DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137
*ЉNO FUSEЉ IN VF DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138
*4WD INDICATOR INOPERATIVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139
*ABS INDICATOR INOPERATIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142
*AIR BAG INDICATOR INOPERATIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143
*ALL GAUGES INOPERATIVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .144
*ANY PCI BUS INDICATOR INOPERATIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146
*AXLE LOCK INDICATOR PROBLEMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147
*BRAKE WARNING INDICATOR ALWAYS ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .150
*BRAKE WARNING INDICATOR INOPERATIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151
*FOG LAMP INDICATOR INOPERATIVE - DOMESTIC. . . . . . . . . . . . . . . . . . . . . . . .153
*HIGH BEAM INDICATOR INOPERATIVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154
*ONE GAUGE INOPERATIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155
*PANEL DIMMNG INOPERATIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .156
*REAR FOG LAMP INDICATOR INOPERATIVE - BUX ONLY. . . . . . . . . . . . . . . . . . .157
*SEAT BELT INDICATOR NOT OPERATING PROPERLY . . . . . . . . . . . . . . . . . . . . . .158
*SPEEDOMETER INACCURATE OR INOPERATIVE. . . . . . . . . . . . . . . . . . . . . . . . . .160
iii
TABLE OF CONTENTS - Continued
*VF DISPLAY INOPERATIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .161
*VF ODOMETER INOPERATIVE WITH DOOR OPEN. . . . . . . . . . . . . . . . . . . . . . . . .162
INTERIOR LIGHTING
*COURTESY LAMPS INOPERATIVE - ALL LAMPS. . . . . . . . . . . . . . . . . . . . . . . . . . .164
*COURTESY LAMPS ON AT ALL TIMES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .165
*ILLUMINATED ENTRY INOPERATIVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .167
VERIFICATION TESTS
VERIFICATION TESTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .168
8.0 SYSTEM COMPONENT LOCATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .171
8.1 DATA LINK CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .171
8.2 AIRBAG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .171
8.2.1 DRIVER AIRBAG MODULE & CLOCKSPRING . . . . . . . . . . . . . . . . .171
8.2.2 DRIVER/PASSENGER AIRBAG MODULES & MECHANICAL
INSTRUMENT CLUSTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .172
8.2.3 AIRBAG CONTROL MODULE AND PASSENGER AIRBAG
ON/OFF SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .172
8.3 FUSE BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .173
8.4 INSTRUMENT CLUSTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .173
8.4.1 FRONT VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .173
8.4.2 REAR VIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .174
8.5 POWER DISTRIBUTION CENTER (PDC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .174
8.6 POWERTRAIN CONTROL MODULE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .175
9.0 CONNECTOR PINOUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .177
AIRBAG CONTROL MODULE - YELLOW 22 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . .177
AMBIENT TEMPERATURE SENSOR - GRAY 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . .177
BRAKE WARNING INDICATOR SWITCH - BLACK 2 WAY . . . . . . . . . . . . . . . . . . . . .177
CLOCKSPRING C2 - YELLOW 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .178
COMPASS/TEMPERATURE MIRROR - BLACK 7 WAY. . . . . . . . . . . . . . . . . . . . . . . .178
CONTROLLER ANTILOCK BRAKE - 25 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .178
DATA LINK CONNECTOR - BLACK 16 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .179
DRIVER AIRBAG SQUIB 1 - YELLOW 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .179
FUSES (FUSE/RELAY BLOCK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .181
IGNITION SWITCH - 10 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .181
INSTRUMENT CLUSTER C1 - 12 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .182
INSTRUMENT CLUSTER C2 - 16 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .182
LEFT FRONT SPEAKER - BLACK 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .182
LEFT REAR SPEAKER - BLACK 3 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .183
PASSENGER AIRBAG ON-OFF SWITCH (LHD) - 6 WAY. . . . . . . . . . . . . . . . . . . . . .183
PASSENGER AIRBAG SQUIB 1 - YELLOW 2 WAY. . . . . . . . . . . . . . . . . . . . . . . . . . .183
FUSES (PDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .185
REAR WINDOW DEFOGGER RELAY (IN PDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .185
POWERTRAIN CONTROL MODULE C1 - BLACK 32 WAY. . . . . . . . . . . . . . . . . . . . .186
POWERTRAIN CONTROL MODULE C2 - WHITE 32 WAY. . . . . . . . . . . . . . . . . . . . .187
POWERTRAIN CONTROL MODULE C3 - GRAY 32 WAY. . . . . . . . . . . . . . . . . . . . . .188
RADIO - GRAY 22 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .189
REAR WINDOW DEFOGGER SWITCH (HARD TOP) - 4 WAY . . . . . . . . . . . . . . . . .189
RIGHT FRONT SPEAKER - BLACK 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .189
RIGHT REAR SPEAKER - BLACK 3 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .189
iv
TABLE OF CONTENTS - Continued
SEAT BELT SWITCH (EXCEPT LHD EXPORT) - BLACK 2 WAY . . . . . . . . . . . . . . . .190
SENTRY KEY IMMOBILIZER MODULE - BLACK 6 WAY . . . . . . . . . . . . . . . . . . . . . .190
SUBWOOFER - 12 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .190
TRANSMISSION CONTROL MODULE - 60 WAY. . . . . . . . . . . . . . . . . . . . . . . . . . . . .191
10.0 SCHEMATIC DIAGRAMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .193
10.1 AIRBAG SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .193
10.2 AUDIO SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .194
10.2.1 BASE AUDIO SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .194
10.2.2 PREMIUM AUDIO SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .195
10.3 CHIME SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .196
10.4 COMPASS/TEMPERATURE MIRROR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .196
10.5 INSTRUMENT CLUSTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .197
10.5.1 INSTRUMENT CLUSTER/AXLE LOCKER SYSTEM . . . . . . . . . . . . .198
10.6 INTERIOR LIGHTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .199
10.7 REAR DEFOGGER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .200
10.8 VEHICLE COMMUNICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201
v
NOTES
vi
1.0 INTRODUCTION
The procedures contai ned i n thi s manual i ncl ude
al l the speci fi cati ons, i nstructi ons, and graphi cs
needed to di agnose body system probl ems. The
di agnosti cs i n thi s manual are based on the fai l ure
condi ti on or symptom bei ng present at ti me of
di agnosi s.
Pl ease fol l ow the recommendati ons bel ow when
choosi ng your di agnosti c path.
1. Fi rst make sure the DRBI I I ௡ i s communi cati ng
wi th the appropri ate modul es: i .e., i f the
DRBI I I ௡ di spl ays a ЉNo ResponseЉ condi ti on, you
must di agnose that fi rst.
2. Read DTC’s (di agnosti c troubl e codes) wi th the
DRBI I I ௡.
3. I f no DTC’s are present, i denti fy the customer
compl ai nt.
4. Once the DTC or customer compl ai nt i s i denti -
fi ed, l ocate the matchi ng test i n the Tabl e of
Contents and begi n to di agnose the symptom.
Al l component l ocati on vi ews are i n Secti on 8.0.
Al l connector pi nouts are i n Secti on 9.0. Al l sche-
mati cs are i n Secti on 10.0.
An asteri sk (*) pl aced before the symptom de-
scri pti on i ndi cates a customer compl ai nt.
When repai rs are requi red, refer to the appropri -
ate servi ce manual for the proper removal and
repai r procedure.
Di agnosti c procedures change every year. New
di agnosti c systems may be added: carryover sys-
tems may be enhanced. READ THI S MANUAL
BEFORE TRYI NG TO DI AGNOSE A VEHI CLE
DI AGNOSTI C TROUBLE CODE. I t i s recom-
mended that you revi ew the enti re manual to be-
come fami l i ar wi th al l the new and changed di ag-
nosti c procedures.
Thi s book refl ects many suggested changes from
readers of past i ssues. After usi ng thi s book, i f you
have any comments or suggesti on, pl ease fi l l out the
form i n the back of the book, and mai l i t back to us.
1. 1 SYSTEM COVERAGE
Thi s di agnosti c procedures manual covers al l
2004 Jeep௡ Wrangl er (TJ) vehi cl es.
1. 2 SIX-STEP TROUBLESHOOTING
PROCEDURE
Di agnosi s of the body system i s performed i n si x
basi c steps:
1. veri fi cati on of compl ai nt
2. veri fi cati on of any rel ated symptoms
3. symptom anal ysi s
4. probl em i sol ati on
5. repai r of i sol ated probl em
6. veri fi cati on of proper operati on
2.0 IDENTIFICATION OF
SYSTEM
The vehi cl e systems that are part of the ЉbodyЉ
system are:
• ai rbag system
• audi o
• chi me
• el ectri cal l y heated systems
• i nstrument cl uster
• vehi cl e communi cati ons
3.0 SYSTEM DESCRIPTION AND
FUNCTIONAL OPERATION
The body system on the 2004 Jeep௡ Wrangl er (TJ)
consi sts of a combi nati on of modul es that commu-
ni cate over the PCI bus (Programmabl e Communi -
cati on I nterface mul ti pl ex system). Through the
PCI bus, i nformati on about the operati on of vehi cl e
components and ci rcui ts i s rel ayed qui ckl y to the
appropri ate modul e(s). Al l modul es recei ve al l the
i nformati on transmi tted on the bus even though a
modul e may not requi re al l i nformati on to perform
i ts functi on. I t wi l l onl y respond to messages Љad-
dressedЉ to i t through a bi nary codi ng process. Thi s
method of data transmi ssi on si gni fi cantl y reduces
the compl exi ty of the wi ri ng i n the vehi cl e and the
si ze of wi ri ng harnesses. Al l of the i nformati on
about the functi oni ng of al l the systems i s orga-
ni zed, control l ed, and communi cated by the PCI
bus, whi ch i s descri bed i n the Vehi cl e Communi ca-
ti on Secti on of the general i nformati on.
3. 1 AIRBAG SYSTEM
The Ai rbag system i s desi gned to provi de i n-
creased dri ver and passenger protecti on i f the vehi -
cl e i s i nvol ved i n a front-end col l i si on. The ai rbag
system i s desi gned to be used i n conjuncti on wi th
the seat bel t system.
Whenever the i gni ti on swi tch i s turned to the
Run or Start posi ti on, the ACM performs a warni ng
i ndi cator bul b-check vi a a PCI bus request to the
i nstrument cl uster to i l l umi nate the Ai rbag Warn-
i ng I ndi cator. The i ndi cator remai ns i l l umi nated for
6 to 8 seconds, and then turns off. I f the i ndi cator
remai ns off, the ACM has checked the system and
found i t to be free of di scernabl e mal functi ons.
The ACM moni tors cri ti cal i nput and output
ci rcui ts wi thi n the ai rbag system, ensuri ng the
ci rcui ts are operati ng properl y. Some ci rcui ts are
1
GENERAL INFORMATION
tested conti nuousl y; other ci rcui ts are tested onl y
under certai n ci rcumstances. The ACM provi des
di agnosti c i nformati on about the ai rbag system to
the techni ci an through the DRBI I I ௡ vi a the PCI bus.
The decel erati on of g-forces resul ti ng from the
i mpact of a front-end col l i si on causes the el ectroni c
sensor i nsi de of the ACM to be tri ggered. Thi s
causes the i nfl ators to be actuated, thus depl oyi ng
the ai rbag(s). The total ti me between determi ni ng
to depl oy and defl ati on of the ai r bag i s 1/10th of one
second (100ms).
The 2004 Jeep Wrangl er (TJ) may be equi pped
wi th a Passenger Ai rbag (PAB) On - Off Swi tch.
Thi s swi tch has an ACM-control l ed l i ght that wi l l
i l l umi nate when the swi tch i s i n the Off posi ti on.
Use the test procedures i n thi s manual to di ag-
nose the cause of any customer compl ai nt regardi ng
the Ai rbag Warni ng I ndi cator (l ocated i n the i nstru-
ment cl uster), such as:
• Ai rbag warni ng i ndi cator does not i l l umi nate at
any ti me
• Ai rbag warni ng i ndi cator i s i l l umi nated at al l
ti mes
3. 1. 1 PASSENGER AIRBAG ON-OFF
SWITCH
Vehi cl es wi thout rear seats wi l l be equi pped wi th
a Passenger Ai rbag (PAB) On - Off Swi tch. The PAB
On - Off Swi tch al l ows the vehi cl e operator to turn
the passenger ai rbag functi on On or Off.
The Off i ndi cator i n the PAB On - Off Swi tch wi l l
be i l l umi nated for 2 seconds whenever the i gni ti on
i s transi ti oned to the Run posi ti on as a bul b check.
The Off i ndi cator wi l l remai n i l l umi nated when the
PAB On - Off Swi tch i s turned to the Off posi ti on.
The PAB On - Off Swi tch assembl y i s mounted i n
the center of the i nstrument panel bel ow the radi o,
thi s al l ows the Off i ndi cator to be vi si bl e to both
front seat occupants.
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, ALWAYS CHECK THE PASSENGER
AIRBAG ON - OFF SWITCH POSITION BEFORE
DRIVING THE VEHICLE. A SWITCH IN THE
WRONG POSITION INCREASES THE RISK OF
SERIOUS INJURY OR DEATH IN A COLLISION.
To operate the Passenger Ai rbag On - Off Swi tch,
i nsert the i gni ti on key i nto the PAB On - Off Swi tch
keyway, push the key i n to rel ease the i nternal
pl unger, and rotate swi tch to the desi red posi ti on.
The spri ng-l oaded l ocki ng pl unger prevents the
user from l eavi ng the key i n the swi tch. The key
wi l l be automati cal l y ejected from the swi tch when
i nward force i s not appl i ed. The i gni ti on key i s the
onl y key or object that shoul d ever be i nserted i nto
the PAB On - Off Swi tch.
NOTE: Do not turn the Passenger Airbag On -
Off Switch while the ignition is in the Run
position.
The ACM conti nuousl y moni tors the resi stance of
the Passenger Ai rbag On - Off Swi tch ci rcui ts to
i denti fy the swi tch posi ti on and to provi de swi tch
ci rcui t di agnosti cs.
• ON Posi ti on: Passenger Ai rbag On - Off Swi tch
resi stance = 175 to 190 ohms
• OFF Posi ti on: Passenger Ai rbag On - Off Swi tch
resi stance = 820 to 870 ohms
I f the ACM detects that the PAB On - Off Swi tch
ci rcui ts are open, shorted to ground, or shorted to
battery vol tage, i t wi l l set Acti ve and Stored DTC’s.
When a DTC i s detected by the ACM, i t wi l l trans-
mi t a PCI bus message to the I nstrument Cl uster to
i l l umi nate the Ai rbag warni ng i ndi cator. Whenever
the Ai rbag warni ng i ndi cator i s i l l umi nated, the
ACM shoul d be the fi rst modul e to be i nterrogated.
I f after repl aci ng the ACM, any of the fol l owi ng
codes are acti ve, the ACM must be re-confi gured to
match the vehi cl e equi pment:
• MODULE NOT CONFI GURED FOR PAB OFF
SWI TCH
• PASSENGER AI RBAG ON - OFF SWTCH CI R-
CUI T OPEN
• PASSENGER AI RBAG ON - OFF SWTCH I NDI -
CATOR CI RCUI T OPEN
To properl y confi gure the ACM, usi ng the
DRBI I I ௡, sel ect Mi scel l aneous from the Ai rbag sys-
tem menu and fol l ow i nstructi ons.
WARNING: IGNORING THE AIRBAG WARNING
INDICATOR IN THE INSTRUMENT CLUSTER
COULD MEAN THE PASSENGERAIRBAG ON - OFF
SWITCH IS NOT FUNCTIONAL AND THE
PASSENGER AIRBAG MAY DEPLOY IF AN IMPACT
OCCURS. IF THE AIRBAG WARNING INDICATOR
ILLUMINATES, WHILE DRIVING, THE AIRBAG ON -
OFF SWITCH WILL REMAIN FUNCTIONAL FOR
THAT KEY CYCLE. IF THE AIRBAG WARNING
INDICATOR ILLUMINATES AGAIN AT THE NEXT
IGNITION ON AND STAYS ILLUMINATED FOR
MORE THAN 6 - 8 SECONDS, THE ACM WILL
DEFAULT TO PASSENGER AIRBAG ON. IF THE
AIRBAG WARNING INDICATOR BULB TEST OR IF
THE OFF INDICATOR DOES NOT ILLUMINATE
WITH THE SWITCH IN THE OFF POSITION THE
PASSENGER AIRBAG MAY DEPLOY IF AN IMPACT
OCCURS. FAILURE TO TAKE THE PROPER
PRECAUTIONS COULD RESULT IN ACCIDENTAL
AIRBAG DEPLOYMENT AND PERSONAL INJURY
OR DEATH.
2
GENERAL INFORMATION
3. 1. 2 SPECIAL TOOLS
Some ai rbag di agnosti c tests use speci al tool s, the
8310 and 8443 ai rbag l oad tool s for testi ng squi b
ci rcui ts. The l oad tool s contai n fi xed resi sti ve l oads,
jumpers, and adapters. The fi xed l oads are con-
nected to cabl es and are mounted i n a storage case.
The cabl es can be di rectl y connected to some
ai rbag system connectors. Jumpers are used to
convert the l oad tool cabl e connectors to other
ai rbag system connectors. The adapters are con-
nected to the modul e harness connector to open
shorti ng cl i ps and to protect the connector termi nal
duri ng testi ng.
When usi ng the l oad tool , fol l ow al l of the safety
procedures i n the servi ce i nformati on for di scon-
necti ng ai rbag system components. I nspect the wi r-
i ng, connector, and termi nal s for damage or mi s-
al i gnment.
Substi tute the ai rbag l oad tool i n pl ace of a Dri ver
or Passenger ai rbag, curtai n ai rbag, cl ockspri ng, or
seat bel t tensi oner, (use a jumper i f needed). Then
fol l ow al l of the safety procedures i n the servi ce
i nformati on for connecti ng ai rbag system compo-
nents.
Read the modul e acti ve DTC’s. I f the modul e
reports NO ACTI VE DTC’S, the defecti ve compo-
nent has been removed from the system and shoul d
be repl aced. I f the DTC i s sti l l acti ve, conti nue thi s
process unti l al l of the components i n the ci rcui t
have been tested.
Then di sconnect the modul e connector and con-
nect the matchi ng adapter to the modul e connector.
Wi th al l ai rbags di sconnected and adapter i n-
stal l ed, the squi b ci rcui ts can be tested for open and
shorted condi ti ons.
3. 1. 3 DIAGNOSTIC TROUBLE CODES
Ai rbag di agnosti c troubl e codes (DTC) consi st of
acti ve and stored codes. I f more than one DTC
exi sts, di agnosti c pri ori ty shoul d be gi ven to the
acti ve code(s). Each DTC i s di agnosed by fol l owi ng a
speci fi c testi ng procedure. The di agnosti c test pro-
cedures contai n step-by-step i nstructi ons for deter-
mi ni ng the cause of the DTC. I t i s not necessary to
perform al l of the tests i n thi s manual to di agnose
an i ndi vi dual DTC.
Al ways begi n by readi ng the DTC’s usi ng the
DRBI I I ௡. I f more than one code exi sts, di agnosti c
pri ori ty shoul d be gi ven to acti ve code(s).
Acti ve DTC’s for the ai rbag system are not per-
manent and wi l l change the moment the cause of
the code i s corrected. I n certai n test procedures
wi thi n thi s manual , DTC’s are used as a di agnosti c
tool .
3. 1. 3. 1 ACTIVE CODES
An acti ve troubl e code i ndi cates an on-goi ng mal -
functi on. Thi s i ndi cates that the defect i s currentl y
acti ve every ti me the ACM checks the parti cul ar
ci rcui t or functi on. I t i s i mpossi bl e to erase an acti ve
code; acti ve codes automati cal l y erase themsel ves
when the cause for the code has been corrected.
Wi th the excepti on of the warni ng i ndi cator trou-
bl e codes or mal functi ons, when a mal functi on has
been detected by the ACM, the Ai rbag warni ng
i ndi cator i s i l l umi nated for a mi ni mum of 12 sec-
onds, or as l ong as the mal functi on i s present.
3. 1. 3. 2 STORED CODES
Ai rbag codes are automati cal l y stored i n the ACM
memory as soon as the mal functi on i s detected,
wi th the excepti on of the Loss Of I gni ti on Run-Onl y
code, whi ch i s an acti ve code onl y. A stored code
i ndi cates that there was an acti ve code present at
some ti me. However, the code currentl y may not be
present as an acti ve code, al though another acti ve
code may be.
When a troubl e code occurs, the Ai rbag warni ng
i ndi cator i l l umi nates for 12 seconds mi ni mum,
(even i f the condi ti on exi sted for l ess than 12
seconds). Stored codes di spl ay the ti me i n mi nutes
that the code was acti ve, and the number of ti mes
that the i gni ti on has been cycl ed si nce the acti ve
code was l ast detected.
The mi ni mum ti me shown for any code wi l l be
one mi nute, even i f the code was actual l y present
for l ess than one mi nute. Thus, the ti me shown for
a code that was present for two mi nutes 13 seconds,
for exampl e, woul d be three mi nutes.
I f a mal functi on i s not acti ve whi l e performi ng a
di agnosti c test, the acti ve code di agnosti c test wi l l
not l ocate the source or the condi ti on. I n thi s case,
the stored code can i ndi cate an area to i nspect. The
fol l owi ng procedure may uncover a mal functi on
that i s di ffi cul t to l ocate:
WARNING: TOAVOID PERSONAL INJURY OR
DEATH, MAINTAIN A SAFE DISTANCE FROM
ALL AIRBAGS WHILE PERFORMING THE
FOLLOWING INSPECTION:
I f no obvi ous probl ems are found:
• Erase the stored codes
• Pl ace the i gni ti on i n the Run posi ti on
• Wi ggl e the wi re harness and connectors
• Rotate the steeri ng wheel from stop to stop
• Recheck for acti ve codes peri odi cal l y as you work
through the system.
3
GENERAL INFORMATION
3. 2 AUDIO SYSTEM
Some radi o systems avai l abl e on the 2004 TJ
communi cate on the PCI Bus. They use the bus for
three reasons. The fi rst i s to communi cate troubl e
codes, second i s to recei ve di mmi ng i nformati on,
and the thi rd i s to recei ve cabi n equal i zati on i nfor-
mati on. The audi o system i s avai l abl e i n a 4
speaker base system and a 7 speaker system wi th
an external subwoofer.
When troubl eshooti ng output shorts or “output”
error messages, the fol l owi ng appl i es:
On radi os wi thout an external ampl i fi er, the term
output refers to the path between the radi o and the
speaker. Thi s type of ci rcui t can be moni tored al l
the way through the speaker connecti ons by the
radi o assembl y. When the radi o di spl ays a shorted
output DTC wi th thi s type of system, the speaker,
radi o, or wi ri ng coul d be at faul t.
On radi os wi th an external ampl i fi er, the term
“output” refers to the ci rcui t between the radi o
connector and the ampl i fi er. The radi o i s capabl e of
moni tori ng onl y thi s porti on and can tel l nothi ng
about the ci rcui t between the ampl i fi er and the
speakers. Consequentl y, a shorted output DTC on
thi s type of system woul d onl y refer to thi s ci rcui t.
A faul ty speaker coul d not cause thi s DTC.
3. 3 ELECTROCHROMIC
COMPASS/TEMPERATURE MIRROR
WITH LIGHTS
DESCRIPTION
The opti onal sel f-di mmi ng El ectrochromi c
Compass/Temperature Mi rror has a vacuum fl uo-
rescent (VF) di spl ay that i s i ntegrated i nto the rear
vi ew mi rror. The Compass/Temp Mi rror i ncl udes
the compass/temperature di spl ay and two map/
readi ng l amps. Thi s di spl ay provi des the outsi de
temperature and one of ei ght compass headi ngs to
i ndi cate the di recti on the vehi cl e i s faci ng. The
Compass/Temp Mi rror di spl ays the compass head-
i ng and the outsi de temperature at the same ti me.
The Ambi ent Temperature Sensor moni tors the
outsi de temperature and i s hardwi red to the
Compass/Temp Mi rror.
BUTTON OPERATION
The Compass/Temp Mi rror i ncorporates 3 (mode/
l amp) buttons to access and control vari ous func-
ti ons.
Left Button
• Press and Rel ease
> Toggl es Left Map Li ght On/Off
• Press w/ Ri ght Swi tch for more than 5 seconds
and Rel ease
> Toggl es El ectrochromi c Status On/Off
-automati c On wi th each i gni ti on cycl e
> On mode i s i ndi cated by green status LED
next to ri ght button
Center Button
• Press for more than 3 seconds and Rel ease
> Cycl e through di spl ay status
– Compass / Temperature (Fahrenhei t) - °F
mode stored to memory
– Compass /Temperature (Cel si us) - °C mode
stored to memory
– Di spl ay Off - off mode stored to memory
• Press and Hol d for 3-6 seconds
> Acti vate zone vari ance mode (adjust compass
for true north)
– ЉZЉ and the currentl y programmed zone
(1-15) wi l l fl ash i n di spl ay wi ndow
– Each press of the center button wi l l i ncre-
ment to the next zone
– When proper zone i s sel ected, wai t 5 sec-
onds and mi rror di spl ay returns to comp/temp
(see vari ance zone map for proper zone num-
ber setti ng)
• Press and Hol d for more than 6 seconds
> Acti vate compass cal i brati on
– ЉCALЉ shows i n di spl ay wi ndow unti l com-
pass i s cal i brated (veri fy correct vari ance zone
pri or to i ni ti al or re-cal i brati on)
– Dri ve vehi cl e i n a sl ow ci rcl e for 1.5 revol u-
ti ons to recal i brate compass
Right Button
• Press and Rel ease
> Toggl es Ri ght Map Li ght On/Off
ELECTROCHROMIC (EC) OPERATION (auto
dimming feature)
The automati c di mmi ng feature detects forward
and rear l i ght condi ti ons and adjusts the refl ec-
tance l evel of the mi rror to el i mi nate unwanted
gl are by the use 2 photoel ectri c sensors. The feature
can be di sabl ed by depressi ng the Left and Ri ght
buttons together for more than 5 seconds. The
di sabl e command wi l l onl y remai n i n effect unti l the
i gni ti on i s turned off. The EC functi on wi l l automat-
i cal l y return to ON wi th each i gni ti on cycl e.
When the forward sensor detects dayti me condi -
ti ons, the rear sensor i s i nacti ve and the mi rror
remai ns i n a hi gh refl ectance state.
When ni ghtti me condi ti ons are sensed by the
forward sensor, the rear faci ng sensor i s acti ve and
detects gl are from rearward approachi ng vehi cl es
or other gl are produci ng l i ght sources. The mi rror
4
GENERAL INFORMATION
wi l l automati cal l y adjust to a l ow refl ectance state
to remove the unwanted gl are from the i nsi de rear
vi ew mi rror. The mi rror wi l l automati cal l y return to
a hi gh refl ectance state whenever the vehi cl e i s
pl aced i n REVERSE to ensure a cl ear vi ew when
backi ng up.
NOTE: Do not allow the forward or rear
sensors to be obstructed since this may
impair proper performance.
ELECTROCHROMIC (EC) DIAGNOSTICS
Ensure that both the forward and rear sensors
are not obstructed by hang i tems, tape, sti ckers,
wi ndow decal s, etc.
1. Wi th the i gni ti on i n the ON posi ti on:
Use a fl ashl i ght or other l i ght source, to i l l umi -
nate the forward faci ng sensor. The mi rror shoul d
remai n/adjust to a hi gh refl ectance state. Thi s
si mul ates dayti me condi ti ons.
Cover the forward faci ng sensor wi th a fi nger or
dark materi al . Usi ng a fl ashl i ght or other l i ght
source, i l l umi nate the rear-faci ng sensor. The
mi rror shoul d di m to a l ow refl ectance state. Thi s
si mul ates ni ghtti me gl are condi ti ons.
Cover the forward and rear faci ng sensors wi th
fi ngers or dark materi al . The mi rror shoul d
remai n/adjust to a hi gh refl ectance state. Thi s
si mul ates ni ghtti me non-gl are condi ti ons.
2. Wi th the i gni ti on i n the ON posi ti on, the BRAKE
appl i ed and the vehi cl e i n REVERSE:
Cover the forward faci ng sensor wi th a fi nger or
dark materi al . Usi ng a fl ashl i ght or other l i ght
source, i l l umi nate the rear-faci ng sensor. The
mi rror shoul d remai n i n a hi gh refl ectance state.
Thi s si mul ates ni ghtti me dri vi ng condi ti ons, pro-
vi di ng a cl ear vi ew whi l e backi ng up.
I f the EC Comp/Temp Mi rror does not respond as
i ndi cated, repl ace the EC Comp/Temp Mi rror i n
accordance wi th the Servi ce I nformati on.
COMPASS OPERATION
The compass i s capabl e of di sti ngui shi ng 8 pri -
mary di recti ons: N, NE, E, SE, S, SW, W, NW. Thi s
el ectroni c compass i s desi gned to di spl ay readi ngs
rel ati ve to True North. Al l compasses measure
readi ngs rel ati ve to Magneti c North. The di fference
between Magneti c North and True North vari es
from pl ace to pl ace across the surface of the earth.
Therefore, the compass must be tol d approxi matel y
where i t i s on the earth’s surface so that the
Magneti c North readi ng can be properl y converted
i nto a True North Di spl ay. Thi s i s done by separat-
i ng di fferent parts of the earth i nto numbered ЉZone
Vari ancesЉ (see zone vari ance map). The Zone Vari -
ance i n whi ch the compass i s to functi on must be
entered i nto the compass.
FIRST TIME / MANUAL CALIBRATION
Set or confi rm the Zone Vari ance, refer to COM-
PASS ZONE VARI ANCE. Duri ng fi rst ti me or man-
ual cal i brati on, the compass may al ready be cal i -
brated (CAL i s not di spl ayed). I t i s recommended
that the CAL mode be i nvoked under al l si tuati ons.
Wi th the i gni ti on i n the ON posi ti on, pressi ng and
hol di ng the CENTER button for more than 6 sec-
onds wi l l toggl e the di spl ay to CAL. Rel easi ng the
button after the 6 second durati on wi l l enter the
compass i nto the cal i brati on mode. CAL wi l l remai n
i l l umi nated unti l the cal i brati on i s compl ete. Move
the vehi cl e to an area away from l arge metal l i c
objects or overhead power l i nes. Whi l e CAL i s
i l l umi nated i n the di spl ay the vehi cl e must be
dri ven i n at l east 1 compl ete 360° ci rcl e at l ess than
5 MPH (8 KPH). Up to 3 compl ete 360° ci rcl es may
be requi red. The compass wi l l cal i brate; CAL wi l l
turn off, and the compass wi l l resume normal
operati on.
COMPASS ZONE VARIANCE (adjust compass
for true north)
The compass has a defaul t zone of 8. Refer to the
Zone Vari ance Map to determi ne the correct zone
number. The correct compass Zone sel ecti on i s cri t-
i cal to proper compass operati on. Wi th the i gni ti on
i n the ON posi ti on, pressi ng the CENTER button
for 3-6 seconds and then rel easi ng whi l e ЉZЉ i s
i l l umi nated enters the compass i nto the Zone di s-
pl ay mode. I n the Zone di spl ay mode, ЉZЉ wi l l be
i l l umi nated i nstead of the temperature. The cur-
rent Zone number, 1 through 15 wi l l be di spl ayed.
Whi l e ЉZЉ i s i l l umi nated; momentari l y pressi ng the
CENTER button advances the zone to the next
hi gher zone. When the desi red zone number i s
di spl ayed, do not press the button agai n. After 5
seconds, the Zone Vari ance number wi l l be stored i n
the modul e memory.
On l ong tri ps, a vehi cl e may l eave i ts ori gi nal
zone and enter one or more new zones. General l y, i f
no more that 3 or 4 zones are temporari l y traversed,
there i s now reason to reset the Zone Vari ance. Onl y
a permanent rel ocati on of the vehi cl e to a new zone
i s reason enough to reset the Zone Vari ance. Each
zone i s magneti cal l y about 4.2° wi de. Unti l a total
neari ng 22.5° i s accumul ated by traversi ng zones,
the typi cal dri ver wi l l not noti ce any di fference on
the di spl ay. Beyond 22.5°, a readi ng may be off by
one or more pri mary di recti ons.
5
GENERAL INFORMATION
CONTINUOUS CALIBRATION
Duri ng normal operati on, the EC Comp/Temp
Mi rror wi l l conti nuousl y update the compass cal i -
brati on to adjust for gradual changes i n the vehi -
cl e’s magneti c remnant fi el d. I f the vehi cl e i s sub-
jected to hi gh magneti c i nfl uences, the compass
may appear to i ndi cate fal se headi ngs, l ocked or
appear unabl e to be cal i brated. I f thi s occurs, refer
to MANUAL CALI BRATI ON.
COMPASS DIAGNOSTICS
I f at any ti me the compass conti nual l y di spl ays
the i ncorrect di recti on, the readi ng i s errati c or
l ocked, veri fy the correct zone vari ance per COM-
PASS ZONE VARI ANCE and manual l y recal i brate
per MANUAL CALI BRATI ON. The el ectroni c com-
pass, al though hi ghl y protected from changes i n
magneti c fi el d, can be suscepti bl e to l arge changes
i n magneti c fi el d. Exampl es i ncl ude, but not l i mi ted
to: hi gh tensi on power l i nes, l arge steel bui l di ngs,
automati c car washes, l arge quanti ti es of scrap
metal , etc. Whi l e occurrence of thi s phenomenon i s
i nfrequent, i t i s possi bl e.
OUTSIDE TEMPERATURE OPERATION
The EC Comp/Temp Mi rror uti l i zes i nternal mod-
ul e memory temperature data to accuratel y di spl ay
the outsi de temperature and to avoi d Љhot soakЉ
condi ti on readi ngs. The di spl ayed outsi de tempera-
ture i nformati on i s stored wi thi n the memory of the
EC Comp/Temp Mi rror. The temperature memory
onl y sets after the EC Comp/Temp Mi rror has been
on for 5 conti nuous mi nutes. When the EC Comp/
Temp Mi rror i s fi rst powered up, i t retri eves the
temperature data from the modul e memory. Wi th
the memory set when the EC Comp/Temp Mi rror i s
powered up, the l ast temperature stored wi l l be
di spl ayed and the modul e enters the Sl ow Update
mode, (Sl ow Update = 1° i ncrease or decrease per
mi nute.) Wi th the memory not set when powered
up, the EC Comp/Temp Mi rror wi l l enter Fast
Update mode for 5 mi nutes and then enter Sl ow
Update mode, (Fast Update = Sampl e and di spl ay
the outsi de ai r temperature every 2 seconds.)
• TEMPERATURE UPDATE - WARM
On power up, when the outsi de temperature
sensed by the ambi ent temperature sensor i s
warmer than the temperature stored i n the modul e
memory, the EC Comp/Temp Mi rror wi l l update the
di spl ayed temperature i n rel ati on to the current
Update rate.
• TEMPERATURE UPDATE - COLD
On power up, when the outsi de ai r temperature
sensed by the ambi ent temperature sensor i s col der
than the stored memory temperature, the EC
Comp/Temp Mi rror wi l l update the di spl ayed tem-
perature to the outsi de temperature at a rate of -1°
every 2 seconds.
• POTENTIAL ؆ICE؆ CONDITIONS
I f the measured outsi de temperature i s 3°C
(37°F) or l ess, the temperature di spl ay wi l l i nter-
mi ttentl y read the word ЉI CEЉ to i ndi cate possi bl e
hazardous dri vi ng condi ti ons. The al ternati ng
ЉI CEЉ di spl ay wi l l end approxi matel y 2 mi nutes
after i ni ti al detecti on of approxi matel y 3°C (37°F).
• EXTREME TEMPERATURE / OPEN OR
SHORT CONDITION
I f the measured outsi de temperature i s more
than 60°C (140°F) or the ambi ent temperature
sensor sense ci rcui t i s shorted to ground, the temp
di spl ay wi l l be ЉSCЉ to i ndi cate a short ci rcui t
condi ti on.
I f the measured outsi de temperature i s l ess than
-45°C (-49°F) or the ambi ent temperature sensor
sense ci rcui t i s open, the temp di spl ay wi l l be ЉOCЉ
to i ndi cate an open ci rcui t condi ti on.
AMBIENT TEMPERATURE SENSOR
DESCRIPTION
The ambi ent temperature sensor i s a vari abl e
resi stor that operates on a 5-vol t reference si gnal
ci rcui t hardwi red to the Compass/Temp Mi rror. The
outsi de ai r temperature i s moni tored and di spl ayed
by the Compass/Temp Mi rror.
The ambi ent temperature sensor cannot be ad-
justed or repai red and, i f faul ty or damaged, i t must
be repl aced.
OPERATION
The resi stance i n the ambi ent temperature sen-
sor changes as the outsi de temperature ri ses or
fal l s. The Compass/Temp Mi rror senses the change
i n reference vol tage through the ambi ent tempera-
ture sensor resi stor. Based on the resi stance of the
ambi ent temperature sensor, the Compass/Temp
Mi rror modul e i s programmed to correspond to a
speci fi c temperature. The Compass/Temp Mi rror
then di spl ays the correspondi ng outsi de tempera-
ture recei ved from the sensor.
6
GENERAL INFORMATION
AMBIENT TEMPERATURE SENSOR
DIAGNOSTICS
The outsi de temperature functi on i s supported by
the ambi ent temperature sensor, a si gnal and
ground ci rcui t hardwi red to the compass/temp mod-
ul e, and the Compass/Temp Mi rror di spl ay.
I f the Compass/Temp Mi rror di spl ay i ndi cates
ЉSCЉ, the ambi ent temperature sensor ci rcui t i s
shorted to ground.
I f the Compass/Temp Mi rror di spl ay i ndi cates
ЉOCЉ, the ambi ent temperature sensor ci rcui t i s
open.
The ambi ent temperature sensor can be di ag-
nosed usi ng the fol l owi ng Sensor Test. Fi rst, con-
fi rm that °C i s not bei ng mi staken for °F or vi se-
versa. I f the ambi ent temperature sensor and the
ci rcui ts are confi rmed to be OK, but the tempera-
ture di spl ay i s i noperati ve or i ncorrect, repl ace the
Compass/Temp Mi rror.
AMBIENT TEMPERATURE SENSOR TEST
1. Turn the i gni ti on OFF.
2. Di sconnect and i sol ate the battery negati ve ca-
bl e.
3. Di sconnect the ambi ent temperature sensor har-
ness connector.
4. Measure the resi stance of the ambi ent tempera-
ture sensor usi ng the fol l owi ng val ues:
> 0° C (32° F) Sensor Resi stance = 29.33 - 35.99
Ki l ohms
> 10° C (50° F) Sensor Resi stance =17.99 - 21.81
Ki l ohms
> 20° C (68° F) Sensor Resi stance = 11.37 - 13.61
Ki l ohms
> 25° C (77° F) Sensor Resi stance = 9.12 - 10.86
Ki l ohms
> 30° C (86° F) Sensor Resi stance = 7.37 - 8.75
Ki l ohms
> 40° C (104° F) Sensor Resi stance = 4.90 - 5.75
Ki l ohms
The sensor resi stance shoul d read between these
mi n/max val ues. I f the resi stance val ue i s OK, refer
to the Wi ri ng Di agrams to test the Si gnal and
Ground ci rcui ts. I f the resi stance val ues are not
OK, repl ace the Sensor.
MAP/READING LAMP OPERATION
The Map/Readi ng l amp feature uses LED (l i ght
emi tti ng di ode) technol ogy as i ts l i ght source. The
dri ver and passenger map l amps each consi st of 6
LED’s, 2 bl ue-green and 4 amber. By mi xi ng these
col ors through the use of a di ffusi ng cover the
output l i ght i s whi te i n appearance. Di rect vi ewi ng
of the LED’s wi l l appear as bl ue-green and amber.
The l i ghts are acti vated by the door swi tch when
enteri ng or exi ti ng the vehi cl e or manual l y by usi ng
the appropri ate button on the mi rror as descri bed
above. LED’s l ast 10-15+years and are not desi gned
to be repl aced i n thi s appl i cati on.
3. 4 ELECTRICALLY HEATED SYSTEMS
3. 4. 1 REAR WINDOW DEFOGGER
The ti mi ng ci rcui t for the Rear Wi ndow Defogger
i s contai ned i nternal l y wi thi n the cl uster. When the
i gni ti on i s on, the fi rst actuati on of the Rear Wi n-
dow Defogger swi tch i ni ti ates a 10 (ten) mi nute
ti me cycl e. After 10 (ten) mi nutes of the same
i gni ti on cycl e has el apsed, the cl uster wi l l turn the
defogger off by openi ng the ground to the Rear
Wi ndow Defogger Rel ay. I f the defogger swi tch i s
actuated a second ti me duri ng the same i gni ti on
cycl e, the cl uster wi l l turn the defogger off after 5
(fi ve) mi nutes. Whi l e the defogger i s on, depressi ng
the swi tch a second ti me wi l l turn the defogger off.
I f the i gni ti on i s turned off whi l e the defogger i s
operati ng, the defogger wi l l remai n off when the
i gni ti on i s cycl ed.
3. 5 ELECTRO/MECHANICAL INSTRUMENT
CLUSTER (EMIC)
3. 5. 1 SMART CLUSTER FEATURES
The El ectro/Mechani cal I nstrument Cl uster
(EMI C) houses the Fuel , Vol tmeter, Engi ne Cool ant
Temp, and Oi l Pressure gauges, the Speedometer
and the Tachometer. The cl uster posi ti ons the ana-
l og gauges usi ng PCI Bus messages recei ved from
the PCM. The cl uster al so contai ns warni ng i ndi ca-
tors as wel l as i ndi cators for the Ri ght and Left turn
si gnal s and the Hi gh Beam headl amps. Some of the
i ndi cators are hardwi red to the cl uster and some
i ndi cators are control l ed by messages recei ved on
the PCI Bus. The vehi cl e Chi me functi on, Courtesy
Lamp Output, the Battery Saver functi on, and the
Rear Wi ndow Defogger ti mer are contai ned i nter-
nal l y wi thi n the cl uster. The cl uster contai ns a
vacuum fl uorescent (VF) di spl ay for the Odometer/
Tri p functi on. The cl uster VF wi l l al so di spl ay
P-codes and vehi cl e status messages. The cl uster
has the abi l i ty to store DTCs, communi cate on the
PCI Bus, di spl ay engi ne i nformati on, and di spl ay
certai n i nputs usi ng the DRBI I I ௡. The cl uster i s
al so abl e to perform a manual sel f-test. For com-
pl ete descri pti on and operati on of the I nstrument
Cl uster, refer to the TJ Servi ce Manual I nstrument
Cl uster secti on. For di agnosti c procedures, refer to
the TJ Body Di agnosti c Procedures Manual .
7
GENERAL INFORMATION
3. 5. 2 INSTRUMENT CLUSTER SELF TEST
The I nstrument Cl uster i s capabl e of performi ng
a di agnosti c sel f test. The sel f test i s actuated by
depressi ng and hol di ng the tri p reset button whi l e
turni ng the i gni ti on from the off to the on posi ti on.
The sel f test can al so be i ni ti ated usi ng the
DRBI I I ௡. The sel f test wi l l termi nate i f the tachom-
eter i s greater than 300 RPM, the i gni ti on i s turned
off, or the test i s compl ete. For di agnosti c proce-
dures, refer to the TJ Body Di agnosti c Procedures
Manual .
3. 6 VEHICLE COMMUNICATION
The Programmabl e Communi cati on I nterface or
PCI Bus i s a si ngl e wi re mul ti pl exed network capa-
bl e of supporti ng bi nary encoded messages shared
between mul ti pl e modul es. The PCI bus ci rcui t i s
i denti fi ed as D25 and i s vi ol et wi th a yel l ow tracer.
The modul es are wi red i n paral l el . Connecti ons are
made i n the harness usi ng spl i ces. The fol l owi ng
modul es are used on 2004 Jeep௡ Wrangl er (TJ).
• Ai rbag Control Modul e
• Mechani cal I nstrument Cl uster
• Radi o
• Powertrai n Control Modul e
• Transmi ssi on Control Modul e
• Sentry Key I mmobi l i zer Modul e
Each modul e provi des i ts own bi as and termi na-
ti on i n order to transmi t and recei ve messages. The
bus vol tage i s at zero vol ts when no modul es are
transmi tti ng and i s pul l ed up to about seven and a
hal f vol ts when modul es are transmi tti ng.
The bus messages are transmi tted at a rate
averagi ng 10800 bi ts per second. Si nce there i s onl y
vol tage present when the modul es transmi t and the
message l ength i s onl y about 500 mi l l i seconds, i t i s
i neffecti ve to try and measure the bus acti vi ty wi th
a conventi onal vol tmeter. The preferred method i s
to use the DRBI I I ௡ l ab scope. The 12v square wave
sel ecti on on the 20-vol t scal e provi des a good vi ew of
the bus acti vi ty. Vol tage on the bus shoul d pul se
between zero and about seven and a hal f vol ts.
Refer to the fol l owi ng fi gure for some typi cal di s-
pl ays.
The PCI Bus Fai l ure modes are broken down i nto
two categori es. Compl ete PCI Bus Communi cati on
Fai l ure and i ndi vi dual modul e no response. Causes
of a compl ete PCI Bus Communi cati on Fai l ure
i ncl ude a short to ground or battery on the PCI
ci rcui t. I ndi vi dual modul e no response can be
caused by an open ci rcui t at the modul e, or an open
battery or ground ci rcui t to the affected modul e.
Symptoms of a compl ete PCI Bus Communi cati on
Fai l ure woul d i ncl ude but are not l i mi ted to:
• Al l gauges on the MI C stay at zero
• Al l tel l tal es on MI C i l l umi nate
• MI C backl i ghti ng at ful l i ntensi ty
• No response recei ved from any modul e on the PCI
bus (except PCM)
• No start (i f equi pped wi th Sentry Key I mmobi -
l i zer)
8
GENERAL INFORMATION
Symptoms of i ndi vi dual modul e fai l ure coul d i n-
cl ude any one or more of the above. The di fference
woul d be that at l east one or more modul es woul d
respond to the DRBI I I ௡.
Di agnosi s starts wi th symptom i denti fi cati on. I f a
compl ete PCI Bus Communi cati on Fai l ure i s sus-
pected, begi n by i denti fyi ng whi ch modul es the
vehi cl e i s equi pped wi th and then attempt to get a
response from the modul e wi th the DRBI I I ௡. I f any
modul es are respondi ng, the fai l ure i s not rel ated to
the total bus, but can be caused by one or more
modul es, PCI ci rcui t or power suppl y and ground
ci rcui ts. The DRBI I I ௡ may di spl ay ЉBUS +/- SI G-
NAL OPENЉ or ЉNO RESPONSEЉ to i ndi cate a
communi cati on probl em. These same messages wi l l
be di spl ayed i f the vehi cl e i s not equi pped wi th that
parti cul ar modul e. The CCD error message i s a
defaul t message used by the DRBI I I ௡ and i n no way
i ndi cates whether or not the PCI Bus i s operati onal .
The message i s onl y an i ndi cati on that a modul e i s
ei ther not respondi ng or the vehi cl e i s not equi pped.
NOTE: Communication over the BUS is
essential to the proper operation of the
vehicles on-board diagnostic systems and
the DRBIIIா. Problems with the operation of
the BUS or DRBIIIா must be corrected before
proceeding with diagnostic testing. If there is
a problem, refer to the communications
category of this manual.
3. 7 USING THE DRBIIIா
Refer to the DRBI I I ௡ user’s gui de for i nstructi ons
and assi stance wi th readi ng troubl e codes, erasi ng
troubl e codes, and other DRBI I I ௡ functi ons.
3. 7. 1 DRBIIIா ERROR MESSAGES AND
BLANK SCREEN
Under normal operati on, the DRBI I I ௡ wi l l di s-
pl ay one of onl y two error messages:
• User-Requested WARM Boot
• User-Requested COLD Boot
Thi s i s a sampl e of such an error message di spl ay:
ver: 2.14
date: 26 Jul 93
fi l e: key_i tf.cc
date: Jul 26 1993
l i ne: 548
err: 0x1
User-Requested COLD Boot
Press MORE to swi tch between thi s di spl ay
and the appl i cati on screen.
Press F4 when done noti ng i nformati on.
I f the DRBI I I ௡ shoul d di spl ay any other error
message, record the enti re di spl ay and cal l the
STAR Center for i nformati on and assi stance.
3. 7. 2 DRBIIIா DOES NOT POWER UP
I f the LED’s do not l i ght or no sound i s emi tted at
start up, check for l oose cabl e connecti ons or a bad
cabl e. Check the vehi cl e battery vol tage (data l i nk
connector cavi ty 16). A mi ni mum of 11 vol ts i s
requi red to adequatel y power the DRBI I I ௡.
I f al l connecti ons are proper between the
DRBI I I ௡ and the vehi cl e or other devi ces, and the
vehi cl e battery i s ful l y charged, an i noperati ve
DRBI I I ௡ may be the resul t of faul ty cabl e or vehi cl e
wi ri ng.
3. 7. 3 DISPLAY IS NOT VISIBLE
Low temperatures wi l l affect the vi si bi l i ty of the
di spl ay. Adjust the contrast to compensate for thi s
condi ti on.
4.0 DISCLAIMERS, SAFETY,
WARNING
4. 1 DISCLAIMERS
Al l i nformati on, i l l ustrati ons, and speci fi cati ons
contai ned i n thi s manual are based on the l atest
i nformati on avai l abl e at the ti me of publ i cati on.
The ri ght i s reserved to make changes at any ti me
wi thout noti ce.
9
GENERAL INFORMATION
4. 2 SAFETY
4. 2. 1 TECHNICIAN SAFETY INFORMATION
WARNING: WHEN OPERATING, ENGINES
PRODUCE AN ODORLESS GAS CALLED
CARBON MONOXIDE. INHALING CARBON
MONOXIDE GAS CAN RESULT IN SLOWER
REACTION TIMES AND CAN LEAD TO
PERSONAL INJURY OR DEATH. WHEN THE
ENGINE IS OPERATING, KEEP SERVICE
AREAS WELL VENTILATED OR ATTACH THE
VEHICLE EXHAUST SYSTEM TO THE SHOP
EXHAUST REMOVAL SYSTEM.
Set the parki ng brake and bl ock the wheel s before
testi ng or repai ri ng the vehi cl e. I t i s especi al l y
i mportant to bl ock the wheel s on front-wheel dri ve
vehi cl es: the parki ng brake does not hol d the dri ve
wheel s.
When servi ci ng a vehi cl e, al ways wear eye pro-
tecti on, and remove any metal jewel ry such as
watchbands or bracel ets that mi ght make an i nad-
vertent el ectri cal contact.
When di agnosi ng a body system probl em, i t i s
i mportant to fol l ow approved procedures where
appl i cabl e. These procedures can be found i n the
servi ce manual . Fol l owi ng these procedures i s very
i mportant to the safety of i ndi vi dual s performi ng
di agnosti c tests.
4. 2. 2 VEHICLE PREPARATION FOR
TESTING
Make sure the vehi cl e bei ng tested has a ful l y
charged battery. I f i t does not, fal se di agnosti c error
messages may occur.
4. 2. 3 SERVICING SUB-ASSEMBLIES
Some components of the body system are i n-
tended to be servi ced i n assembl y onl y. Attempti ng
to remove or repai r certai n system sub-components
may resul t i n personal i njury and/or i mproper sys-
tem operati on. Onl y those components wi th ap-
proved repai r and i nstal l ati on procedures i n the
servi ce manual shoul d be servi ced.
4. 2. 4 DRBIIIா SAFETY INFORMATION
WARNING: EXCEEDING THE LIMITS OF THE
DRBIIIா MULTIMETER IS DANGEROUS.
READ ALL DRBIIIா INSTRUCTIONS BEFORE
USING THE MULTIMETER. FAILURE TO
FOLLOW THESE INSTRUCTIONS CAN
RESULT IN PERSONAL INJURY OR DEATH.
• Fol l ow the vehi cl e manufacturer’s servi ce speci -
fi cati ons at al l ti mes.
• Do not use the DRBI I I ௡ i f i t has been damaged.
• Do not use the test l eads i f the i nsul ati on i s
damaged or i f metal i s exposed.
• To avoi d el ectri cal shock, do not touch the test
l eads, ti ps or the ci rcui t bei ng tested.
• Choose the proper range and functi on for the
measurement. Do not try vol tage or current mea-
surements that may exceed the rated capaci ty.
• Do not exceed the l i mi ts shown i n the tabl e bel ow:
FUNCTI ON I NPUT LI MI T
Vol ts 0-500 vol ts peak AC
0-500 vol ts DC
Ohms (resi stance)* 0-1.12 megohms
Frequency measured
Frequency generated
1-10 khz
Temperature -58-1100°F
-50-600C
*Ohms cannot be measured i f vol tage i s present.
Ohms can be measured onl y i n a non-powered
ci rcui t.
• Vol tage between any termi nal and ground must
not exceed 500v DC or 500v peak AC.
• Use cauti on when measured vol tage above 25v
DC or 25v AC.
• The ci rcui t bei ng tested must be protected by a
10A fuse or ci rcui t breaker.
• Use the l ow current shunt to measure ci rcui ts up
to 10A. Use the hi gh current cl amp to measure
ci rcui ts exceedi ng 10A.
• When testi ng for the presence of vol tage or cur-
rent, make sure the meter i s functi oni ng cor-
rectl y. Take a readi ng of a known vol tage or
current before accepti ng a zero readi ng.
• When measuri ng current, connect the meter i n
seri es wi th the l oad.
• Di sconnect the l i ve test l ead before di sconnecti ng
the common test l ead.
• When usi ng the meter functi on, keep the
DRBI I I ௡ away from spark pl ug or coi l wi res to
avoi d measuri ng error from outsi de i nterference.
10
GENERAL INFORMATION
4. 3 WARNINGS
4. 3. 1 VEHICLE DAMAGE WARNINGS
Before di sconnecti ng any control modul e, make
sure the i gni ti on i s ЉoffЉ. Fai l ure to do so coul d
damage the modul e.
When testi ng vol tage or conti nui ty at any control
modul e, use the termi nal si de (not the wi re end) of
the connector. Do not probe a wi re through the
i nsul ati on: thi s wi l l damage i t and eventual l y cause
i t to fai l because of corrosi on.
Be careful when performi ng el ectri cal tests so as
to prevent acci dental shorti ng of termi nal s. Such
mi stakes can damage fuses or components. Al so, a
second code coul d be set, maki ng di agnosi s of the
ori gi nal probl em more di ffi cul t.
When repl aci ng a bl own fuse, i t i s i mportant to use
onl y a fuse havi ng the correct amperage rati ng. The
use of a fuse wi th a rati ng other than i ndi cated may
resul t i n a dangerous el ectri cal system overl oad. I f a
properl y rated fuse conti nues to bl ow, i t i ndi cates a
probl em i n the ci rcui t that must be corrected.
Servi ce and general i nformati on l abel s about the
ai rbag system can be found on the dri ver’s sun vi sor,
the gl ove box door, and i n the engi ne compartment.
To ensure that the ai rbag wi l l be ready to depl oy
i n a col l i si on, have the system servi ced by an
authori zed deal er.
4. 3. 2 ROAD TESTING A COMPLAINT
VEHICLE
Some compl ai nts wi l l requi re a test dri ve as part
of the repai r veri fi cati on procedure. The purpose of
the test dri ve i s to try to dupl i cate the di agnosti c
code or symptom condi ti on.
WARNING: REASSEMBLE ALL COMPONENTS
BEFORE ROAD TESTING A VEHICLE. DO NOT
TRY TO READ THE DRBIIIா SCREEN OR OTHER
TEST EQUIPMENT DURING A TEST DRIVE. DO
NOT HANG THE DRBIIIா OR OTHER TEST
EQUIPMENT FROM THE REARVIEW MIRROR
DURING A TEST DRIVE. HAVE AN ASSISTANT
AVAILABLE TO OPERATE THE DRBIIIா OR
OTHER TEST EQUIPMENT. FAILURE TO
FOLLOW THESE INSTRUCTIONS CAN RESULT
IN PERSONAL INJURY OR DEATH.
5.0 REQUIRED TOOLS AND
EQUIPMENT
• 8310 Ai rbag System Load Tool
• 8443 Suppl emental Restrai nts System Load Tool
• DRBI I I ௡ (di agnosti c read-out box)
• jumper wi res
• ohmmeter
• test l i ght
• vol tmeter
6.0 GLOSSARY OF TERMS
4WD 4-Wheel Dri ve
ABS Anti l ock Braki ng System
ACM Ai rbag Control Modul e
AECM Ai rbag El ectroni c Control Modul e
AIRBAG Al so cal l ed Љsqui bЉ i ni ti ator. Located
i nsi de the dri ver si de ai rbag assem-
bl y.
ASDM Ai rbag System Di agnosti c System
CAB Control l er Anti l ock Brake
CTMM Compass Temperature Mi rror Mod-
ul e
DAB Dri ver Ai rBag
DLC Data Li nk Connector
DTC Di agnosti c Troubl e Code
EMIC El ectro/Mechani cal I nstrument
Cl uster
LED Li ght Emi tti ng Di ode
LFW Low Fuel Warni ng
MIC Mechani cal I nstrument Cl uster
MIL Mal functi on I ndi cator Lamp
PAB Passenger Ai rBag
PCI Programmabl e Communi cati on I n-
terface
PCM Powertrai n Control Modul e
PDC Power Di stri buti on Center
S.T.A.R. Servi ce Techni cal Assi stance Re-
source
SKIM Sentry Key I mmobi l i zer Modul e
SKIS Sentry Key I mmobi l i zer System
SRS Suppl emental Restrai nts System
TCM Transmi ssi on Control Modul e
VFD Vacuum Fl uorescent Di spl ay
11
GENERAL INFORMATION
NOTES
12
7.0
DIAGNOSTIC INFORMATION AND
PROCEDURES
13
SymptomList:
ACCELEROMETER 1
INTERNAL 1
OUTPUT DRIVER 1
SAFING SENSOR
STORED ENERGY FIRING 1
STORED ENERGY LOGIC
Test Note: All symptomslistedabovearediagnosedusingthesametests.
The title for the tests will beACCELEROMETER 1.
When Monitored and Set Condition:
ACCELEROMETER 1
When Moni tored: Wi th the i gni ti on on, the modul e on board di agnosti cs conti nuousl y
performs i nternal ci rcui t tests.
Set Condi ti on: Thi s DTC wi l l set i f the modul e i denti fi es an out of range i nternal ci rcui t.
INTERNAL 1
When Moni tored: Wi th the i gni ti on on, the modul e on board di agnosti cs conti nuousl y
performs i nternal ci rcui t tests.
Set Condi ti on: Thi s DTC wi l l set i f the modul e i denti fi es an out of range i nternal ci rcui t.
OUTPUT DRIVER 1
When Moni tored: Wi th the i gni ti on on, the modul e on board di agnosti cs conti nuousl y
performs i nternal ci rcui t tests.
Set Condi ti on: Thi s DTC wi l l set i f the modul e i denti fi es an out of range i nternal ci rcui t.
SAFING SENSOR
When Moni tored: Wi th the i gni ti on on, the modul e on board di agnosti cs conti nuousl y
performs i nternal ci rcui t tests.
Set Condi ti on: Thi s DTC wi l l set i f the modul e i denti fi es an out of range i nternal sensor.
STORED ENERGY FIRING 1
When Moni tored: Wi th the i gni ti on on, the modul e on board di agnosti cs conti nuousl y
performs i nternal ci rcui t tests.
Set Condi ti on: Thi s DTC wi l l set i f the modul e i denti fi es an out of range i nternal ci rcui t.
14
AIRBAG
STORED ENERGY LOGIC
When Moni tored: Wi th the i gni ti on on, the modul e on board di agnosti cs conti nuousl y
performs i nternal ci rcui t tests.
Set Condi ti on: Thi s DTC wi l l set i f the modul e i denti fi es an out of range i nternal ci rcui t.
POSSIBLE CAUSES
AI RBAG CONTROL MODULE - ACM
TEST ACTION APPLICABILITY
1 Turn the i gni ti on on.
NOTE: Ensure the battery is fully charged.
NOTE: For the purpose of this test, the AECM and ORC modules will be
referred to as an ACM.
Sel ect the appropri ate modul e and DTC type combi nati on:
Al l
ACM - ACTI VE DTC
Repl ace the Ai rbag Control Modul e i n accordance wi th Servi ce
I nstructi ons.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
ACM - STORED DTC
Repl ace the Ai rbag Control Modul e i n accordance wi th Servi ce
I nstructi ons.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
NOTE: When reconnectingAirbagsystemcomponents, theignition must be
turned off and the battery must be disconnected.
15
AIRBAG
ACCELEROMETER 1 — Continued
SymptomList:
AIRBAG WARNING INDICATOR OPEN
AIRBAG WARNING INDICATOR SHORT
Test Note: All symptomslistedabovearediagnosedusingthesametests.
Thetitlefor thetests will beAIRBAG WARNING INDICATOR
OPEN.
When Monitored and Set Condition:
AIRBAG WARNING INDICATOR OPEN
When Moni tored: Wi th i gni ti on on the ACM moni tors the PCI Bus for a message from the
MI C contai ni ng the ai rbag warni ng i ndi cator status. The ACM request the warni ng l amp
status from the MI C once every second.
Set Condi ti on: Thi s DTC wi l l set i mmedi atel y i f the i ndi cator status i s OPEN.
AIRBAG WARNING INDICATOR SHORT
When Moni tored: Wi th i gni ti on on the ACM moni tors the PCI Bus for a message from the
MI C contai ni ng the ai rbag warni ng i ndi cator status. The ACM request the warni ng l amp
status from the MI C once every second.
Set Condi ti on: Thi s DTC wi l l set i mmedi atel y i f the i ndi cator status i s SHORT.
POSSIBLE CAUSES
MI C, COMMUNI CATI ON FAI LURE
WARNI NG I NDI CATOR
ACM, WARNI NG I NDI CATOR
STORED CODE OR I NTERMI TTENT CONDI TI ON
ACTI VE CODE PRESENT
TEST ACTION APPLICABILITY
1 Turn the i gni ti on on.
Ensure the battery i s ful l y charged.
NOTE: For the purpose of this test, the AECM and ORC modules will be
referred to as an ACM.
SELECT ACTI VE or STORED DTC:
Al l
ACM - ACTI VE DTC
Go To 2
ACM - STORED DTC
Go To 5
NOTE: When reconnectingAirbagsystemcomponents, theignition must be
turned off and the battery must be disconnected.
16
AIRBAG
TEST ACTION APPLICABILITY
2 Wi th the DRBI I I ௡, ensure PCI Bus communi cati ons wi th the I nstrument Cl uster.
I s the I nstrument Cl uster communi cati ng on the PCI Bus?
Al l
Yes → Go To 3
No → Refer to category COMMUNI CATI ON CATEGORY and sel ect the
rel ated symptom NO RESPONSE or I NSTRUMENT CLUSTER
BUS +/- SI GNAL OPEN.
3 Wi th the DRBI I I ௡ sel ect PASSI VE RESTRAI NTS, AI RBAG and MONI TOR DI S-
PLAY.
Usi ng the DRBI I I ௡, read the WARNI NG LAMP MONI TOR screen.
Sel ect the LAMP STATUS di spl ayed on the DRB moni tors screen.
Observe the Lamp Dri ver State and Actual l amp
I s the LAMP DRI VER and ACTUAL LAMP STATE: OK?
Al l
YES
Go To 4
NO
Repl ace I nstrument Cl uster.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
4 WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION OFF, DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE-
FORE PROCEEDING.
WARNING: IF THE AIRBAG CONTROL MODULE IS DROPPED AT ANY
TIME, IT MUST BE REPLACED. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND PERSONAL INJ URY OR DEATH.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace the Ai rbag Control Modul e i n accordance wi th Servi ce
I nstructi ons.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
17
AIRBAG
AIRBAG WARNING INDICATOR OPEN — Continued
TEST ACTION APPLICABILITY
5 Wi th the DRBI I I ௡, record and erase al l DTC’s from al l Ai rbag modul es.
I f equi pped wi th Passenger Ai rbag On - Off swi tch, read the DTC’s i n al l swi tch
posi ti ons.
I f any ACTI VE codes are present they must be resol ved before di agnosi ng any stored
codes.
WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION OFF, DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE-
FORE PROCEEDING.
Usi ng the wi ri ng di agram/schemati c as a gui de, i nspect the wi ri ng and connectors.
Look for chaffed, pi erced, pi nched, or parti al l y broken wi res and broken, bent, pushed
out, spread, corroded, or contami nated termi nal s.
The fol l owi ng addi ti onal checks may assi st you i n i denti fyi ng a possi bl e i ntermi ttent
probl em.
Reconnect any di sconnected components and harness connector.
WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION ON, THEN RECONNECT THE BATTERY.
Wi th the DRBI I I ௡ moni tor acti ve codes as you work through the fol l owi ng steps.
WARNING: TOAVOID PERSONAL INJ URY OR DEATH, MAINTAINASAFE
DISTANCE FROMALL AIRBAGSWHILE PERFORMING THE FOLLOWING
STEPS.
Wi ggl e the wi ri ng harness and connectors of the rel ated ai rbag ci rcui t or component.
I f codes are rel ated to the Dri ver Ai rbag ci rcui ts, rotate the steeri ng wheel from stop
to stop.
You have just attempted to si mul ate the condi ti on that i ni ti al l y set the troubl e code
message.
Di d the DTC become acti ve?
Al l
Yes → Sel ect appropri ate symptom from Symptom Li st.
No → No probl em found at thi s ti me. Erase al l codes before returni ng
vehi cl e to customer.
18
AIRBAG
AIRBAG WARNING INDICATOR OPEN — Continued
Symptom:
CLUSTER MESSAGE MISMATCH
When Monitored and Set Condition:
CLUSTER MESSAGE MISMATCH
When Moni tored: After the MI C bul b test i s compl eted, the ACM compares the Lamp
Request by ACM, On or Off, and the Lamp on by MI C, On or Off, PCI Bus messages. Each
message i s transmi tted one ti me per second or when a change i n the l amp state occur.
Set Condi ti on: I f the Lamp Request by ACM, On or Off, and the Lamp on by MI C, On or
Off, messages do not match, the code wi l l set.
POSSIBLE CAUSES
MI C DI AGNOSTI C CODES
CLUSTER MESSAGE MI SMATCH
STORED CODE OR I NTERMI TTENT CONDI TI ON
ACM, CLUSTER MESSAGE MI SMATCH
ACTI VE CODE PRESENT
TEST ACTION APPLICABILITY
1 Turn the i gni ti on on.
Ensure the battery i s ful l y charged.
NOTE: For the purpose of this test, the AECM and ORC modules will be
referred to as an ACM.
SELECT ACTI VE or STORED DTC:
Al l
ACM - ACTI VE DTC
Go To 2
ACM - STORED DTC
Go To 5
NOTE: When reconnectingAirbagsystemcomponents, theignition must be
turned off and the battery must be disconnected.
2 Turn the i gni ti on on.
Wi th the DRBI I I ௡, read the MI C DTCs.
Does the DRBI I I ௡ di spl ay any acti ve Di agnosti c Codes?
Al l
Yes → Refer to symptom l i st for probl ems rel ated to I nstrument Cl uster.
No → Go To 3
19
AIRBAG
TEST ACTION APPLICABILITY
3 Wi th the DRBI I I ௡ sel ect PASSI VE RESTRAI NTS, AI RBAG, MONI TOR DI SPLAY
and WARNI NG LAMP STATUS.
Cycl e the i gni ti on key and observe the LAMP ON BY MI C and LAMP REQ BY ACM
moni tors after the 6 to 8 second i ndi cator test.
Does the LAMP ON BY MI C and LAMP REQ BY ACM moni tors match?
Al l
YES
Go To 4
NO
Repl ace Mechani cal I nstrument Cl uster.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
4 WARNING: TOAVOID PERSONAL INJ URY OR DEATH, DISCONNECT THE
BATTERY AND WAIT TWO MINUTES BEFORE PROCEEDING.
WARNING: IF THE AIRBAG CONTROL MODULE IS DROPPED AT ANY
TIME, IT MUST BE REPLACED. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND PERSONAL INJ URY OR DEATH.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace the Ai rbag Control Modul e i n accordance wi th Servi ce
I nstructi ons.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
5 Wi th the DRBI I I ௡, record and erase al l DTC’s from al l Ai rbag modul es.
I f equi pped wi th Passenger Ai rbag On - Off swi tch, read the DTC’s i n al l swi tch
posi ti ons.
I f any ACTI VE codes are present they must be resol ved before di agnosi ng any stored
codes.
WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION OFF, DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE-
FORE PROCEEDING.
Usi ng the wi ri ng di agram/schemati c as a gui de, i nspect the wi ri ng and connectors.
Look for chaffed, pi erced, pi nched, or parti al l y broken wi res and broken, bent, pushed
out, spread, corroded, or contami nated termi nal s.
The fol l owi ng addi ti onal checks may assi st you i n i denti fyi ng a possi bl e i ntermi ttent
probl em.
Reconnect any di sconnected components and harness connector.
WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION ON, THEN RECONNECT THE BATTERY.
Wi th the DRBI I I ௡ moni tor acti ve codes as you work through the fol l owi ng steps.
WARNING: TOAVOID PERSONAL INJ URY OR DEATH, MAINTAINASAFE
DISTANCE FROMALL AIRBAGSWHILE PERFORMING THE FOLLOWING
STEPS.
Wi ggl e the wi ri ng harness and connectors of the rel ated ai rbag ci rcui t or component.
I f codes are rel ated to the Dri ver Ai rbag ci rcui ts, rotate the steeri ng wheel from stop
to stop.
You have just attempted to si mul ate the condi ti on that i ni ti al l y set the troubl e code
message.
Di d the DTC become acti ve?
Al l
Yes → Sel ect appropri ate symptom from Symptom Li st.
No → No probl em found at thi s ti me. Erase al l codes before returni ng
vehi cl e to customer.
20
AIRBAG
CLUSTER MESSAGE MISMATCH — Continued
Symptom:
DRIVER SQUIB 1 CIRCUIT OPEN
When Monitored and Set Condition:
DRIVER SQUIB 1 CIRCUIT OPEN
When Moni tored: Wi th the i gni ti on on, the ACM moni tors the resi stance of the Dri ver
Squi b 1 ci rcui ts.
Set Condi ti on: The ACM detects an open ci rcui t or hi gh resi stance i n the Dri ver Squi b 1
ci rcui ts.
POSSIBLE CAUSES
DRI VER AI RBAG SQUI B 1 CI RCUI T OPEN
CLOCKSPRI NG SQUI B 1 CI RCUI T OPEN
DRI VER SQUI B 1 LI NE 1 OR LI NE 2 CI RCUI TS OPEN
ACM, DRI VER SQUI B 1 CI RCUI T OPEN
STORED CODE OR I NTERMI TTENT CONDI TI ON
ACTI VE CODE PRESENT
TEST ACTION APPLICABILITY
1 Turn the i gni ti on on.
NOTE: Ensure the battery is fully charged.
NOTE: For the purpose of this test, the AECM and ORC modules will be
referred to as an ACM.
SELECT ACTI VE or STORED DTC:
Al l
ACM - ACTI VE DTC
Go To 2
ACM - STORED DTC
Go To 6
NOTE: When reconnectingAirbagsystemcomponents, theignition must be
turned off and the battery must be disconnected.
21
AIRBAG
TEST ACTION APPLICABILITY
2 WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION OFF, DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE-
FORE PROCEEDING.
Di sconnect the Dri ver Ai rbag Squi b connector(s).
NOTE: Check connectors - Clean and repair as necessary.
WARNING: TOAVOID PERSONAL INJ URY OR DEATH, DONOT PLACE AN
INTACT UNDEPLOYEDAIRBAG FACE DOWN ONAHARD SURFACE, THE
AIRBAG WILL PROPEL INTO THE AIR IF ACCIDENTALLY DEPLOYED.
Connect the appropri ate Load Tool to the Dri ver Ai rbag connector(s).
WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION ON, THEN RECONNECT THE BATTERY.
Wi th the DRBI I I ௡, read the acti ve Ai rbag Control Modul e DTC’s.
Does the DRBI I I ௡ show DRI VER SQUI B 1 CI RCUI T OPEN?
Al l
Yes → Go To 3
No → Repl ace the Dri ver Ai rbag i n accordance wi th the Servi ce I nfor-
mati on.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
3 WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION OFF, DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE-
FORE PROCEEDING.
Di sconnect the Load Tool from the Dri ver Ai rbag connector(s).
Di sconnect the Cl ockspri ng connector(s).
NOTE: Check connectors - Clean and repair as necessary.
Connect the appropri ate Load Tool to the Cl ockspri ng connector(s).
WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION ON, THEN RECONNECT THE BATTERY.
Wi th the DRBI I I ௡, read the acti ve Ai rbag Control Modul e DTC’s.
Does the DRBI I I ௡ show DRI VER SQUI B 1 CI RCUI T OPEN?
Al l
Yes → Go To 4
No → Repl ace the Cl ockspri ng i n accordance wi th the Servi ce I nforma-
ti on.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
4 WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION OFF, DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE-
FORE PROCEEDING.
Di sconnect the Load Tool from the Cl ockspri ng connector(s).
Di sconnect the Ai rbag Control Modul e connector(s).
NOTE: Check connectors - Clean and repair as necessary.
Connect the appropri ate Load Tool Adaptor to the Ai rbag Control Modul e connec-
tor(s).
Measure the resi stance of the Dri ver Squi b 1 Li ne 1 and Li ne 2 ci rcui ts between the
ACM Adaptor and the Cl ockspri ng connector(s).
I s the resi stance bel ow 1.0 ohm on both ci rcui ts?
Al l
Yes → Go To 5
No → Repai r open or hi gh resi stance i n the Dri ver Squi b 1 Li ne 1 or
Li ne 2 ci rcui ts.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
22
AIRBAG
DRIVER SQUIB 1 CIRCUIT OPEN — Continued
TEST ACTION APPLICABILITY
5 WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION OFF, DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE-
FORE PROCEEDING.
WARNING: IF THE AIRBAG CONTROL MODULE IS DROPPED AT ANY
TIME, IT MUST BE REPLACED. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND PERSONAL INJ URY OR DEATH.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r:
Repl ace the Ai rbag Control Modul e i n accordance wi th Servi ce
I nformati on.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
6 Wi th the DRBI I I ௡, record and erase al l DTC’s from al l Ai rbag modul es.
I f equi pped wi th Passenger Ai rbag On - Off swi tch, read the DTC’s i n al l swi tch
posi ti ons.
I f any ACTI VE codes are present they must be resol ved before di agnosi ng any stored
codes.
WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION OFF, DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE-
FORE PROCEEDING.
Usi ng the wi ri ng di agram/schemati c as a gui de, i nspect the wi ri ng and connectors.
Look for chaffed, pi erced, pi nched, or parti al l y broken wi res and broken, bent, pushed
out, spread, corroded, or contami nated termi nal s.
The fol l owi ng addi ti onal checks may assi st you i n i denti fyi ng a possi bl e i ntermi ttent
probl em.
Reconnect any di sconnected components and harness connector.
WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION ON, THEN RECONNECT THE BATTERY.
Wi th the DRBI I I ௡ moni tor acti ve codes as you work through the fol l owi ng steps.
WARNING: TOAVOID PERSONAL INJ URY OR DEATH, MAINTAINASAFE
DISTANCE FROMALL AIRBAGSWHILE PERFORMING THE FOLLOWING
STEPS.
Wi ggl e the wi ri ng harness and connectors of the rel ated ai rbag ci rcui t or component.
I f codes are rel ated to the Dri ver Ai rbag ci rcui ts, rotate the steeri ng wheel from stop
to stop.
You have just attempted to si mul ate the condi ti on that i ni ti al l y set the troubl e code
message.
Di d the DTC become acti ve?
Al l
Yes → Sel ect appropri ate symptom from Symptom Li st.
No → No probl em found at thi s ti me. Erase al l codes before returni ng
vehi cl e to customer.
23
AIRBAG
DRIVER SQUIB 1 CIRCUIT OPEN — Continued
Symptom:
DRIVER SQUIB 1 CIRCUIT SHORT
When Monitored and Set Condition:
DRIVER SQUIB 1 CIRCUIT SHORT
When Moni tored: Wi th the i gni ti on on, the ACM moni tors the resi stance of the Dri ver
Squi b 1 ci rcui ts.
Set Condi ti on: The ACM has detected l ow resi stance on the Dri ver Squi b 1 ci rcui ts.
POSSIBLE CAUSES
DRI VER AI RBAG SQUI B 1 CI RCUI T SHORT
CLOCKSPRI NG, DRI VER SQUI B 1 CI RCUI TS SHORT
DRI VER AI RBAG SQUI B 1 LI NE 1 SHORT TO LI NE 2
ACM, DRI VER SQUI B LI NE 1 SHORT TO LI NE 2
STORED CODE OR I NTERMI TTENT CONDI TI ON
ACTI VE CODE PRESENT
TEST ACTION APPLICABILITY
1 Turn the i gni ti on on.
NOTE: Ensure the battery is fully charged.
NOTE: For the purpose of this test, the AECM and ORC modules will be
referred to as an ACM.
SELECT ACTI VE or STORED DTC:
Al l
ACM - ACTI VE DTC
Go To 2
ACM - STORED DTC
Go To 6
NOTE: When reconnectingairbagsystemcomponents the Ignition must be
turned off and the Battery must be disconnected.
24
AIRBAG
TEST ACTION APPLICABILITY
2 WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION OFF, DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE-
FORE PROCEEDING.
Di sconnect the Dri ver Ai rbag connector(s).
NOTE: Check connectors - Clean and repair as necessary.
WARNING: TOAVOID PERSONAL INJ URY OR DEATH, DONOT PLACE AN
INTACT UNDEPLOYEDAIRBAG FACE DOWN ONAHARD SURFACE, THE
AIRBAG WILL PROPEL INTO THE AIR IF ACCIDENTALLY DEPLOYED.
Connect the appropri ate Load Tool to the Dri ver Ai rbag connector(s).
WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION ON, THEN RECONNECT THE BATTERY.
Wi th the DRBI I I ௡, read the acti ve Ai rbag Control Modul e DTC’s.
Does the DRBI I I ௡ show DRI VER SQUI B 1 CI RCUI T SHORT?
Al l
Yes → Go To 3
No → Repl ace the Dri ver Ai rbag i n accordance wi th the Servi ce I nfor-
mati on.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
3 WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION OFF, DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE-
FORE PROCEEDING.
Di sconnect the Load Tool from the Dri ver Ai rbag connector(s).
Di sconnect the Cl ockspri ng connector(s).
NOTE: Check connectors - Clean and repair as necessary.
Connect the appropri ate Load Tool to the Cl ockspri ng connector(s).
WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION ON, THEN RECONNECT THE BATTERY.
Wi th the DRBI I I ௡, read the acti ve Ai rbag Control Modul e DTC’s.
Does the DRBI I I ௡ show DRI VER SQUI B 1 CI RCUI T SHORT?
Al l
Yes → Go To 4
No → Repl ace the Cl ockspri ng i n accordance wi th the Servi ce I nforma-
ti on.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
4 WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION OFF, DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE-
FORE PROCEEDING.
Di sconnect the Load Tool from the Cl ockspri ng connector(s).
Di sconnect the Ai rbag Control Modul e connector(s).
NOTE: Check connectors - Clean and repair as necessary.
Connect the appropri ate Load Tool Adaptor to the Ai rbag Control Modul e connec-
tor(s).
Measure the resi stance between the Dri ver Squi b 1 Li ne 1 and Li ne 2 at the
Cl ockspri ng connector.
I s the resi stance bel ow 10K ohms?
Al l
Yes → Repai r the Dri ver Squi b 1 Li ne 1 ci rcui t shorted to Dri ver Squi b
1 Li ne 2 ci rcui t.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
No → Go To 5
25
AIRBAG
DRIVER SQUIB 1 CIRCUIT SHORT — Continued
TEST ACTION APPLICABILITY
5 WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION OFF, DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE-
FORE PROCEEDING.
WARNING: IF THE AIRBAG CONTROL MODULE IS DROPPED AT ANY
TIME, IT MUST BE REPLACED. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND PERSONAL INJ URY OR DEATH.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r:
Repl ace the Ai rbag Control Modul e i n accordance wi th Servi ce
I nformati on.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
6 Wi th the DRBI I I ௡, record and erase al l DTC’s from al l Ai rbag modul es.
I f equi pped wi th Passenger Ai rbag On - Off swi tch, read the DTC’s i n al l swi tch
posi ti ons.
I f any ACTI VE codes are present they must be resol ved before di agnosi ng any stored
codes.
WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION OFF, DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE-
FORE PROCEEDING.
Usi ng the wi ri ng di agram/schemati c as a gui de, i nspect the wi ri ng and connectors.
Look for chaffed, pi erced, pi nched, or parti al l y broken wi res and broken, bent, pushed
out, spread, corroded, or contami nated termi nal s.
The fol l owi ng addi ti onal checks may assi st you i n i denti fyi ng a possi bl e i ntermi ttent
probl em.
Reconnect any di sconnected components and harness connector.
WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION ON, THEN RECONNECT THE BATTERY.
Wi th the DRBI I I ௡ moni tor acti ve codes as you work through the fol l owi ng steps.
WARNING: TOAVOID PERSONAL INJ URY OR DEATH, MAINTAINASAFE
DISTANCE FROMALL AIRBAGSWHILE PERFORMING THE FOLLOWING
STEPS.
Wi ggl e the wi ri ng harness and connectors of the rel ated ai rbag ci rcui t or component.
I f codes are rel ated to the Dri ver Ai rbag ci rcui ts, rotate the steeri ng wheel from stop
to stop.
You have just attempted to si mul ate the condi ti on that i ni ti al l y set the troubl e code
message.
Di d the DTC become acti ve?
Al l
Yes → Sel ect appropri ate symptom from Symptom Li st.
No → No probl em found at thi s ti me. Erase al l codes before returni ng
vehi cl e to customer.
26
AIRBAG
DRIVER SQUIB 1 CIRCUIT SHORT — Continued
Symptom:
DRIVER SQUIB 1 SHORT TO BATTERY
When Monitored and Set Condition:
DRIVER SQUIB 1 SHORT TO BATTERY
When Moni tored: Wi th the i gni ti on on, the ACM moni tors the vol tage of the Dri ver Squi b
1 ci rcui ts.
Set Condi ti on: The ACM has detected hi gh vol tage on the Dri ver Squi b 1 ci rcui ts.
POSSIBLE CAUSES
DRI VER AI RBAG SQUI B 1 SHORT TO BATTERY
CLOCKSPRI NG, DRI VER SQUI B 1 SHORT TO BATTERY
DRI VER SQUI B 1 LI NE 1 OR LI NE 2 SHORT TO BATTERY
ACM, DRI VER SQUI B 1 SHORT TO BATTERY
STORED CODE OR I NTERMI TTENT CONDI TI ON
ACTI VE CODE PRESENT
TEST ACTION APPLICABILITY
1 Turn the i gni ti on on.
NOTE: Ensure the battery is fully charged.
NOTE: For the purpose of this test, the AECM and ORC modules will be
referred to as an ACM.
SELECT ACTI VE or STORED ACM DTC:
Al l
ACM - ACTI VE DTC
Go To 2
ACM - STORED DTC
Go To 5
NOTE: When reconnectingAirbagsystemcomponents, theignition must be
turned off and the battery must be disconnected.
27
AIRBAG
TEST ACTION APPLICABILITY
2 WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION OFF, DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE-
FORE PROCEEDING.
Di sconnect the Dri ver Ai rbag Squi b connector(s).
WARNING: TOAVOID PERSONAL INJ URY OR DEATH, DONOT PLACE AN
INTACT UNDEPLOYEDAIRBAG FACE DOWN ONAHARD SURFACE, THE
AIRBAG WILL PROPEL INTO THE AIR IF ACCIDENTALLY DEPLOYED.
NOTE: Check connectors - Clean and repair as necessary.
Connect the appropri ate Load Tool to the Dri ver Ai rbag connector(s).
WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION ON, THEN RECONNECT THE BATTERY.
Wi th the DRBI I I ௡, read the acti ve Ai rbag Control Modul e DTC’s.
Does the DRBI I I ௡ show DRI VER SQUI B 1 SHORT TO BATTERY?
Al l
Yes → Go To 3
No → Repl ace the Dri ver Ai rbag i n accordance wi th the Servi ce I nfor-
mati on.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
3 WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION OFF, DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE-
FORE PROCEEDING.
Di sconnect the Load Tool from the Dri ver Ai rbag connector(s).
Di sconnect the Cl ockspri ng connector(s).
NOTE: Check connectors - Clean and repair as necessary.
Connect the appropri ate Load Tool to the Cl ockspri ng connector(s).
WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION ON, THEN RECONNECT THE BATTERY.
Wi th the DRBI I I ௡, read the acti ve Ai rbag Control Modul e DTC’s.
Does the DRBI I I ௡ show DRI VER SQUI B 1 SHORT TO BATTERY ?
Al l
Yes → Go To 4
No → Repl ace the Cl ockspri ng i n accordance wi th the Servi ce I nforma-
ti on.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
28
AIRBAG
DRIVER SQUIB 1 SHORT TO BATTERY — Continued
TEST ACTION APPLICABILITY
4 WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION OFF, DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE-
FORE PROCEEDING.
WARNING: IF THE AIRBAG CONTROL MODULE IS DROPPED AT ANY
TIME, IT MUST BE REPLACED. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND PERSONAL INJ URY OR DEATH.
Di sconnect the Load Tool from the Cl ockspri ng connector(s).
Di sconnect the Ai rbag Control Modul e connector(s).
NOTE: Check connectors - Clean and repair as necessary.
Connect the appropri ate Load Tool Adaptor to the Ai rbag Control Modul e connec-
tor(s).
WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION ON, THEN RECONNECT THE BATTERY.
Measure the vol tage on the Dri ver Squi b 1 Li ne 1 and Li ne 2 ci rcui ts between the
Cl ockspri ng connector and ground.
I s there any vol tage present?
Al l
Yes → Repai r the Dri ver Squi b 1 Li ne 1 or Li ne 2 ci rcui ts shorted to
battery.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
No → Repl ace the Ai rbag Control Modul e i n accordance wi th Servi ce
I nformati on.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
5 Wi th the DRBI I I ௡, record and erase al l DTC’s from al l Ai rbag modul es.
I f equi pped wi th Passenger Ai rbag On - Off swi tch, read the DTC’s i n al l swi tch
posi ti ons.
I f any ACTI VE codes are present they must be resol ved before di agnosi ng any stored
codes.
WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION OFF, DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE-
FORE PROCEEDING.
Usi ng the wi ri ng di agram/schemati c as a gui de, i nspect the wi ri ng and connectors.
Look for chaffed, pi erced, pi nched, or parti al l y broken wi res and broken, bent, pushed
out, spread, corroded, or contami nated termi nal s.
The fol l owi ng addi ti onal checks may assi st you i n i denti fyi ng a possi bl e i ntermi ttent
probl em.
Reconnect any di sconnected components and harness connector.
WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION ON, THEN RECONNECT THE BATTERY.
Wi th the DRBI I I ௡ moni tor acti ve codes as you work through the fol l owi ng steps.
WARNING: TOAVOID PERSONAL INJ URY OR DEATH, MAINTAINASAFE
DISTANCE FROMALL AIRBAGSWHILE PERFORMING THE FOLLOWING
STEPS.
Wi ggl e the wi ri ng harness and connectors of the rel ated ai rbag ci rcui t or component.
I f codes are rel ated to the Dri ver Ai rbag ci rcui ts, rotate the steeri ng wheel from stop
to stop.
You have just attempted to si mul ate the condi ti on that i ni ti al l y set the troubl e code
message.
Di d the DTC become acti ve?
Al l
Yes → Sel ect appropri ate symptom from Symptom Li st.
No → No probl em found at thi s ti me. Erase al l codes before returni ng
vehi cl e to customer.
29
AIRBAG
DRIVER SQUIB 1 SHORT TO BATTERY — Continued
Symptom:
DRIVER SQUIB 1 SHORT TO GROUND
When Monitored and Set Condition:
DRIVER SQUIB 1 SHORT TO GROUND
When Moni tored: Wi th the i gni ti on on, the ACM moni tors the resi stance of the Dri ver
Squi b 1 ci rcui ts.
Set Condi ti on: When the ACM detects a short to ground i n ei ther Dri ver Squi b 1 ci rcui ts.
POSSIBLE CAUSES
DRI VER AI RBAG SQUI B 1 SHORT TO GROUND
CLOCKSPRI NG, DRI VER SQUI B 1 SHORT TO GROUND
DRI VER SQUI B 1 LI NE 1 OR LI NE 2 SHORTED TO GROUND
ACM, DRI VER SQUI B 1 SHORT TO GROUND
STORED CODE OR I NTERMI TTENT CONDI TI ON
ACTI VE CODE PRESENT
TEST ACTION APPLICABILITY
1 Turn the i gni ti on on.
NOTE: Ensure the battery is fully charged.
NOTE: For the purpose of this test, the AECM and ORC modules will be
referred to as an ACM.
SELECT ACTI VE or STORED DTC:
Al l
ACM - ACTI VE DTC
Go To 2
ACM - STORED DTC
Go To 6
NOTE: When reconnectingAirbagsystemcomponents, theignition must be
turned off and the battery must be disconnected.
30
AIRBAG
TEST ACTION APPLICABILITY
2 WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION OFF, DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE-
FORE PROCEEDING.
Di sconnect the Dri ver Ai rbag Squi b connector(s).
NOTE: Check connectors - Clean and repair as necessary.
WARNING: TOAVOID PERSONAL INJ URY OR DEATH, DONOT PLACE AN
INTACT UNDEPLOYEDAIRBAG FACE DOWN ONAHARD SURFACE, THE
AIRBAG WILL PROPEL INTO THE AIR IF ACCIDENTALLY DEPLOYED.
Connect the appropri ate Load Tool to the Dri ver Ai rbag connector(s).
WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION ON, THEN RECONNECT THE BATTERY.
Wi th the DRBI I I ௡, read the acti ve Ai rbag Control Modul e DTC’s.
Does the DRBI I I ௡ show DRI VER SQUI B 1 SHORT TO GROUND?
Al l
Yes → Go To 3
No → Repl ace the Dri ver Ai rbag i n accordance wi th the Servi ce I nfor-
mati on.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
3 WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION OFF, DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE-
FORE PROCEEDING.
Di sconnect the Load Tool from the Dri ver Ai rbag connector(s).
Di sconnect the Cl ockspri ng connector.
NOTE: Check connectors - Clean and repair as necessary.
Connect the appropri ate Load Tool to the Cl ockspri ng connector.
WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION ON, THEN RECONNECT THE BATTERY.
Wi th the DRBI I I ௡, read the acti ve Ai rbag Control Modul e DTC’s.
Does the DRBI I I ௡ show DRI VER SQUI B 1 SHORT TO GROUND?
Al l
Yes → Go To 4
No → Repl ace the Cl ockspri ng i n accordance wi th the Servi ce I nforma-
ti on.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
4 WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION OFF, DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE-
FORE PROCEEDING.
Di sconnect the Load Tool from the Cl ockspri ng connector.
Di sconnect the Ai rbag Control Modul e connector(s).
NOTE: Check connectors - Clean and repair as necessary.
Connect the appropri ate Load Tool Adaptor to the Ai rbag Control Modul e connector.
Measure the resi stance of the Dri ver Squi b 1 Li ne 1 and Li ne 2 ci rcui ts between
Cl ockspri ng connector and ground.
I s the resi stance bel ow 10K ohms on ei ther ci rcui t?
Al l
Yes → Repai r Dri ver Squi b 1 Li ne 1 or Li ne 2 ci rcui ts shorted to ground.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
No → Go To 5
31
AIRBAG
DRIVER SQUIB 1 SHORT TO GROUND — Continued
TEST ACTION APPLICABILITY
5 WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION OFF, DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE-
FORE PROCEEDING.
WARNING: IF THE AIRBAG CONTROL MODULE IS DROPPED AT ANY
TIME, IT MUST BE REPLACED. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT,
PERSONAL INJ URY OR DEATH, .
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r:
Repl ace the Ai rbag Control Modul e i n accordance wi th Servi ce
I nformati on.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
6 Wi th the DRBI I I ௡, record and erase al l DTC’s from al l Ai rbag modul es.
I f equi pped wi th Passenger Ai rbag On - Off swi tch, read the DTC’s i n al l swi tch
posi ti ons.
I f any ACTI VE codes are present they must be resol ved before di agnosi ng any stored
codes.
WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION OFF, DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE-
FORE PROCEEDING.
Usi ng the wi ri ng di agram/schemati c as a gui de, i nspect the wi ri ng and connectors.
Look for chaffed, pi erced, pi nched, or parti al l y broken wi res and broken, bent, pushed
out, spread, corroded, or contami nated termi nal s.
The fol l owi ng addi ti onal checks may assi st you i n i denti fyi ng a possi bl e i ntermi ttent
probl em.
Reconnect any di sconnected components and harness connector.
WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION ON, THEN RECONNECT THE BATTERY.
Wi th the DRBI I I ௡ moni tor acti ve codes as you work through the fol l owi ng steps.
WARNING: TOAVOID PERSONAL INJ URY OR DEATH, MAINTAINASAFE
DISTANCE FROMALL AIRBAGSWHILE PERFORMING THE FOLLOWING
STEPS.
Wi ggl e the wi ri ng harness and connectors of the rel ated ai rbag ci rcui t or component.
I f codes are rel ated to the Dri ver Ai rbag ci rcui ts, rotate the steeri ng wheel from stop
to stop.
You have just attempted to si mul ate the condi ti on that i ni ti al l y set the troubl e code
message.
Di d the DTC become acti ve?
Al l
Yes → Sel ect appropri ate symptom from Symptom Li st.
No → No probl em found at thi s ti me. Erase al l codes before returni ng
vehi cl e to customer.
32
AIRBAG
DRIVER SQUIB 1 SHORT TO GROUND — Continued
Symptom:
LOSS OF IGNITION RUN - START
When Monitored and Set Condition:
LOSS OF IGNITION RUN - START
When Moni tored: Wi th the i gni ti on i n the Run-Start posi ti on the ACM moni tors the
Fused I gni ti on Swi tch Output Run-Start ci rcui t for proper system vol tage.
Set Condi ti on: I f the vol tage on the Fused I gni ti on Swi tch Output Run-Start ci rcui t drops
bel ow approxi matel y 4.5 vol ts, the code wi l l set.
POSSIBLE CAUSES
FUSED I GNI TI ON SW OUTPUT RUN-START SHORT TO GROUND
I GNI TI ON SWI TCH RUN - START CI RCUI T OPEN
FUSED I GNI TI ON SWI TCH OUTPUT RUN-START CI RCUI T OPEN
ACM, FUSED I GNI TI ON OUTPUT RUN-START CI RCUI T OPEN
ACM, RUN - START SHORTED TO GROUND
ACM, RUN - START CI RCUI T SHORTED
ON - OFF SWI TCH, RUN - START CI RCUI T SHORTED TO GROUND
FUSED I GNI TI ON SWI TCH OUTPUT RUN - START CI RCUI T SHORT TO GROUND
FUSED I GNI TI ON SWI TCH OUTPUT RUN - START CI RCUI T SHORT TO GROUND
STORED CODE OR I NTERMI TTENT CONDI TI ON
ACTI VE CODE PRESENT
TEST ACTION APPLICABILITY
1 Ensure the battery i s ful l y charged.
Turn the i gni ti on on.
NOTE: For the purpose of this test, the AECM and ORC modules will be
referred to as an ACM.
DETERMI NE ACTI VE OR STORED DTC:
Al l
ACM - ACTI VE DTC
Go To 2
ACM - STORED DTC
Go To 10
NOTE: When reconnectingAirbagsystemcomponents, theignition must be
turned off and the battery must be disconnected.
2 Turn I gni ti on off.
Remove and i nspect the Ai rbag Run-Start Fuse.
NOTE: Check connectors - Clean and repair as necessary.
I s the Fuse open?
Al l
Yes → Go To 3
No → Go To 8
33
AIRBAG
TEST ACTION APPLICABILITY
3 Measure the resi stance of the Fused I gni ti on Swi tch Output Run-Start ci rcui t
between the Ai rbag Run - Start Fuse and ground.
I s the resi stance bel ow 10.0 ohms?
Al l
Yes → Go To 4
No → Repl ace Ai rbag Run - Start Fuse.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
4 I s thi s vehi cl e equi pped wi th a Passenger Ai rbag On - Off Swi tch? Al l
Yes → Go To 5
No → Go To 7
5 Di sconnect the Passenger Ai rbag On - Off Swi tch connector
NOTE: Check connectors - Clean and repair as necessary.
Measure the resi stance of the Fused I gni ti on Swi tch Output Run-Start Ci rcui t
between the On - Off Swi tch connector and ground.
I s the resi stance bel ow 10K ohms?
Al l
Yes → Go To 6
No → Repl ace the Passenger Ai rbag On - Off Swi tch and Ai rbag Run -
Start Fuse.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
6 WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION OFF, DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE-
FORE PROCEEDING.
WARNING: IF THE AIRBAG CONTROL MODULE IS DROPPED AT ANY
TIME, IT MUST BE REPLACED. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND PERSONAL INJ URY OR DEATH.
Di sconnect the Ai rbag Control Modul e connector.
NOTE: Check connectors - Clean and repair as necessary.
Connect the Ai rbag Load Tool ACM Adaptor to the Ai rbag Control Modul e connector.
Measure the resi stance of the Fused I gni ti on Swi tch Output Run-Start ci rcui t
between the Ai rbag Control Modul e connector and ground.
I s the resi stance bel ow 10K ohms?
Al l
Yes → Repai r the Fused I gni ti on Swi tch Output Run - Start ci rcui t short
to ground.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
No → Go To 11
34
AIRBAG
LOSS OF IGNITION RUN - START — Continued
TEST ACTION APPLICABILITY
7 WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION OFF, DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE-
FORE PROCEEDING.
WARNING: IF THE AIRBAG CONTROL MODULE IS DROPPED AT ANY
TIME, IT MUST BE REPLACED. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND PERSONAL INJ URY OR DEATH.
Di sconnect the Ai rbag Control Modul e connector
NOTE: Check connectors - Clean and repair as necessary.
Measure the resi stance of the Fused I gni ti on Swi tch Output Run-Start ci rcui t
between the Ai rbag Control Modul e connector and ground.
I s the resi stance bel ow 10K ohms?
Al l
Yes → Repai r the Fused I gni ti on Swi tch Output Run - Start ci rcui t short
to ground.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
No → Go To 11
8 Turn the i gni ti on on.
Measure the vol tage of the I gni ti on Swi tch Output ci rcui t at the Ai rbag Run - Start
fuse.
I s the vol tage above approxi matel y 4.5 vol ts?
Al l
Yes → Go To 9
No → Repai r the open I gni ti on Swi tch Output Run - Start ci rcui t.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
NOTE: Reinstall the fuse after performing this test.
9 WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION OFF, DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE-
FORE PROCEEDING.
WARNING: IF THE AIRBAG CONTROL MODULE IS DROPPED AT ANY
TIME, IT MUST BE REPLACED. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND PERSONAL INJ URY OR DEATH.
Di sconnect the Ai rbag Control Modul e connector.
NOTE: Check connectors - Clean and repair as necessary.
Rei nstal l the previ ousl y removed Ai rbag Run-Start Fuse.
WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION ON, THEN RECONNECT THE BATTERY.
Measure the vol tage of the Fused I gni ti on Swi tch Output Run-Start Ci rcui t between
the Ai rbag Control Modul e connector ground.
I s the vol tage above approxi matel y 4.5 vol ts?
Al l
Yes → Go To 11
No → Repai r open Fused I gni ti on Swi tch Output Run-Start ci rcui t.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
35
AIRBAG
LOSS OF IGNITION RUN - START — Continued
TEST ACTION APPLICABILITY
10 Wi th the DRBI I I ௡, record and erase al l DTC’s from al l Ai rbag modul es.
I f equi pped wi th Passenger Ai rbag On - Off swi tch, read the DTC’s i n al l swi tch
posi ti ons.
I f any ACTI VE codes are present they must be resol ved before di agnosi ng any stored
codes.
WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION OFF, DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE-
FORE PROCEEDING.
Usi ng the wi ri ng di agram/schemati c as a gui de, i nspect the wi ri ng and connectors.
Look for chaffed, pi erced, pi nched, or parti al l y broken wi res and broken, bent, pushed
out, spread, corroded, or contami nated termi nal s.
The fol l owi ng addi ti onal checks may assi st you i n i denti fyi ng a possi bl e i ntermi ttent
probl em.
Reconnect any di sconnected components and harness connector.
WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION ON, THEN RECONNECT THE BATTERY.
Wi th the DRBI I I ௡ moni tor acti ve codes as you work through the fol l owi ng steps.
WARNING: TOAVOID PERSONAL INJ URY OR DEATH, MAINTAINASAFE
DISTANCE FROMALL AIRBAGSWHILE PERFORMING THE FOLLOWING
STEPS.
Wi ggl e the wi ri ng harness and connectors of the rel ated ai rbag ci rcui t or component.
I f codes are rel ated to the Dri ver Ai rbag ci rcui ts, rotate the steeri ng wheel from stop
to stop.
You have just attempted to si mul ate the condi ti on that i ni ti al l y set the troubl e code
message.
Di d the DTC become acti ve?
Al l
Yes → Sel ect appropri ate symptom from Symptom Li st.
No → No probl em found at thi s ti me. Erase al l codes before returni ng
vehi cl e to customer.
11 WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION OFF, DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE-
FORE PROCEEDING.
WARNING: IF THE AIRBAG CONTROL MODULE IS DROPPED AT ANY
TIME, IT MUST BE REPLACED. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND PERSONAL INJ URY OR DEATH.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace the Ai rbag Control Modul e i n accordance wi th Servi ce
I nstructi ons.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
36
AIRBAG
LOSS OF IGNITION RUN - START — Continued
Symptom:
LOSS OF IGNITION RUN ONLY
When Monitored and Set Condition:
LOSS OF IGNITION RUN ONLY
When Moni tored: Wi th the i gni ti on i n the run posi ti on the modul e moni tors the Run Onl y
ci rcui t for proper system vol tage.
Set Condi ti on: I f the vol tage on the Run Onl y ci rcui t drops bel ow 4.5 vol ts, the code wi l l
set.
POSSIBLE CAUSES
I GNI TI ON SWI TCH OUTPUT RUN CI RCUI T OPEN
FUSED I GNI TI ON SWI TCH OUTPUT RUN CI RCUI T OPEN
ACM, FUSED I GNI TI ON OUTPUT RUN CI RCUI T OPEN
CHECKI NG FOR A SHORTED RUN CI RCUI T
FUSED I GNI TI ON SWI TCH OUTPUT RUN CI RCUI T SHORT TO GROUND
ACM, FUSED I GNI TI ON RUN CI RCUI T SHORT TO GROUND
TEST ACTION APPLICABILITY
1 Turn the i gni ti on on.
Ensure the battery i s ful l y charged.
NOTE: For the purpose of this test, the AECM and ORC modules will be
referred to as an ACM.
SELECT ACTI VE :
Al l
ACM - ACTI VE DTC
Go To 2
NOTE: When reconnectingAirbagsystemcomponents, theignition must be
turned off and the battery must be disconnected.
2 Turn the i gni ti on off.
Remove and i nspect the Ai rbag Run ci rcui t fuse.
I s the Fuse open?
Al l
Yes → Go To 3
No → Go To 6
3 Remove the Ai rbag Run fuse.
NOTE: Check connectors - Clean and repair as necessary.
Measure the resi stance of the Fused I gni ti on Swi tch Output Run ci rcui t between the
Run Fuse and ground.
I s the resi stance bel ow 10.0 ohms ?
Al l
Yes → Go To 4
No → Repl ace the defecti ve fuse.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
37
AIRBAG
TEST ACTION APPLICABILITY
4 WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION OFF, DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE-
FORE PROCEEDING.
Di sconnect the Ai rbag Control Modul e connector.
NOTE: Check connectors - Clean and repair as necessary.
Measure the resi stance of the Fused I gni ti on Swi tch Output Run ci rcui t between the
ACM connector and ground.
I s the resi stance bel ow 10K ohms ?
Al l
Yes → Repai r the Fused I gni ti on Swi tch Output Run ci rcui t for a short
to ground and repl ace Ai rbag Run Fuse.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
No → Go To 5
5 WARNING: TURN THE IGNITION OFF, DISCONNECT THE BATTERY AND
WAIT TWO MINUTES BEFORE PROCEEDING.
WARNING: IF THE AIRBAG CONTROL MODULE IS DROPPED AT ANY
TIME, IT MUST BE REPLACED.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace the Ai rbag Control Modul e i n accordance wi th Servi ce
I nstructi ons and repl ace the Run Onl y Fuse.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
6 Turn the i gni ti on on.
Measure the vol tage of the I gni ti on Swi tch Output Run ci rcui t between the Ai rbag
Run ci rcui t fuse and ground.
I s the vol tage above approxi matel y 4.5 vol ts?
Al l
Yes → Go To 7
No → Repai r the open I gni ti on Swi tch Output Run ci rcui t.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
7 WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION OFF, DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE-
FORE PROCEEDING.
Di sconnect the Ai rbag Control Modul e connector.
NOTE: Check connectors - Clean and repair as necessary.
WARNING: IF THE AIRBAG CONTROL MODULE IS DROPPED AT ANY
TIME, IT MUST BE REPLACED. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND PERSONAL INJ URY OR DEATH.
Rei nstal l the ai rbag Run fuse.
WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION ON, THEN RECONNECT THE BATTERY.
Measure the vol tage of the Fused I gni ti on Swi tch Output Run ci rcui t at the Ai rbag
Control Modul e connector.
I s the vol tage above approxi matel y 4.5 vol ts?
Al l
Yes → Go To 8
No → Repai r the an open or hi gh resi stance i n the Fused I gni ti on
Swi tch Output Run ci rcui t.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
38
AIRBAG
LOSS OF IGNITION RUN ONLY — Continued
TEST ACTION APPLICABILITY
8 WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION OFF, DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE-
FORE PROCEEDING.
WARNING: IF THE AIRBAG CONTROL MODULE IS DROPPED AT ANY
TIME, IT MUST BE REPLACED. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND PERSONAL INJ URY OR DEATH.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace the Ai rbag Control Modul e i n accordance wi th Servi ce
I nstructi ons.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
39
AIRBAG
LOSS OF IGNITION RUN ONLY — Continued
Symptom:
MODULE NOT CONFIGURED FOR PAB OFF SWITCH
When Monitored and Set Condition:
MODULE NOT CONFIGURED FOR PAB OFF SWITCH
When Moni tored: When the ACM i s not confi gured for an ON - OFF swi tch, the ACM
moni tors the Passenger Ai rbag On - Off Swi tch i nputs to determi ne i f a swi tch i s present.
Set Condi ti on: The code wi l l set, i f the ACM detects a Passenger Ai rbag ON - OFF Swi tch
connected to the Ai rbag Control Modul e.
POSSIBLE CAUSES
I NTERMI TTENT CODES PRESENT
VERI FY CI RCUI TS
ACM NOT CONFI GURED FOR PAB OFF SWI TCH
ACM, MODULE NOT CONFI GURED FOR PAB OFF SWI TCH
PASSENGER AI RBAG I NDI CATOR DRI VER CI RCUI T SHORT
PAB MUX SWI TCH CI RCUI T SHORT TO GROUND
PAB MUX SWI TCH CI RCUI T SHORT TOGETHER
ACM, PAB ON - OFF SWI TCH CI RCUI T SHORTED
TEST ACTION APPLICABILITY
1 Turn the i gni ti on on.
Ensure the battery i s ful l y charged.
NOTE: For the purpose of this test, the AECM and ORC modules will be
referred to as an ACM.
SELECT ACTI VE or STORED DTC:
Al l
ACM - ACTI VE DTC
Go To 2
ACM - STORED DTC
No probl em found at thi s ti me.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
NOTE: When reconnectingAirbagsystemcomponents, theignition must be
turned off and the battery must be disconnected.
2 I nspect vehi cl e for a Passenger Ai rbag On - Off Swi tch l ocated i n the center of the
i nstrument panel .
I s thi s vehi cl e equi pped wi th a Passenger Ai rbag On - OFF Swi tch?
Al l
Yes → Go To 3
No → Go To 5
40
AIRBAG
TEST ACTION APPLICABILITY
3 Sel ect Restrai nts, Ai rbag and then Mi scel l aneous from the DRB menu.
Fol l ow i nstructi ons to veri fy the ACM swi tch confi gurati on.
Does the DRB show Confi gured for PAB OFF Swi tch?
Al l
Yes → Go To 4
No → Fol l ow i nstructi ons on the DRB to reconfi gured the Ai rbag Con-
trol Modul e to support the Passenger Ai rbag Swi tch On - Off
Swi tch.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
4 WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION OFF, DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE-
FORE PROCEEDING.
WARNING: IF THE AIRBAG CONTROL MODULE IS DROPPED AT ANY
TIME, IT MUST BE REPLACED. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND PERSONAL INJ URY OR DEATH.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace the Ai rbag Control Modul e i n accordance wi th Servi ce
I nstructi ons.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
5 I nspect vehi cl e for a Passenger Ai rbag On - Off Swi tch wi ri ng at the ACM connector.
NOTE: Some vehi cl es may have the wi ri ng for the Passenger Ai rbag Off Swi tch and
no swi tch.
I s thi s vehi cl e equi pped wi th a Passenger Ai rbag On - OFF Swi tch wi ri ng?
Al l
Yes → Go To 6
No → Go To 9
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
6 WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION OFF, DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE-
FORE PROCEEDING.
Di sconnect the Ai rbag Control Modul e connector(s).
NOTE: Check connectors - Clean and repair as necessary.
WARNING: IF THE AIRBAG CONTROL MODULE IS DROPPED AT ANY
TIME, IT MUST BE REPLACED. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND PERSONAL INJ URY OR DEATH.
Connect the appropri ate Load Tool ACM Adaptor to the Ai rbag Control Modul e
connector.
Measure the resi stance of the PAB I ndi cator Dri ver ci rcui t between the ACM Adaptor
and ground.
I s the resi stance bel ow 10K ohms?
Al l
Yes → Repai r the Passenger Ai rbag I ndi cator Dri ver ci rcui t short to
ground.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
No → Go To 7
41
AIRBAG
MODULE NOT CONFIGURED FOR PAB OFF SWITCH — Continued
TEST ACTION APPLICABILITY
7 Measure the resi stance of the PAB MUX Swi tch Sense ci rcui t between the ACM
Adaptor and ground.
I s the resi stance bel ow 10K ohms?
Al l
Yes → Repai r the Passenger Ai rbag MUX Swi tch Sense ci rcui t short to
ground.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
No → Go To 8
8 Measure the resi stance between the PAB MUX Swi tch Sense ci rcui t and the PAB
MUX Swi tch Return ci rcui t at the ACM Adaptor.
I s the resi stance bel ow 10K ohms?
Al l
Yes → Repai r the Passenger Ai rbag MUX Swi tch ci rcui ts shorted to-
gether.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
No → Go To 9
9 WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION OFF, DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE-
FORE PROCEEDING.
WARNING: IF THE AIRBAG CONTROL MODULE IS DROPPED AT ANY
TIME, IT MUST BE REPLACED. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND PERSONAL INJ URY OR DEATH.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace the Ai rbag Control Modul e i n accordance wi th Servi ce
I nstructi ons.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
42
AIRBAG
MODULE NOT CONFIGURED FOR PAB OFF SWITCH — Continued
Symptom:
NO CLUSTER MESSAGE
When Monitored and Set Condition:
NO CLUSTER MESSAGE
When Moni tored: Wi th i gni ti on on, the ACM moni tors the PCI Bus for a message from
the MI C contai ni ng the ai rbag warni ng i ndi cator status. The MI C transmi ts the message
one ti me at i gni ti on on, l amp state change, or i n response to the ACM message.
Set Condi ti on: I f the MI C message i s not recei ved for 10 consecuti ve seconds, the code
wi l l set.
POSSIBLE CAUSES
MI C, COMMUNI CATI ON FAI LURE
ACM, NO CLUSTER MESSAGES
STORED CODE OR I NTERMI TTENT CONDI TI ON
ACTI VE CODE PRESENT
TEST ACTION APPLICABILITY
1 Turn the i gni ti on on.
NOTE: Ensure the battery is fully charged.
NOTE: For the purpose of this test, the AECM and ORC modules will be
referred to as an ACM.
SELECT ACTI VE or STORED DTC:
Al l
ACM - ACTI VE DTC
Go To 2
ACM - STORED DTC
Go To 4
NOTE: When reconnectingAirbagsystemcomponents, theignition must be
turned off and the battery must be disconnected.
2 Turn the i gni ti on on.
Wi th the DRBI I I ௡, ensure PCI Bus communi cati ons wi th the I nstrument Cl uster.
I s the I nstrument Cl uster communi cati ng on the PCI Bus?
Al l
Yes → Go To 3
No → Refer to category COMMUNI CATI ON CATEGORY and sel ect the
rel ated symptom NO RESPONSE or I NSTRUMENT CLUSTER
BUS +/- SI GNAL OPEN.
43
AIRBAG
TEST ACTION APPLICABILITY
3 WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION OFF, TOAVOID PERSONAL INJ URY OR DEATH, DISCONNECT THE
BATTERY AND WAIT TWO MINUTES BEFORE PROCEEDING.
WARNING: IF THE AIRBAG CONTROL MODULE IS DROPPED AT ANY
TIME, IT MUST BE REPLACED. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND PERSONAL INJ URY OR DEATH.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace the Ai rbag Control Modul e i n accordance wi th Servi ce
I nstructi ons.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
NOTE: When reconnectingairbagsystemcomponents the Ignition must be
turned off and the Battery must be disconnected.
4 Wi th the DRBI I I ௡, record and erase al l DTC’s from al l Ai rbag modul es.
I f equi pped wi th Passenger Ai rbag On - Off swi tch, read the DTC’s i n al l swi tch
posi ti ons.
I f any ACTI VE codes are present they must be resol ved before di agnosi ng any stored
codes.
WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION OFF, DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE-
FORE PROCEEDING.
Usi ng the wi ri ng di agram/schemati c as a gui de, i nspect the wi ri ng and connectors.
Look for chaffed, pi erced, pi nched, or parti al l y broken wi res and broken, bent, pushed
out, spread, corroded, or contami nated termi nal s.
The fol l owi ng addi ti onal checks may assi st you i n i denti fyi ng a possi bl e i ntermi ttent
probl em.
Reconnect any di sconnected components and harness connector.
WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION ON, THEN RECONNECT THE BATTERY.
Wi th the DRBI I I ௡ moni tor acti ve codes as you work through the fol l owi ng steps.
WARNING: TOAVOID PERSONAL INJ URY OR DEATH, MAINTAINASAFE
DISTANCE FROMALL AIRBAGSWHILE PERFORMING THE FOLLOWING
STEPS.
Wi ggl e the wi ri ng harness and connectors of the rel ated ai rbag ci rcui t or component.
I f codes are rel ated to the Dri ver Ai rbag ci rcui ts, rotate the steeri ng wheel from stop
to stop.
You have just attempted to si mul ate the condi ti on that i ni ti al l y set the troubl e code
message.
Di d the DTC become acti ve?
Al l
Yes → Sel ect appropri ate symptom from Symptom Li st.
No → No probl em found at thi s ti me. Erase al l codes before returni ng
vehi cl e to customer.
44
AIRBAG
NO CLUSTER MESSAGE — Continued
Symptom:
NO PCI TRANSMISSION
When Monitored and Set Condition:
NO PCI TRANSMISSION
When Moni tored: Wi th the i gni ti on on and the modul e transmi tti ng i nformati on on the
BUS.
Set Condi ti on: The code wi l l set i mmedi atel y i f the onboard di agnosti c cannot detect the
modul e transmi tti ng i nformati on on the BUS. NOTE: Any Bus Fai l ure wi l l may cause a
stored code to set.
POSSIBLE CAUSES
AI RBAG CONTROL MODULE - ACM
STORED CODE OR I NTERMI TTENT CONDI TI ON
ACTI VE CODE PRESENT
TEST ACTION APPLICABILITY
1 Turn the i gni ti on on.
NOTE: Ensure the battery is fully charged.
NOTE: For the purpose of this test, the AECM and ORC modules will be
referred to as an ACM.
From the l i st bel ow, sel ect the appropri ate modul e and DTC type for the thi s
di agnosti c troubl e code.
DETERMI NE ACTI VE OR STORED DTC
Al l
ACM - ACTI VE
Go To 2
ACM - STORED
Go To 3
NOTE: When reconnectingairbagsystemcomponents the Ignition must be
turned off and the Battery must be disconnected.
2 WARNING: TOAVOID PERSONAL INJ URY OR DEATH, DISCONNECT THE
BATTERY AND WAIT TWO MINUTES BEFORE PROCEEDING.
WARNING: IF THE AIRBAG CONTROL MODULE IS DROPPED AT ANY
TIME, IT MUST BE REPLACED. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND PERSONAL INJ URY OR DEATH.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace the Ai rbag Control Modul e i n accordance wi th Servi ce
I nstructi ons.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
45
AIRBAG
TEST ACTION APPLICABILITY
3 Wi th the DRBI I I ௡, record and erase al l DTC’s from al l Ai rbag modul es.
I f equi pped wi th Passenger Ai rbag On - Off swi tch, read the DTC’s i n al l swi tch
posi ti ons.
I f any ACTI VE codes are present they must be resol ved before di agnosi ng any stored
codes.
WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION OFF, DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE-
FORE PROCEEDING.
Usi ng the wi ri ng di agram/schemati c as a gui de, i nspect the wi ri ng and connectors.
Look for chaffed, pi erced, pi nched, or parti al l y broken wi res and broken, bent, pushed
out, spread, corroded, or contami nated termi nal s.
The fol l owi ng addi ti onal checks may assi st you i n i denti fyi ng a possi bl e i ntermi ttent
probl em.
Reconnect any di sconnected components and harness connector.
WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION ON, THEN RECONNECT THE BATTERY.
Wi th the DRBI I I ௡ moni tor acti ve codes as you work through the fol l owi ng steps.
WARNING: TOAVOID PERSONAL INJ URY OR DEATH, MAINTAINASAFE
DISTANCE FROMALL AIRBAGSWHILE PERFORMING THE FOLLOWING
STEPS.
Wi ggl e the wi ri ng harness and connectors of the rel ated ai rbag ci rcui t or component.
I f codes are rel ated to the Dri ver Ai rbag ci rcui ts, rotate the steeri ng wheel from stop
to stop.
You have just attempted to si mul ate the condi ti on that i ni ti al l y set the troubl e code
message.
Di d the DTC become acti ve?
Al l
Yes → Sel ect appropri ate symptom from Symptom Li st.
No → No probl em found at thi s ti me. Erase al l codes before returni ng
vehi cl e to customer.
46
AIRBAG
NO PCI TRANSMISSION — Continued
Symptom:
PASSENGER AIRBAG ON - OFF SWITCH OPEN
When Monitored and Set Condition:
PASSENGER AIRBAG ON - OFF SWITCH OPEN
When Moni tored: Wi th the i gni ti on on, the PAB MUX Swi tch Sense ci rcui t suppl i es a 3
to 10 ms pul se every 100 ms across the On or Off swi tch resi stor to the MUX Swi tch Return
ci rcui t.
Set Condi ti on: The code wi l l set i f the ACM senses an open or hi gh resi stance on the PAB
MUX Swi tch Sense ci rcui t or PAB MUX Swi tch Return ci rcui t.
POSSIBLE CAUSES
CHECKI NG EQUI PMENT
PAB ON - OFF SWI TCH OPEN
SWI TCH DI SCONNECTED
PASSENGER AI RBAG MUX SWI TCH CI RCUI T OPEN
ACM, PASSENGER ON - OFF SWI TCH CI RCUI T OPEN
STORED CODE OR I NTERMI TTENT CONDI TI ON
ACTI VE CODE PRESENT
TEST ACTION APPLICABILITY
1 Turn the i gni ti on on.
NOTE: Ensure that the battery is fully charged.
NOTE: For the purpose of this test, the AECM and ORC modules will be
referred to as an ACM.
SELECT ACTI VE or STORED DTC:
Al l
ACM - ACTI VE DTC
Go To 2
ACM - STORED DTC
Go To 7
NOTE: When reconnectingAirbagsystemcomponents, theignition must be
turned off and the battery must be disconnected.
2 I s thi s vehi cl e equi pped wi th a Passenger Ai rbag On - Off Swi tch? Al l
Yes → Go To 3
No → Wi th the DRBI I I ௡ i n MI SCELLANEOUS, read the Confi gure for
Ai rbag ON - OFF Swi tch current status. Enter the number 1 and
press enter to re confi gure the ACM for NO AI RBAG ON/OFF
SWI TCH.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
47
AIRBAG
TEST ACTION APPLICABILITY
3 Gai n access to the Passenger Ai rbag On - Off Swi tch connector.
I s the Passenger Ai rbag On - Off Swi tch connected to the dash harness?
Al l
Yes → Go To 4
No → Connect the Passenger Ai rbag On - Off swi tch to the dash harness
connector.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
4 WARNING: TURN THE IGNITION OFF, DISCONNECT THE BATTERY AND
WAIT TWO MINUTES BEFORE PROCEEDING.
Di sconnect the Passenger Ai rbag On - Off Swi tch.
NOTE: Check connectors - Clean and repair as necessary.
Measure the PAB On - Off Swi tch resi stance between termi nal s 1 and 2 i n both
swi tch posi ti ons.
The swi tch resi stance speci fi cati ons are: ON posi ti on = 175.0 to 190.0 ohms and OFF
posi ti on = 820.0 to 870.0 ohms.
I s the resi stance wi thi n range for both swi tch posi ti ons?
Al l
Yes → Go To 5
No → Repl ace the Passenger Ai rbag ON - OFF Swi tch i n accordance
wi th the servi ce i nformati on.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
5 Di sconnect the Ai rbag Control Modul e connector(s).
NOTE: Check connectors - Clean and repair as necessary.
WARNING: IF THE AIRBAG CONTROL MODULE IS DROPPED AT ANY
TIME, IT MUST BE REPLACED.
Connect the appropri ate Load Tool Adaptor to the Ai rbag Control Modul e connector.
Measure the resi stance of the PAB MUX Swi tch Sense between the ACM Adaptor and
the PAB On - Off Swi tch connector.
Measure the resi stance of the PAB MUX Swi tch Return ci rcui t between the ACM
Adaptor and the PAB On - Off Swi tch connector.
I s the resi stance bel ow 5.0 ohms on both ci rcui ts?
Al l
Yes → Go To 6
No → Repai r the open Passenger Ai rbag MUX Swi tch ci rcui t(s).
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
6 WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION OFF, DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE-
FORE PROCEEDING.
WARNING: IF THE AIRBAG CONTROL MODULE IS DROPPED AT ANY
TIME, IT MUST BE REPLACED. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND PERSONAL INJ URY OR DEATH.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace the Ai rbag Control Modul e i n accordance wi th Servi ce
I nstructi ons.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
48
AIRBAG
PASSENGER AIRBAG ON - OFF SWITCH OPEN — Continued
TEST ACTION APPLICABILITY
7 Wi th the DRBI I I ௡, record and erase al l DTC’s from al l Ai rbag modul es.
I f equi pped wi th Passenger Ai rbag On - Off swi tch, read the DTC’s i n al l swi tch
posi ti ons.
I f any ACTI VE codes are present they must be resol ved before di agnosi ng any stored
codes.
WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION OFF, DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE-
FORE PROCEEDING.
Usi ng the wi ri ng di agram/schemati c as a gui de, i nspect the wi ri ng and connectors.
Look for chaffed, pi erced, pi nched, or parti al l y broken wi res and broken, bent, pushed
out, spread, corroded, or contami nated termi nal s.
The fol l owi ng addi ti onal checks may assi st you i n i denti fyi ng a possi bl e i ntermi ttent
probl em.
Reconnect any di sconnected components and harness connector.
WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION ON, THEN RECONNECT THE BATTERY.
Wi th the DRBI I I ௡ moni tor acti ve codes as you work through the fol l owi ng steps.
WARNING: TOAVOID PERSONAL INJ URY OR DEATH, MAINTAINASAFE
DISTANCE FROMALL AIRBAGSWHILE PERFORMING THE FOLLOWING
STEPS.
Wi ggl e the wi ri ng harness and connectors of the rel ated ai rbag ci rcui t or component.
I f codes are rel ated to the Dri ver Ai rbag ci rcui ts, rotate the steeri ng wheel from stop
to stop.
You have just attempted to si mul ate the condi ti on that i ni ti al l y set the troubl e code
message.
Di d the DTC become acti ve?
Al l
Yes → Sel ect appropri ate symptom from Symptom Li st.
No → No probl em found at thi s ti me. Erase al l codes before returni ng
vehi cl e to customer.
49
AIRBAG
PASSENGER AIRBAG ON - OFF SWITCH OPEN — Continued
Symptom:
PASSENGER AIRBAG ON - OFF SWITCH SHORT TO BATTERY
When Monitored and Set Condition:
PASSENGER AIRBAG ON - OFF SWITCH SHORT TO BATTERY
When Moni tored: Wi th the i gni ti on on, the MUX Swi tch Sense ci rcui t suppl i es a 3 to 10
ms pul se every 100 ms across the swi tch resi ster to the MUX Swi tch Return ci rcui t. Once
the code i s acti ve, the ACM wi l l di sabl e the i ndi cator for the durati on of the i gni ti on cycl e.
Set Condi ti on: The code wi l l set i f the ACM senses constant vol tage over approxi matel y
4.0 vol ts on the PAB MUX Swi tch ci rcui ts.
POSSIBLE CAUSES
CHECKI NG EQUI PMENT
PAB ON - OFF SWI TCH CI RCUI T SHORT
PAB ON - OFF SWI TCH SHORT
PAB MUX SWI TCH CI RCUI T SHORT TO BATTERY
ACM, PAB ON - OFF SWI TCH CI RCUI T SHORT
STORED CODE OR I NTERMI TTENT CONDI TI ON
ACTI VE CODE PRESENT
TEST ACTION APPLICABILITY
1 Turn the i gni ti on on.
NOTE: Ensure that the battery is fully charged.
NOTE: For the purpose of this test, the AECM and ORC modules will be
referred to as an ACM.
SELECT ACTI VE or STORED DTC:
Al l
ACM - ACTI VE DTC
Go To 2
ACM - STORED DTC
Go To 6
NOTE: When reconnectingAirbagsystemcomponents, theignition must be
turned off and the battery must be disconnected.
2 I s thi s vehi cl e equi pped wi th a Passenger Ai rbag On - Off Swi tch? Al l
Yes → Go To 3
No → Wi th the DRBI I I ௡ i n MI SCELLANEOUS, read the Confi gure for
Ai rbag ON - OFF Swi tch current status. Enter the number 1 and
press enter to re confi gure the ACM for NO AI RBAG ON/OFF
SWI TCH.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
50
AIRBAG
TEST ACTION APPLICABILITY
3 WARNING: TURN THE IGNITION OFF, DISCONNECT THE BATTERY AND
WAIT TWO MINUTES BEFORE PROCEEDING.
Di sconnect the Passenger Ai rbag On - Off Swi tch.
NOTE: Check connectors - Clean and repair as necessary.
Measure the PAB On - Off Swi tch resi stance between termi nal s 1 & 4 and 2 & 4.
I s the resi stance bel ow 10K ohms on ei ther test?
Al l
Yes → Repl ace the Passenger Ai rbag ON - OFF Swi tch i n accordance
wi th the servi ce i nformati on.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
No → Go To 4
4 Measure the PAB On - Off Swi tch resi stance between termi nal s 1 and 2 i n both
swi tch posi ti ons.
The swi tch resi stance speci fi cati ons are: ON posi ti on = 175.0 to 190.0 ohms and OFF
posi ti on = 820.0 to 870.0 ohms.
I s the resi stance wi thi n range for both swi tch posi ti ons?
Al l
Yes → Go To 5
No → Repl ace the Passenger Ai rbag ON - OFF Swi tch i n accordance
wi th the servi ce i nformati on.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
5 WARNING: TURNIGNITIONOFF, DISCONNECT THE BATTERYANDWAIT
TWO MINUTES BEFORE PROCEEDING.
Di sconnect the Ai rbag Control Modul e connector(s).
NOTE: Check connectors - Clean and repair as necessary.
WARNING: IF THE AIRBAG CONTROL MODULE IS DROPPED AT ANY
TIME, IT MUST BE REPLACED.
WARNING: TURN IGNITION ON, THEN RECONNECT THE BATTERY.
Measure the vol tage on the PAB MUX Swi tch Sense and PAB MUX Swi tch Return
ci rcui ts at the PAB On - Off Swi tch connector.
I s there any vol tage on ei ther ci rcui t?
Al l
Yes → Repai r the Passenger Ai rbag MUX Swi tch ci rcui ts shorted to
battery.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
No → Go To 7
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
51
AIRBAG
PASSENGER AIRBAG ON - OFF SWITCH SHORT TO BATTERY —
Continued
TEST ACTION APPLICABILITY
6 Wi th the DRBI I I ௡, record and erase al l DTC’s from al l Ai rbag modul es.
I f equi pped wi th Passenger Ai rbag On - Off swi tch, read the DTC’s i n al l swi tch
posi ti ons.
I f any ACTI VE codes are present they must be resol ved before di agnosi ng any stored
codes.
WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION OFF, DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE-
FORE PROCEEDING.
Usi ng the wi ri ng di agram/schemati c as a gui de, i nspect the wi ri ng and connectors.
Look for chaffed, pi erced, pi nched, or parti al l y broken wi res and broken, bent, pushed
out, spread, corroded, or contami nated termi nal s.
The fol l owi ng addi ti onal checks may assi st you i n i denti fyi ng a possi bl e i ntermi ttent
probl em.
Reconnect any di sconnected components and harness connector.
WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION ON, THEN RECONNECT THE BATTERY.
Wi th the DRBI I I ௡ moni tor acti ve codes as you work through the fol l owi ng steps.
WARNING: TOAVOID PERSONAL INJ URY OR DEATH, MAINTAINASAFE
DISTANCE FROMALL AIRBAGSWHILE PERFORMING THE FOLLOWING
STEPS.
Wi ggl e the wi ri ng harness and connectors of the rel ated ai rbag ci rcui t or component.
I f codes are rel ated to the Dri ver Ai rbag ci rcui ts, rotate the steeri ng wheel from stop
to stop.
You have just attempted to si mul ate the condi ti on that i ni ti al l y set the troubl e code
message.
Di d the DTC become acti ve?
Al l
Yes → Sel ect appropri ate symptom from Symptom Li st.
No → No probl em found at thi s ti me. Erase al l codes before returni ng
vehi cl e to customer.
7 WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION OFF, DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE-
FORE PROCEEDING.
WARNING: IF THE AIRBAG CONTROL MODULE IS DROPPED AT ANY
TIME, IT MUST BE REPLACED. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND PERSONAL INJ URY OR DEATH.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace the Ai rbag Control Modul e i n accordance wi th Servi ce
I nstructi ons.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
52
AIRBAG
PASSENGER AIRBAG ON - OFF SWITCH SHORT TO BATTERY —
Continued
Symptom:
PASSENGER AIRBAG ON - OFF SWITCH SHORT TO GROUND
When Monitored and Set Condition:
PASSENGER AIRBAG ON - OFF SWITCH SHORT TO GROUND
When Moni tored: Wi th the i gni ti on on, the PAB MUX Swi tch Sense ci rcui t suppl i es a 3
to 10 ms pul se every 100 ms across the On or Off Swi tch resi stor to the MUX Swi tch Return
ci rcui t.
Set Condi ti on: The code wi l l set i f the ACM senses l ow resi stance on the PAB MUX
Swi tch sense ci rcui t.
POSSIBLE CAUSES
CHECKI NG EQUI PMENT
PAB ON - OFF SWI TCH CI RCUI T SHORT
PAB ON - OFF SWI TCH SHORT
PAB MUX SWI TCH CI RCUI T SHORT TO GROUND
PAB MUX SWI TCH CI RCUI T SHORT TOGETHER
ACM, PAB ON - OFF SWI TCH CONNECTOR.
STORED CODE OR I NTERMI TTENT CONDI TI ON
ACTI VE CODE PRESENT
TEST ACTION APPLICABILITY
1 Turn the i gni ti on on.
NOTE: Ensure that the battery is fully charged.
NOTE: For the purpose of this test, the AECM and ORC modules will be
referred to as an ACM.
SELECT ACTI VE or STORED DTC:
Al l
ACM - ACTI VE DTC
Go To 2
ACM - STORED DTC
Go To 7
NOTE: When reconnectingAirbagsystemcomponents, theignition must be
turned off and the battery must be disconnected.
2 I s thi s vehi cl e equi pped wi th a Passenger Ai rbag On - Off Swi tch? Al l
Yes → Go To 3
No → Wi th the DRBI I I ௡ i n MI SCELLANEOUS, read the Confi gure for
Ai rbag ON - OFF Swi tch current status. Enter the number 1 and
press enter to re confi gure the ACM for NO AI RBAG ON/OFF
SWI TCH.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
53
AIRBAG
TEST ACTION APPLICABILITY
3 WARNING: TURN THE IGNITION OFF, DISCONNECT THE BATTERY AND
WAIT TWO MINUTES BEFORE PROCEEDING.
Di sconnect the Passenger Ai rbag On - Off Swi tch.
NOTE: Check connectors - Clean and repair as necessary.
Measure the PAB On - Off Swi tch resi stance between termi nal s 1 & 3 and 2 & 3.
I s the resi stance bel ow 10K ohms on ei ther test?
Al l
Yes → Repl ace the Passenger Ai rbag ON - OFF Swi tch i n accordance
wi th the servi ce i nformati on.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
No → Go To 4
4 Measure the PAB On - Off Swi tch resi stance between termi nal s 1 and 2 i n both
swi tch posi ti ons.
The swi tch resi stance speci fi cati ons are: ON posi ti on = 175.0 to 190.0 ohms and OFF
posi ti on = 820.0 870.0 ohms.
I s the resi stance wi thi n range for both swi tch posi ti ons?
Al l
Yes → Go To 5
No → Repl ace the Passenger Ai rbag ON - OFF Swi tch i n accordance
wi th the servi ce i nformati on.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
5 Di sconnect the Ai rbag Control Modul e connector(s).
NOTE: Check connectors - Clean and repair as necessary.
WARNING: IF THE AIRBAG CONTROL MODULE IS DROPPED AT ANY
TIME, IT MUST BE REPLACED.
Connect the appropri ate Load Tool Adaptor to the Ai rbag Control Modul e connector.
Measure the resi stance of the PAB MUX Swi tch Sense ci rcui t between the PAB On
- Off Swi tch connector and ground.
I s the resi stance bel ow 10K ohms?
Al l
Yes → Repai r the Passenger Ai rbag MUX Swi tch Sense ci rcui t short to
ground.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
No → Go To 6
6 Measure the resi stance between the PAB MUX Swi tch Sense ci rcui t and the PAB
MUX Swi tch Return ci rcui t at the PAB On - Off Swi tch connector.
I s the resi stance on ei ther ci rcui ts bel ow 10K ohms?
Al l
Yes → Repai r the Passenger Ai rbag MUX Swi tch ci rcui ts shorted to-
gether.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
No → Go To 8
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
54
AIRBAG
PASSENGERAIRBAGON- OFF SWITCH SHORT TOGROUND—Continued
TEST ACTION APPLICABILITY
7 Wi th the DRBI I I ௡, record and erase al l DTC’s from al l Ai rbag modul es.
I f equi pped wi th Passenger Ai rbag On - Off swi tch, read the DTC’s i n al l swi tch
posi ti ons.
I f any ACTI VE codes are present they must be resol ved before di agnosi ng any stored
codes.
WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION OFF, DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE-
FORE PROCEEDING.
Usi ng the wi ri ng di agram/schemati c as a gui de, i nspect the wi ri ng and connectors.
Look for chaffed, pi erced, pi nched, or parti al l y broken wi res and broken, bent, pushed
out, spread, corroded, or contami nated termi nal s.
The fol l owi ng addi ti onal checks may assi st you i n i denti fyi ng a possi bl e i ntermi ttent
probl em.
Reconnect any di sconnected components and harness connector.
WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION ON, THEN RECONNECT THE BATTERY.
Wi th the DRBI I I ௡ moni tor acti ve codes as you work through the fol l owi ng steps.
WARNING: TOAVOID PERSONAL INJ URY OR DEATH, MAINTAINASAFE
DISTANCE FROMALL AIRBAGSWHILE PERFORMING THE FOLLOWING
STEPS.
Wi ggl e the wi ri ng harness and connectors of the rel ated ai rbag ci rcui t or component.
I f codes are rel ated to the Dri ver Ai rbag ci rcui ts, rotate the steeri ng wheel from stop
to stop.
You have just attempted to si mul ate the condi ti on that i ni ti al l y set the troubl e code
message.
Di d the DTC become acti ve?
Al l
Yes → Sel ect appropri ate symptom from Symptom Li st.
No → No probl em found at thi s ti me. Erase al l codes before returni ng
vehi cl e to customer.
8 WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION OFF, DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE-
FORE PROCEEDING.
WARNING: IF THE AIRBAG CONTROL MODULE IS DROPPED AT ANY
TIME, IT MUST BE REPLACED. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND PERSONAL INJ URY OR DEATH.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace the Ai rbag Control Modul e i n accordance wi th Servi ce
I nstructi ons.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
55
AIRBAG
PASSENGERAIRBAGON- OFF SWITCH SHORT TOGROUND—Continued
Symptom:
PASSENGER OFF INDICATOR CIRCUIT SHORT TO BATTERY
When Monitored and Set Condition:
PASSENGER OFF INDICATOR CIRCUIT SHORT TO BATTERY
When Moni tored: Wi th the i gni ti on on, the ACM moni tors the PAB I ndi cator Dri ver
ci rcui t for vol tage from the PAB On - Off Swi tch i ndi cator ci rcui t.
Set Condi ti on: The code wi l l set i f the ACM senses battery vol tage on the PAB I ndi cator
Dri ver ci rcui t.
POSSIBLE CAUSES
CHECKI NG EQUI PMENT
PAB ON - OFF SWI TCH I NDI CATOR SHORT
PASSENGER AI RBAG I NDI CATOR SHORT TO FUSED RUN - START CI RCUI T
PASSENGER AI RBAG I NDI CATOR DRI VER CI RCUI T SHORTED TO BATTERY
ACM, PAB I NDI CATOR DRI VER CI RCUI T SHORT TO BATTERY
STORED CODE OR I NTERMI TTENT CONDI TI ON
ACTI VE CODE PRESENT
TEST ACTION APPLICABILITY
1 Turn the i gni ti on on.
NOTE: Ensure that the battery is fully charged.
NOTE: For the purpose of this test, the AECM and ORC modules will be
referred to as an ACM.
SELECT ACTI VE or STORED DTC:
Al l
ACM - ACTI VE DTC
Go To 2
ACM - STORED DTC
Go To 6
NOTE: When reconnectingAirbagsystemcomponents, theignition must be
turned off and the battery must be disconnected.
2 I s thi s vehi cl e equi pped wi th a Passenger Ai rbag On - Off Swi tch? Al l
Yes → Go To 3
No → Wi th the DRBI I I ௡ i n MI SCELLANEOUS, read the Confi gure for
Ai rbag ON - OFF Swi tch current status. Enter the number 1 and
press enter to re confi gure the ACM for NO AI RBAG ON/OFF
SWI TCH.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
56
AIRBAG
TEST ACTION APPLICABILITY
3 WARNING: TURN THE IGNITION OFF, DISCONNECT THE BATTERY AND
WAIT TWO MINUTES BEFORE PROCEEDING.
Di sconnect the Passenger Ai rbag On - Off Swi tch.
NOTE: Check connectors - Clean and repair as necessary.
Measure the resi stance between PAB On - Off Swi tch termi nal s 3 and 4.
I s the resi stance bel ow 14.0 ohms?
Al l
Yes → Go To 4
No → Repl ace the Passenger Ai rbag On - Off Swi tch i n accordance wi th
the Servi ce I nformati on.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
4 WARNING: TURNIGNITIONOFF, DISCONNECT THE BATTERYANDWAIT
TWO MINUTES BEFORE PROCEEDING.
Di sconnect the Ai rbag Control Modul e connector.
NOTE: Check connectors - Clean and repair as necessary.
WARNING: IF THE AIRBAG CONTROL MODULE IS DROPPED AT ANY
TIME, IT MUST BE REPLACED.
WARNING: TURN THE IGNITION ON, THEN RECONNECT THE BATTERY.
Measure the vol tage on the Passenger Ai rbag I ndi cator Dri ver ci rcui t between the
PAB On - Off Swi tch connector and ground.
I s there any vol tage present?
Al l
Yes → Go To 5
No → Go To 7
5 Remove the Fused I gni ti on Swi tch Output Run - Start ci rcui t fuse.
Measure the vol tage on the Passenger Ai rbag I ndi cator Dri ver ci rcui t at the PAB On
- Off Swi tch connector.
I s there any vol tage present?
Al l
Yes → Repai r the Passenger Ai rbag I ndi cator Dri ver ci rcui t shorted to
battery.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
No → Repai r the Fused i gni ti on Swi tch Output Run - Start ci rcui t
shorted to the PAB I ndi cator Dri ver ci rcui t.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
57
AIRBAG
PASSENGER OFF INDICATOR CIRCUIT SHORT TO BATTERY —
Continued
TEST ACTION APPLICABILITY
6 Wi th the DRBI I I ௡, record and erase al l DTC’s from al l Ai rbag modul es.
I f equi pped wi th Passenger Ai rbag On - Off swi tch, read the DTC’s i n al l swi tch
posi ti ons.
I f any ACTI VE codes are present they must be resol ved before di agnosi ng any stored
codes.
WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION OFF, DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE-
FORE PROCEEDING.
Usi ng the wi ri ng di agram/schemati c as a gui de, i nspect the wi ri ng and connectors.
Look for chaffed, pi erced, pi nched, or parti al l y broken wi res and broken, bent, pushed
out, spread, corroded, or contami nated termi nal s.
The fol l owi ng addi ti onal checks may assi st you i n i denti fyi ng a possi bl e i ntermi ttent
probl em.
Reconnect any di sconnected components and harness connector.
WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION ON, THEN RECONNECT THE BATTERY.
Wi th the DRBI I I ௡ moni tor acti ve codes as you work through the fol l owi ng steps.
WARNING: TOAVOID PERSONAL INJ URY OR DEATH, MAINTAINASAFE
DISTANCE FROMALL AIRBAGSWHILE PERFORMING THE FOLLOWING
STEPS.
Wi ggl e the wi ri ng harness and connectors of the rel ated ai rbag ci rcui t or component.
I f codes are rel ated to the Dri ver Ai rbag ci rcui ts, rotate the steeri ng wheel from stop
to stop.
You have just attempted to si mul ate the condi ti on that i ni ti al l y set the troubl e code
message.
Di d the DTC become acti ve?
Al l
Yes → Sel ect appropri ate symptom from Symptom Li st.
No → No probl em found at thi s ti me. Erase al l codes before returni ng
vehi cl e to customer.
7 WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION OFF, DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE-
FORE PROCEEDING.
WARNING: IF THE AIRBAG CONTROL MODULE IS DROPPED AT ANY
TIME, IT MUST BE REPLACED. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND PERSONAL INJ URY OR DEATH.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace the Ai rbag Control Modul e i n accordance wi th Servi ce
I nstructi ons.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
58
AIRBAG
PASSENGER OFF INDICATOR CIRCUIT SHORT TO BATTERY —
Continued
Symptom:
PASSENGER OFF INDICATOR CIRCUIT SHORT TO GROUND
When Monitored and Set Condition:
PASSENGER OFF INDICATOR CIRCUIT SHORT TO GROUND
When Moni tored: Wi th the i gni ti on on, the ACM moni tors the PAB I ndi cator Dri ver
ci rcui t for vol tage from the PAB On - Off Swi tch i ndi cator ci rcui t.
Set Condi ti on: The code wi l l set i f the ACM cannot detect vol tage on the PAB I ndi cator
Dri ver ci rcui t.
POSSIBLE CAUSES
ACTI VE ACM RUN - START CODES
CHECKI NG EQUI PMENT
FUSED I GNI TI ON SWI TCH OUTPUT RUN - START
SWI TCH DI SCONNECTED
PAB ON - OFF I NDI CATOR OPEN
PASSENGER AI RBAG I NDI CATOR DRI VER CI RCUI T OPEN
PASSENGER AI RBAG I NDI CATOR DRI VER CI RCUI T SHORT
ACM, PASSENGER ON - OFF I NDI CATOR CI RCUI T OPEN
STORED CODE OR I NTERMI TTENT CONDI TI ON
ACTI VE CODE PRESENT
TEST ACTION APPLICABILITY
1 Turn the i gni ti on on.
NOTE: Ensure that the battery is fully charged.
NOTE: For the purpose of this test, the AECM and ORC modules will be
referred to as an ACM.
SELECT ACTI VE or STORED DTC:
Al l
ACM - ACTI VE DTC
Go To 2
ACM - STORED DTC
Go To 9
NOTE: When reconnectingAirbagsystemcomponents, theignition must be
turned off and the battery must be disconnected.
2 Wi th the DRBI I I ௡, read acti ve Ai rbag Control Modul e DTC’s.
Does the DRBI I I ௡ di spl ay LOSS OF I GNI TI ON RUN - START ?
Al l
Yes → Refer to symptom l i st for probl ems rel ated to Loss of I gni ti on Run
- Start acti ve di agnosti c troubl e code test.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
No → Go To 3
59
AIRBAG
TEST ACTION APPLICABILITY
3 I s thi s vehi cl e equi pped wi th a Passenger Ai rbag On - Off Swi tch? Al l
Yes → Go To 4
No → Wi th the DRBI I I ௡ i n MI SCELLANEOUS, read the Confi gure for
Ai rbag ON - OFF Swi tch current status. Enter the number 1 and
press enter to re confi gure the ACM for NO AI RBAG ON/OFF
SWI TCH.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
4 Gai n access to the Passenger Ai rbag On - Off Swi tch connector.
I s the Passenger Ai rbag On - Off Swi tch connected to the dash harness?
Al l
Yes → Go To 5
No → Connect the Passenger Ai rbag On - Off swi tch to the dash harness
connector.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
5 WARNING: TURNIGNITIONOFF, DISCONNECT THE BATTERYANDWAIT
TWO MINUTES BEFORE PROCEEDING.
Di sconnect the Passenger On - Off Swi tch connector.
NOTE: Check connectors - Clean and repair as necessary.
WARNING: TURN IGNITION ON, THEN RECONNECT THE BATTERY.
Measure the vol tage on the Fused I gni ti on Swi tch Output Run - Start ci rcui t between
the PAB On - Off Swi tch connector and ground.
I s the vol tage above 10.0 vol ts?
Al l
Yes → Go To 6
No → Repai r the open Fused i gni ti on Swi tch Output Run - Start ci rcui t.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
6 WARNING: TURN THE IGNITION OFF, DISCONNECT THE BATTERY AND
WAIT TWO MINUTES BEFORE PROCEEDING.
Di sconnect the Passenger Ai rbag On - Off Swi tch.
NOTE: Check connectors - Clean and repair as necessary.
Measure the resi stance between PAB On - Off Swi tch termi nal s 3 and 4.
I s the resi stance approxi matel y 14 ohms?
Al l
Yes → Go To 7
No → Repl ace the Passenger Ai rbag ON - OFF Swi tch i n accordance
wi th the servi ce i nformati on.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
7 Di sconnect the Ai rbag Control Modul e connector
NOTE: Check connectors - Clean and repair as necessary.
WARNING: IF THE AIRBAG CONTROL MODULE IS DROPPED AT ANY
TIME, IT MUST BE REPLACED.
Connect the appropri ate Load Tool ACM Adaptor to the Ai rbag Control Modul e
connector(s).
Measure the resi stance of the PAB I ndi cator Dri ver ci rcui t between the ACM and the
PAB On - Off Swi tch connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 8
No → Repai r the open Passenger Ai rbag I ndi cator Dri ver ci rcui t.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
60
AIRBAG
PASSENGER OFF INDICATOR CIRCUIT SHORT TOGROUND—Continued
TEST ACTION APPLICABILITY
8 Measure the resi stance of the PAB I ndi cator Dri ver ci rcui t between the PAB On - Off
Swi tch connector and ground.
I s the resi stance bel ow 10K ohms?
Al l
Yes → Repai r the Passenger Ai rbag I ndi cator Dri ver ci rcui t short to
ground.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
No → Go To 10
9 Wi th the DRBI I I ௡, record and erase al l DTC’s from al l Ai rbag modul es.
I f equi pped wi th Passenger Ai rbag On - Off swi tch, read the DTC’s i n al l swi tch
posi ti ons.
I f any ACTI VE codes are present they must be resol ved before di agnosi ng any stored
codes.
WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION OFF, DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE-
FORE PROCEEDING.
Usi ng the wi ri ng di agram/schemati c as a gui de, i nspect the wi ri ng and connectors.
Look for chaffed, pi erced, pi nched, or parti al l y broken wi res and broken, bent, pushed
out, spread, corroded, or contami nated termi nal s.
The fol l owi ng addi ti onal checks may assi st you i n i denti fyi ng a possi bl e i ntermi ttent
probl em.
Reconnect any di sconnected components and harness connector.
WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION ON, THEN RECONNECT THE BATTERY.
Wi th the DRBI I I ௡ moni tor acti ve codes as you work through the fol l owi ng steps.
WARNING: TOAVOID PERSONAL INJ URY OR DEATH, MAINTAINASAFE
DISTANCE FROMALL AIRBAGSWHILE PERFORMING THE FOLLOWING
STEPS.
Wi ggl e the wi ri ng harness and connectors of the rel ated ai rbag ci rcui t or component.
I f codes are rel ated to the Dri ver Ai rbag ci rcui ts, rotate the steeri ng wheel from stop
to stop.
You have just attempted to si mul ate the condi ti on that i ni ti al l y set the troubl e code
message.
Di d the DTC become acti ve?
Al l
Yes → Sel ect appropri ate symptom from Symptom Li st.
No → No probl em found at thi s ti me. Erase al l codes before returni ng
vehi cl e to customer.
10 WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION OFF, DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE-
FORE PROCEEDING.
WARNING: IF THE AIRBAG CONTROL MODULE IS DROPPED AT ANY
TIME, IT MUST BE REPLACED. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND PERSONAL INJ URY OR DEATH.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace the Ai rbag Control Modul e i n accordance wi th Servi ce
I nstructi ons.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
61
AIRBAG
PASSENGER OFF INDICATOR CIRCUIT SHORT TOGROUND—Continued
Symptom:
PASSENGER SQUIB 1 CIRCUIT OPEN
When Monitored and Set Condition:
PASSENGER SQUIB 1 CIRCUIT OPEN
When Moni tored: Wi th the i gni ti on on, the ACM moni tors the resi stance of the Passenger
Squi b 1 ci rcui ts.
Set Condi ti on: When the ACM detects an open ci rcui t or hi gh resi stance on the Passenger
Squi b 1 ci rcui ts.
POSSIBLE CAUSES
PAB SQUI B 1 CI RCUI T OPEN
PAB SQUI B 1 LI NE 1 OR LI NE 2 CI RCUI T OPEN
ACM, PAB SQUI B 1 CI RCUI T OPEN
STORED CODE OR I NTERMI TTENT CONDI TI ON
ACTI VE CODE PRESENT
TEST ACTION APPLICABILITY
1 Turn the i gni ti on on.
NOTE: Ensure the battery is fully charged.
NOTE: For the purpose of this test, the AECM and ORC modules will be
referred to as an ACM.
SELECT ACTI VE or STORED DTC:
Al l
ACM - ACTI VE DTC
Go To 2
ACM - STORED DTC
Go To 5
NOTE: When reconnectingAirbagsystemcomponents, theignition must be
turned off and the battery must be disconnected.
62
AIRBAG
TEST ACTION APPLICABILITY
2 WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION OFF, DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE-
FORE PROCEEDING.
Di sconnect the Passenger Ai rbag connector(s).
NOTE: Check connectors - Clean and repair as necessary.
WARNING: TOAVOID PERSONAL INJ URY OR DEATH, DONOT PLACE AN
INTACT UNDEPLOYEDAIRBAG FACE DOWN ONAHARD SURFACE, THE
AIRBAG WILL PROPEL INTO THE AIR IF ACCIDENTALLY DEPLOYED.
Connect the Load Tool to the Passenger Ai rbag connector(s).
WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN IGNITION
ON, THEN RECONNECT THE BATTERY.
Wi th the DRBI I I ௡, read the acti ve Ai rbag Control Modul e DTC’s.
Does the DRBI I I ௡ show PASSENGER SQUI B 1 CI RCUI T OPEN?
Al l
Yes → Go To 3
No → Repl ace the Passenger Ai rbag i n accordance wi th the Servi ce
I nformati on.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
3 WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION OFF, DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE-
FORE PROCEEDING.
Di sconnect the Load Tool from the Passenger Ai rbag connector(s).
Di sconnect the Ai rbag Control modul e connector(s).
NOTE: Check connectors - Clean and repair as necessary.
Connect the Load Tool ACM Adaptor to the Ai rbag Control Modul e connector(s).
Measure the resi stance of the Passenger Squi b 1 Li ne 1 and Li ne 2 ci rcui t between
the ACM Adaptor and the Passenger Ai rbag connector.
I s the resi stance bel ow 1.0 ohms on both ci rcui ts?
Al l
Yes → Go To 4
No → Repai r open or hi gh resi stance i n Passenger Squi b 1 Li ne 1 or
Li ne 2 ci rcui ts.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
4 WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION OFF, DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE-
FORE PROCEEDING.
WARNING: IF THE AIRBAG CONTROL MODULE IS DROPPED AT ANY
TIME, IT MUST BE REPLACED. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND PERSONAL INJ URY OR DEATH.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r:
Repl ace the Ai rbag Control Modul e i n accordance wi th Servi ce
I nstructi ons.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
63
AIRBAG
PASSENGER SQUIB 1 CIRCUIT OPEN — Continued
TEST ACTION APPLICABILITY
5 Wi th the DRBI I I ௡, record and erase al l DTC’s from al l Ai rbag modul es.
I f equi pped wi th Passenger Ai rbag On - Off swi tch, read the DTC’s i n al l swi tch
posi ti ons.
I f any ACTI VE codes are present they must be resol ved before di agnosi ng any stored
codes.
WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION OFF, DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE-
FORE PROCEEDING.
Usi ng the wi ri ng di agram/schemati c as a gui de, i nspect the wi ri ng and connectors.
Look for chaffed, pi erced, pi nched, or parti al l y broken wi res and broken, bent, pushed
out, spread, corroded, or contami nated termi nal s.
The fol l owi ng addi ti onal checks may assi st you i n i denti fyi ng a possi bl e i ntermi ttent
probl em.
Reconnect any di sconnected components and harness connector.
WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION ON, THEN RECONNECT THE BATTERY.
Wi th the DRBI I I ௡ moni tor acti ve codes as you work through the fol l owi ng steps.
WARNING: TOAVOID PERSONAL INJ URY OR DEATH, MAINTAINASAFE
DISTANCE FROMALL AIRBAGSWHILE PERFORMING THE FOLLOWING
STEPS.
Wi ggl e the wi ri ng harness and connectors of the rel ated ai rbag ci rcui t or component.
I f codes are rel ated to the Dri ver Ai rbag ci rcui ts, rotate the steeri ng wheel from stop
to stop.
You have just attempted to si mul ate the condi ti on that i ni ti al l y set the troubl e code
message.
Di d the DTC become acti ve?
Al l
Yes → Sel ect appropri ate symptom from Symptom Li st.
No → No probl em found at thi s ti me. Erase al l codes before returni ng
vehi cl e to customer.
64
AIRBAG
PASSENGER SQUIB 1 CIRCUIT OPEN — Continued
Symptom:
PASSENGER SQUIB 1 CIRCUIT SHORT
When Monitored and Set Condition:
PASSENGER SQUIB 1 CIRCUIT SHORT
When Moni tored: Wi th the i gni ti on on, the ACM moni tors the resi stance between the
Passenger Squi b 1 ci rcui ts.
Set Condi ti on: When the ACM detects l ow resi stance i n the Passenger Squi b 1 ci rcui ts.
POSSIBLE CAUSES
PAB SQUI B 1 CI RCUI T SHORT
PAB SQUI B 1 LI NE 1 SHORT TO LI NE 2
ACM, PAB SQUI B 1 CI RCUI T SHORT
STORED CODE OR I NTERMI TTENT CONDI TI ON
ACTI VE CODE PRESENT
TEST ACTION APPLICABILITY
1 Turn the i gni ti on on.
NOTE: Ensure the battery is fully charged.
NOTE: For the purpose of this test, the AECM and ORC modules will be
referred to as an ACM.
SELECT ACTI VE or STORED DTC:
Al l
ACM - ACTI VE DTC
Go To 2
ACM - STORED DTC
Go To 5
NOTE: When reconnectingAirbagsystemcomponents, theignition must be
turned off and the battery must be disconnected.
65
AIRBAG
TEST ACTION APPLICABILITY
2 WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION OFF, DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE-
FORE PROCEEDING.
Di sconnect the Passenger Ai rbag connector(s).
NOTE: Check connectors - Clean and repair as necessary.
WARNING: TOAVOID PERSONAL INJ URY OR DEATH, DONOT PLACE AN
INTACT UNDEPLOYEDAIRBAG FACE DOWN ONAHARD SURFACE, THE
AIRBAG WILL PROPEL INTO THE AIR IF ACCIDENTALLY DEPLOYED.
Connect the appropri ate Load Tool to the Passenger Ai rbag connector(s).
WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION ON, THEN RECONNECT THE BATTERY.
Wi th the DRBI I I ௡, read the acti ve Ai rbag Control Modul e DTC’s.
Does the DRBI I I ௡ show PASSENGER SQUI B 1 CI RCUI T SHORT?
Al l
Yes → Go To 3
No → Repl ace the Passenger Ai rbag i n accordance wi th the Servi ce
I nformati on.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
3 WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION OFF, DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE-
FORE PROCEEDING.
Di sconnect the Load Tool from the Passenger Ai rbag connector(s).
Di sconnect the Ai rbag Control Modul e connector(s).
NOTE: Check connectors - Clean and repair as necessary.
Connect the appropri ate Load Tool Adapter to the Ai rbag Control Modul e connec-
tor(s).
Measure the resi stance between Passenger Squi b 1 Li ne 1 and Li ne 2 ci rcui ts at the
Passenger Ai rbag connector.
I s the resi stance bel ow 10K ohms?
Al l
Yes → Repai r Passenger Squi b 1 Li ne 1 ci rcui t short to Passenger Squi b
1 Li ne 2 ci rcui t.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
No → Go To 4
4 WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION OFF, DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE-
FORE PROCEEDING.
WARNING: IF THE AIRBAG CONTROL MODULE IS DROPPED AT ANY
TIME, IT MUST BE REPLACED. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND PERSONAL INJ URY OR DEATH.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r:
Repl ace the Ai rbag Control Modul e i n accordance wi th Servi ce
I nformati on.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
66
AIRBAG
PASSENGER SQUIB 1 CIRCUIT SHORT — Continued
TEST ACTION APPLICABILITY
5 Wi th the DRBI I I ௡, record and erase al l DTC’s from al l Ai rbag modul es.
I f equi pped wi th Passenger Ai rbag On - Off swi tch, read the DTC’s i n al l swi tch
posi ti ons.
I f any ACTI VE codes are present they must be resol ved before di agnosi ng any stored
codes.
WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION OFF, DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE-
FORE PROCEEDING.
Usi ng the wi ri ng di agram/schemati c as a gui de, i nspect the wi ri ng and connectors.
Look for chaffed, pi erced, pi nched, or parti al l y broken wi res and broken, bent, pushed
out, spread, corroded, or contami nated termi nal s.
The fol l owi ng addi ti onal checks may assi st you i n i denti fyi ng a possi bl e i ntermi ttent
probl em.
Reconnect any di sconnected components and harness connector.
WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION ON, THEN RECONNECT THE BATTERY.
Wi th the DRBI I I ௡ moni tor acti ve codes as you work through the fol l owi ng steps.
WARNING: TOAVOID PERSONAL INJ URY OR DEATH, MAINTAINASAFE
DISTANCE FROMALL AIRBAGSWHILE PERFORMING THE FOLLOWING
STEPS.
Wi ggl e the wi ri ng harness and connectors of the rel ated ai rbag ci rcui t or component.
I f codes are rel ated to the Dri ver Ai rbag ci rcui ts, rotate the steeri ng wheel from stop
to stop.
You have just attempted to si mul ate the condi ti on that i ni ti al l y set the troubl e code
message.
Di d the DTC become acti ve?
Al l
Yes → Sel ect appropri ate symptom from Symptom Li st.
No → No probl em found at thi s ti me. Erase al l codes before returni ng
vehi cl e to customer.
67
AIRBAG
PASSENGER SQUIB 1 CIRCUIT SHORT — Continued
Symptom:
PASSENGER SQUIB 1 SHORT TO BATTERY
When Monitored and Set Condition:
PASSENGER SQUIB 1 SHORT TO BATTERY
When Moni tored: Wi th the i gni ti on on, the ACM moni tors the vol tage on the Passenger
Squi b 1 ci rcui ts.
Set Condi ti on: When the ACM detects vol tage on the Passenger Squi b 1 ci rcui ts.
POSSIBLE CAUSES
PAB SQUI B 1 CI RCUI TS SHORT TO BATTERY
PAB SQUI B 1 LI NE 1 OR LI NE 2 SHORT TO BATTERY
ACM, PAB SQUI B 1 CI RCUI T SHORT TO BATTERY
STORED CODE OR I NTERMI TTENT CONDI TI ON
ACTI VE CODE PRESENT
TEST ACTION APPLICABILITY
1 Turn the i gni ti on on.
NOTE: Ensure the battery is fully charged.
NOTE: For the purpose of this test, the AECM and ORC modules will be
referred to as an ACM.
SELECT ACTI VE or STORED DTC:
Al l
ACM - ACTI VE DTC
Go To 2
ACM - STORED DTC
Go To 5
NOTE: When reconnectingAirbagsystemcomponents, theignition must be
turned off and the battery must be disconnected.
68
AIRBAG
TEST ACTION APPLICABILITY
2 WARNING: TOAVOID PERSONAL INJ URY OR DEATH, DISCONNECT THE
BATTERY AND WAIT TWO MINUTES BEFORE PROCEEDING.
Di sconnect the Passenger Ai rbag connector(s).
NOTE: Check connectors - Clean and repair as necessary.
WARNING: IF THE AIRBAG CONTROL MODULE IS DROPPED AT ANY
TIME, IT MUST BE REPLACED. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND PERSONAL INJ URY OR DEATH.
Connect the appropri ate Load Tool to the Passenger Ai rbag connector(s).
WARNING: TOAVOID PERSONAL INJ URY OR DEATH, THE IGNITIONON,
THEN RECONNECT THE BATTERY.
Wi th the DRBI I I ௡, read the acti ve Ai rbag Control Modul e DTC’s.
Does the DRBI I I ௡ show PASSENGER SQUI B 1 CI RCUI T SHORT TO BATTERY?
Al l
Yes → Go To 3
No → Repl ace Passenger Ai rbag i n accordance wi th the Servi ce I nfor-
mati on.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
3 WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION OFF, DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE-
FORE PROCEEDING.
Di sconnect the Load Tool from the Passenger Ai rbag connector(s).
Di sconnect the Ai rbag Control Modul e connector(s).
NOTE: Check connectors - Clean and repair as necessary.
Connect the appropri ate Load Tool Adaptor to the Ai rbag Control Modul e connec-
tor(s).
WARNING: AVOID PERSONAL INJ URY OR DEATH, TURN IGNITION ON,
THEN RECONNECT THE BATTERY.
Measure the vol tage on the Passenger Squi b 1 Li ne 1 and Li ne 2 ci rcui ts between the
Passenger Ai rbag connector and ground.
I s there any vol tage present?
Al l
Yes → Repai r Passenger Squi b 1 Li ne 1 or Li ne 2 ci rcui t short to battery.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
No → Go To 4
4 WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION OFF, DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE-
FORE PROCEEDING.
WARNING: IF THE AIRBAG CONTROL MODULE IS DROPPED AT ANY
TIME, IT MUST BE REPLACED. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND PERSONAL INJ URY OR DEATH.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r:
Repl ace the Ai rbag Control Modul e i n accordance wi th Servi ce
I nstructi ons.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
69
AIRBAG
PASSENGER SQUIB 1 SHORT TO BATTERY — Continued
TEST ACTION APPLICABILITY
5 Wi th the DRBI I I ௡, record and erase al l DTC’s from al l Ai rbag modul es.
I f equi pped wi th Passenger Ai rbag On - Off swi tch, read the DTC’s i n al l swi tch
posi ti ons.
I f any ACTI VE codes are present they must be resol ved before di agnosi ng any stored
codes.
WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION OFF, DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE-
FORE PROCEEDING.
Usi ng the wi ri ng di agram/schemati c as a gui de, i nspect the wi ri ng and connectors.
Look for chaffed, pi erced, pi nched, or parti al l y broken wi res and broken, bent, pushed
out, spread, corroded, or contami nated termi nal s.
The fol l owi ng addi ti onal checks may assi st you i n i denti fyi ng a possi bl e i ntermi ttent
probl em.
Reconnect any di sconnected components and harness connector.
WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION ON, THEN RECONNECT THE BATTERY.
Wi th the DRBI I I ௡ moni tor acti ve codes as you work through the fol l owi ng steps.
WARNING: TOAVOID PERSONAL INJ URY OR DEATH, MAINTAINASAFE
DISTANCE FROMALL AIRBAGSWHILE PERFORMING THE FOLLOWING
STEPS.
Wi ggl e the wi ri ng harness and connectors of the rel ated ai rbag ci rcui t or component.
I f codes are rel ated to the Dri ver Ai rbag ci rcui ts, rotate the steeri ng wheel from stop
to stop.
You have just attempted to si mul ate the condi ti on that i ni ti al l y set the troubl e code
message.
Di d the DTC become acti ve?
Al l
Yes → Sel ect appropri ate symptom from Symptom Li st.
No → No probl em found at thi s ti me. Erase al l codes before returni ng
vehi cl e to customer.
70
AIRBAG
PASSENGER SQUIB 1 SHORT TO BATTERY — Continued
Symptom:
PASSENGER SQUIB 1 SHORT TO GROUND
When Monitored and Set Condition:
PASSENGER SQUIB 1 SHORT TO GROUND
When Moni tored: Wi th the i gni ti on on, the ACM moni tors the resi stance of the Passenger
Squi b 1 ci rcui ts.
Set Condi ti on: When the ACM detects a short to ground i n ei ther Passenger Squi b 1
ci rcui ts.
POSSIBLE CAUSES
PAB SQUI B 1 CI RCUI TS SHORT TO GROUND
PAB SQUI B 1 LI NE 1 OR LI NE 2 SHORT TO GROUND
ACM, PAB SQUI B 1 SHORT TO GROUND
STORED CODE OR I NTERMI TTENT CONDI TI ON
ACTI VE CODE PRESENT
TEST ACTION APPLICABILITY
1 Turn the i gni ti on on.
NOTE: Ensure the battery is fully charged.
NOTE: For the purpose of this test, the AECM and ORC modules will be
referred to as an ACM.
SELECT ACTI VE or STORED DTC:
Al l
ACM - ACTI VE DTC
Go To 2
ACM - STORED DTC
Go To 5
NOTE: When reconnectingAirbagsystemcomponents, theignition must be
turned off and the battery must be disconnected.
71
AIRBAG
TEST ACTION APPLICABILITY
2 WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION OFF, DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE-
FORE PROCEEDING.
Di sconnect the Passenger Ai rbag connector(s).
NOTE: Check connectors - Clean and repair as necessary.
WARNING: DO NOT PLACE AN INTACT UNDEPLOYED AIRBAG FACE
DOWN ONAHARD SURFACE, THE AIRBAG WILL PROPEL INTOTHE AIR
IF ACCIDENTALLY DEPLOYED, AND COULD RESULT IN SERIOUS OR
FATAL INJ URY.
Connect the appropri ate Load Tool to the Passenger Ai rbag connector(s).
WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION ON, THEN RECONNECT THE BATTERY.
Wi th the DRBI I I ௡, read the acti ve Ai rbag Control Modul e DTC’s.
Does the DRBI I I ௡ show PASSENGER SQUI B 1 SHORT TO GROUND?
Al l
Yes → Go To 3
No → Repl ace the Passenger Ai rbag i n accordance wi th the Servi ce
I nformati on.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
3 WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION OFF, DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE-
FORE PROCEEDING.
Di sconnect the Load Tool from the Passenger Ai rbag connector(s).
Di sconnect the Ai rbag Control Modul e connector(s).
NOTE: Check connectors - Clean repair as necessary.
Connect the appropri ate Load Tool Adaptor to the Ai rbag Control Modul e connector.
Measure the resi stance of the Passenger Squi b 1 Li ne 1 or Li ne 2 ci rcui t between the
Passenger Ai rbag Modul e Connector and ground.
I s the resi stance bel ow 10K ohms on ei ther ci rcui t?
Al l
Yes → Repai r Passenger Squi b 1 Li ne 1 and Li ne 2 ci rcui ts for a short to
ground.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
No → Go To 4
4 WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION OFF, DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE-
FORE PROCEEDING.
WARNING: IF THE AIRBAG CONTROL MODULE IS DROPPED AT ANY
TIME, IT MUST BE REPLACED. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND PERSONAL INJ URY OR DEATH.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r:
Repl ace the Ai rbag Control Modul e i n accordance wi th Servi ce
I nformati on.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
72
AIRBAG
PASSENGER SQUIB 1 SHORT TO GROUND — Continued
TEST ACTION APPLICABILITY
5 Wi th the DRBI I I ௡, record and erase al l DTC’s from al l Ai rbag modul es.
I f equi pped wi th Passenger Ai rbag On - Off swi tch, read the DTC’s i n al l swi tch
posi ti ons.
I f any ACTI VE codes are present they must be resol ved before di agnosi ng any stored
codes.
WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION OFF, DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE-
FORE PROCEEDING.
Usi ng the wi ri ng di agram/schemati c as a gui de, i nspect the wi ri ng and connectors.
Look for chaffed, pi erced, pi nched, or parti al l y broken wi res and broken, bent, pushed
out, spread, corroded, or contami nated termi nal s.
The fol l owi ng addi ti onal checks may assi st you i n i denti fyi ng a possi bl e i ntermi ttent
probl em.
Reconnect any di sconnected components and harness connector.
WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION ON, THEN RECONNECT THE BATTERY.
Wi th the DRBI I I ௡ moni tor acti ve codes as you work through the fol l owi ng steps.
WARNING: TOAVOID PERSONAL INJ URY OR DEATH, MAINTAINASAFE
DISTANCE FROMALL AIRBAGSWHILE PERFORMING THE FOLLOWING
STEPS.
Wi ggl e the wi ri ng harness and connectors of the rel ated ai rbag ci rcui t or component.
I f codes are rel ated to the Dri ver Ai rbag ci rcui ts, rotate the steeri ng wheel from stop
to stop.
You have just attempted to si mul ate the condi ti on that i ni ti al l y set the troubl e code
message.
Di d the DTC become acti ve?
Al l
Yes → Sel ect appropri ate symptom from Symptom Li st.
No → No probl em found at thi s ti me. Erase al l codes before returni ng
vehi cl e to customer.
73
AIRBAG
PASSENGER SQUIB 1 SHORT TO GROUND — Continued
Symptom:
*AIRBAG INDICATOR ON WITHOUT ACTIVE TROUBLE CODES
POSSIBLE CAUSES
AI RBAG WARNI NG I NDI CATOR ON WI THOUT TROUBLE CODES
I NSTRUMENT CLUSTER PROBLEMS
TEST ACTION APPLICABILITY
1 Turn the i gni ti on on.
Make sure that al l Ai rbag and I nstrument Cl uster DTCs have been repai red before
performi ng thi s procedure.
Wi th the DRBI I I ௡ sel ect MONI TOR DI SPLAY, WARNI NG LAMP STATUS and read
the PASSI VE RESTRAI NTS, AI RBAG, MONI TOR DI SPLAY, WARNI NG LAMP
STATES.
Wi th no acti ve DTCs, Does the LAMP REQ by ACM moni tor show ON?
Al l
Yes → Go To 2
No → Repai r or repl ace the I nstrument Cl uster as necessary.
Perform BODY VERI FI CATI ON TEST - VER 1.
NOTE: When reconnectingAirbagsystemcomponents, theignition must be
turned off and the battery must be disconnected.
2 WARNING: TO AVOID PERSONAL INJ URY OR DEATH, TURN THE IGNI-
TION OFF, DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE-
FORE PROCEEDING.
WARNING: IF THE AIRBAG CONTROL MODULE IS DROPPED AT ANY
TIME, IT MUST BE REPLACED. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND PERSONAL INJ URY OR DEATH.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace the Ai rbag Control Modul e i n accordance wi th Servi ce
I nstructi ons.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
74
AIRBAG
Symptom:
ALL OUTPUTS SHORT - BASE AUDIO SYSTEM
When Monitored and Set Condition:
ALL OUTPUTS SHORT - BASE AUDIO SYSTEM
When Moni tored: I gni ti on i n RUN and I OD fuse i nstal l ed.
Set Condi ti on: The radi o has sensed a short on the output for more than 10 seconds.
POSSIBLE CAUSES
DETERMI NE FAULT
FRONT SHORTED SPEAKER
REAR SHORTED SPEAKER
(+) CI RCUI T SHORTED TO GROUND
(-) CI RCUI T SHORTED TO GROUND
SPEAKER (+) & (-) CI RCUI TS SHORTED TOGETHER
SPEAKER SECTI ON OF RADI O
TEST ACTION APPLICABILITY
1 Turn the i gni ti on on.
Turn the Radi o on.
Wi th the DRBI I I ௡, erase the audi o DTC’s.
Cycl e the i gni ti on swi tch from off to on and wai t 10 seconds.
Wi th the DRBI I I ௡, read the audi o DTC’s.
Does the DRBI I I ௡ di spl ay ALL OUTPUTS SHORT?
Al l
Yes → Go To 2
No → Refer to the wi ri ng di agrams l ocated i n the servi ce i nformati on to
hel p i sol ate a possi bl e i ntermi ttent short.
Perform BODY VERI FI CATI ON TEST - VER 1.
2 Turn the i gni ti on off.
NOTE: Perform this procedure after disconnecting each front speaker
connector.
Di sconnect each front speaker harness connector one at a ti me.
Turn the i gni ti on on.
Turn the radi o on.
Wi th the DRBI I I ௡, erase the audi o DTCs.
Cycl e the i gni ti on swi tch from off to on and wai t 10 seconds.
Wi th the DRBI I I ௡, read DTC’s.
Does the DRBI I I ௡ di spl ay ALL OUTPUTS SHORT wi th al l the front speakers
di sconnected?
Al l
Yes → Go To 3
No → Repl ace the Speaker that when di sconnected the DTC di d not
reset.
Perform BODY VERI FI CATI ON TEST - VER 1.
75
AUDIO
TEST ACTION APPLICABILITY
3 Turn the i gni ti on off.
NOTE: Perform this procedure after disconnecting each rear speaker
connector.
Di sconnect each rear speaker harness connector one at a ti me.
Turn the i gni ti on on.
Turn the radi o on.
Wi th the DRBI I I ௡, erase the audi o DTCs.
Cycl e the i gni ti on swi tch from off to on and wai t 10 seconds.
Wi th the DRBI I I ௡, read DTC’s.
Does the DRBI I I ௡ di spl ay ALL OUTPUTS SHORT wi th al l the rear speakers
di sconnected?
Al l
Yes → Go To 4
No → Repl ace the Speaker that when di sconnected the DTC di d not
reset.
Perform BODY VERI FI CATI ON TEST - VER 1.
4 Turn the i gni ti on off.
Di sconnect each front and rear speaker harness connector.
Di sconnect the Radi o harness connector.
Measure the resi stance between ground and each speaker (+) ci rcui t.
I s the resi stance bel ow 1000.0 (1K) ohms?
Al l
Yes → Repai r the speaker (+) ci rcui t for a short to ground.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Go To 5
5 Turn the i gni ti on off.
Di sconnect each front and rear speaker harness connector.
Di sconnect the Radi o harness connector.
Measure the resi stance between ground and each speaker (-) ci rcui t.
I s the resi stance bel ow 1000.0 (1K) ohms?
Al l
Yes → Repai r the speaker (-) ci rcui t for a short to ground.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Go To 6
6 Turn the i gni ti on off.
Di sconnect each front and rear speaker harness connector.
Di sconnect the Radi o harness connector.
Measure the resi stance between each speaker (+) ci rcui t and each speaker (-) ci rcui t.
I s the resi stance bel ow 1000.0 (1K) ohms for any of the measurements?
Al l
Yes → Repai r the speaker ci rcui ts shorted together.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Go To 7
7 I f there are no possi bl e causes remai ni ng, vi ew repai r. Al l
Repai r
Repl ace the Radi o.
Perform BODY VERI FI CATI ON TEST - VER 1.
76
AUDIO
ALL OUTPUTS SHORT - BASE AUDIO SYSTEM — Continued
Symptom:
ALL OUTPUTS SHORT - PREMIUMAUDIO SYSTEM
When Monitored and Set Condition:
ALL OUTPUTS SHORT - PREMIUMAUDIO SYSTEM
When Moni tored: I gni ti on i n RUN and I OD fuse i nstal l ed.
Set Condi ti on: The radi o has sensed a short on the output for more than 10 seconds.
POSSIBLE CAUSES
DETERMI NE FAULT
FRONT SHORTED SPEAKER
SUBWOOFER
REAR SHORTED SPEAKER
(+) CI RCUI T SHORTED TO GROUND
(-) CI RCUI T SHORTED TO GROUND
SPEAKER (+) & (-) CI RCUI TS SHORTED TOGETHER
SPEAKER SECTI ON OF RADI O
TEST ACTION APPLICABILITY
1 Turn the i gni ti on on.
Turn the Radi o on.
Wi th the DRBI I I ௡, erase the audi o DTC’s.
Cycl e the i gni ti on swi tch from off to on and wai t 10 seconds.
Wi th the DRBI I I ௡, read the audi o DTC’s.
Does the DRBI I I ௡ di spl ay ALL OUTPUTS SHORT?
Al l
Yes → Go To 2
No → Refer to the wi ri ng di agrams l ocated i n the servi ce i nformati on to
hel p i sol ate a possi bl e i ntermi ttent short.
Perform BODY VERI FI CATI ON TEST - VER 1.
2 Turn the i gni ti on off.
Di sconnect the Subwoofer harness connector.
Turn the i gni ti on on.
Turn the radi o on.
Wi th the DRBI I I ௡, erase the audi o DTCs.
Cycl e the i gni ti on swi tch from off to on and wai t 10 seconds.
Wi th the DRBI I I ௡, read DTC’s.
Does the DRBI I I ௡ di spl ay ALL OUTPUTS SHORTwi th the Subwoofer di sconnected?
Al l
Yes → Go To 3
No → Repl ace the Subwoofer i n accordance wi th the servi ce i nforma-
ti on.
Perform BODY VERI FI CATI ON TEST - VER 1.
77
AUDIO
TEST ACTION APPLICABILITY
3 Turn the i gni ti on off.
NOTE: Perform this procedure after disconnecting each front speaker
connector.
Di sconnect each front speaker harness connector one at a ti me.
Turn the i gni ti on on.
Turn the radi o on.
Wi th the DRBI I I ௡, erase the audi o DTCs.
Cycl e the i gni ti on swi tch from off to on and wai t 10 seconds.
Wi th the DRBI I I ௡, read DTC’s.
Does the DRBI I I ௡ di spl ay ALL OUTPUTS SHORT wi th al l the front speakers
di sconnected?
Al l
Yes → Go To 4
No → Repl ace the Speaker that when di sconnected the DTC di d not
reset.
Perform BODY VERI FI CATI ON TEST - VER 1.
4 Turn the i gni ti on off.
NOTE: Perform this procedure after disconnecting each rear speaker
connector.
Di sconnect each rear speaker harness connector one at a ti me.
Turn the i gni ti on on.
Turn the radi o on.
Wi th the DRBI I I ௡, erase the audi o DTCs.
Cycl e the i gni ti on swi tch from off to on and wai t 10 seconds.
Wi th the DRBI I I ௡, read DTC’s.
Does the DRBI I I ௡ di spl ay ALL OUTPUTS SHORT wi th al l the rear speakers
di sconnected?
Al l
Yes → Go To 5
No → Repl ace the Speaker that when di sconnected the DTC di d not
reset.
Perform BODY VERI FI CATI ON TEST - VER 1.
5 Turn the i gni ti on off.
Di sconnect each front and rear speaker harness connector.
Di sconnect the Radi o harness connector.
Measure the resi stance between ground and each speaker (+) ci rcui t.
I s the resi stance bel ow 1000.0 (1K) ohms?
Al l
Yes → Repai r the speaker (+) ci rcui t for a short to ground.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Go To 6
6 Turn the i gni ti on off.
Di sconnect each front and rear speaker harness connector.
Di sconnect the Radi o harness connector.
Measure the resi stance between ground and each speaker (-) ci rcui t.
I s the resi stance bel ow 1000.0 (1K) ohms?
Al l
Yes → Repai r the speaker (-) ci rcui t for a short to ground.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Go To 7
78
AUDIO
ALL OUTPUTS SHORT - PREMIUMAUDIO SYSTEM — Continued
TEST ACTION APPLICABILITY
7 Turn the i gni ti on off.
Di sconnect each front and rear speaker harness connector.
Di sconnect the Radi o harness connector.
Measure the resi stance between each speaker (+) ci rcui t and each speaker (-) ci rcui t.
I s the resi stance bel ow 1000.0 (1K) ohms for any of the measurements?
Al l
Yes → Repai r the speaker ci rcui ts shorted together.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Go To 8
8 I f there are no possi bl e causes remai ni ng, vi ew repai r. Al l
Repai r
Repl ace the Radi o.
Perform BODY VERI FI CATI ON TEST - VER 1.
79
AUDIO
ALL OUTPUTS SHORT - PREMIUMAUDIO SYSTEM — Continued
SymptomList:
CASSETTE PLAYER INOP
CD MECHANICAL FAILURE
NO PCI TRANSMISSION
*AM/FM SWITCH INOPERATIVE
*ANY STATION PRESET SWITCH INOPERATIVE
*BALANCE INOPERATIVE
*CD EJ ECT SWITCH INOPERATIVE
*EQUALIZER INOPERATIVE
*FADER INOPERATIVE
*FF/RWSWITCH INOPERATIVE
*HOUR/MINUTE SWITCHES INOPERATIVE
*PAUSE/PLAY SWITCH INOPERATIVE
*PWR SWITCH INOPERATIVE
*SCAN SWITCH INOPERATIVE
*SEEK SWITCH INOPERATIVE
*SET SWITCH INOPERATIVE
*TAPE EJ ECT SWITCH INOPERATIVE
*TIME SWITCH INOPERATIVE
*TUNE SWITCH INOPERATIVE
Test Note: All symptomslistedabovearediagnosedusingthesametests.
The title for the tests will be CASSETTE PLAYER INOP.
When Monitored and Set Condition:
CASSETTE PLAYER INOP
When Moni tored: Conti nuousl y wi th the i gni ti on and radi o turned on.
Set Condi ti on: The code wi l l set i f the radi o detects a i nternal cassette fai l ure.
CD MECHANICAL FAILURE
When Moni tored: Conti nuousl y wi th the i gni ti on and CD pl ayer turned on.
Set Condi ti on: The code wi l l set i f the radi o detects a CD mechani cal fai l ure.
POSSIBLE CAUSES
I NTERNAL FAI LURE
80
AUDIO
TEST ACTION APPLICABILITY
1 NOTE: If a DTC is set, erase the DTC and attempt to reset the DTC. If DTC
resets, follow this test.
Thi s i s an i nternal radi o fai l ure.
Vi ew repai r
Al l
Repai r
Repl ace the Radi o.
Perform BODY VERI FI CATI ON TEST - VER 1.
81
AUDIO
CASSETTE PLAYER INOP — Continued
Symptom:
CD PLAY FAILURE
When Monitored and Set Condition:
CD PLAY FAILURE
When Moni tored: Conti nuousl y wi th the i gni ti on and the radi o CD pl ayer turned on.
Set Condi ti on: The code wi l l set i f a CD that i s not formatted as a musi c CD or i s
scratched, di rty so the radi o can not pl ay the CD.
POSSIBLE CAUSES
CD PLAY FAI LURE
TEST ACTION APPLICABILITY
1 Repl ace the probl em CD wi th a good, cl ean, unscratched, musi c CD.
Turn the radi o CD pl ayer on.
Wi th the DRBI I I ௡, read DTC’s.
Does the DRBI I I ௡ di spl ay CD PLAY FAI LURE?
Al l
Yes → Repl ace the Radi o.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Test Compl ete.
82
AUDIO
Symptom:
CD READ FAILURE
When Monitored and Set Condition:
CD READ FAILURE
When Moni tored: Conti nuousl y wi th the i gni ti on and the radi o CD pl ayer turned on.
Set Condi ti on: The code wi l l set i f a CD that i s not formatted as a musi c CD i s i nstal l ed
i n the radi o CD pl ayer.
POSSIBLE CAUSES
CD READ FAI LURE
TEST ACTION APPLICABILITY
1 Repl ace the probl em CD wi th a good, cl ean, unscratched, musi c CD.
Turn the radi o CD pl ayer on.
Wi th the DRBI I I ௡, read DTC’s.
Does the DRBI I I ௡ di spl ay CD READ FAI LURE?
Al l
Yes → Repl ace the Radi o.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Test Compl ete.
83
AUDIO
Symptom:
CD TEMPERATURE HIGH
When Monitored and Set Condition:
CD TEMPERATURE HIGH
When Moni tored: Conti nuousl y wi th the i gni ti on and the radi o CD pl ayer turned on.
Set Condi ti on: The code wi l l set i f the temperature i nsi de the radi o CD pl ayer i s above
+85° C (+185° F).
POSSIBLE CAUSES
HI GH TEMPERATURE FAI LURE
TEST ACTION APPLICABILITY
1 Wi th the DRBI I I ௡, erase the audi o DTC’s.
Start the engi ne and al l ow the engi ne to reach normal operati ng temperature.
I f the vehi cl e has been i n the hot sunl i ght or extreme col d move the vehi cl e i ndoors
and open the doors to al l ow the i nsi de temperature to stabi l i ze.
The radi o CD pl ayer wi l l operate between -30° C and 85° C (-22° F and +185° F).
Wi th the DRBI I I ௡, read DTC’s.
Does the DRBI I I ௡ di spl ay CD TEMPERATURE HI GH?
Al l
Yes → Repl ace the Radi o.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Test Compl ete.
84
AUDIO
Symptom:
LOWVOLTAGE LEVEL
When Monitored and Set Condition:
LOWVOLTAGE LEVEL
When Moni tored:
Set Condi ti on: The radi o detects l ower than normal vol tage.
POSSIBLE CAUSES
CHECK CHARGI NG SYSTEM
CHECK VOLTAGE LEVEL AT RADI O
RADI O
TEST ACTION APPLICABILITY
1 Check the chargi ng system i n accordance wi th the servi ce i nformati on.
I s the chargi ng system operati ng properl y?
Al l
Yes → Go To 2
No → Refer to the appropri ate servi ce i nformati on and repai r as neces-
sary.
Perform BODY VERI FI CATI ON TEST - VER 1.
2 Turn the i gni ti on off.
Di sconnect the Radi o harness connector.
Start the engi ne.
Measure the vol tage of each Fused B+ ci rcui t and the Fused I gni ti on Swi tch Output
ci rcui t.
I s the vol tage above or approxi matel y 14 vol ts for each measurement?
Al l
Yes → Go To 3
No → Repai r the ci rcui t for hi gh resi stance.
Perform BODY VERI FI CATI ON TEST - VER 1.
3 Note: Reconnect all previously disconnected components.
Turn the i gni ti on and Radi o on.
Wi th the DRBI I I ௡, erase the audi o DTC’s.
Start the engi ne.
Wi th the DRBI I I ௡, read the audi o DTC’s.
Di d thi s DTC reset?
Al l
Yes → Repl ace the Radi o.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Test Compl ete.
85
AUDIO
Symptom:
NO ANTENNA CONNECTION
When Monitored and Set Condition:
NO ANTENNA CONNECTION
When Moni tored: Wi th the i gni ti on on and the radi o i n seek up/down mode.
Set Condi ti on: Wi th the radi o i n seek or scan mode for two mi nutes and the radi o does not
detect an antenna connecti on or does not recei ve a radi o stati on si gnal .
POSSIBLE CAUSES
BAD ANTENNA CONNECTI ON
TEST ANTENNA
RADI O
TEST ACTION APPLICABILITY
1 Turn the i gni ti on off.
Di sconnect the Radi o Antenna connector.
I nspect the Radi o Antenna connecti on.
Was the Antenna connecti on cl ean and ti ght?
Al l
Yes → Go To 2
No → Repai r Antenna connecti on as needed.
Perform BODY VERI FI CATI ON TEST - VER 1.
2 Refer to the Audi o System i n the servi ce i nformati on and test the Antenna i n
accordance wi th the servi ce procedure.
I s the Antenna ok?
Al l
Yes → Go To 3
No → Repai r or repl ace the Antenna assembl y as necessary.
Perform BODY VERI FI CATI ON TEST - VER 1.
3 NOTE: Reconnect all previously disconnected components.
Turn the i gni ti on and Radi o on.
NOTE: Move vehicle outside approximately 30ft fromany structure.
Wi th the DRBI I I ௡, erase the audi o DTC’s, put the radi o i n seek up and seek down
mode for approxi matel y 2 mi nutes before proceedi ng.
Wi th the DRBI I I ௡, read the audi o DTC’s.
Di d thi s DTC reset?
Al l
Yes → Repl ace the Radi o.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Test Compl ete.
86
AUDIO
Symptom:
POWER AMP SHUTDOWN - BASE AUDIO SYSTEM
When Monitored and Set Condition:
POWER AMP SHUTDOWN - BASE AUDIO SYSTEM
When Moni tored: I gni ti on i n RUN and I OD fuse i nstal l ed.
Set Condi ti on: The radi o has sensed a short on the output for more than 10 seconds.
POSSIBLE CAUSES
DETERMI NE FAULT
FRONT SHORTED SPEAKER
REAR SHORTED SPEAKER
(+) CI RCUI T SHORTED TO GROUND
(-) CI RCUI T SHORTED TO GROUND
SPEAKER (+) & (-) CI RCUI TS SHORTED TOGETHER
SPEAKER SECTI ON OF RADI O
TEST ACTION APPLICABILITY
1 Turn the i gni ti on on.
Turn the Radi o on.
Wi th the DRBI I I ௡, erase the audi o DTC’s.
Cycl e the i gni ti on swi tch from off to on and wai t 10 seconds.
Wi th the DRBI I I ௡, read the audi o DTC’s.
Does the DRBI I I ௡ di spl ay POWER AMP SHUTDOWN?
Al l
Yes → Go To 2
No → Refer to the wi ri ng di agrams l ocated i n the servi ce i nformati on to
hel p i sol ate a possi bl e i ntermi ttent short.
Perform BODY VERI FI CATI ON TEST - VER 1.
2 Turn the i gni ti on off.
NOTE: Perform this procedure after disconnecting each front speaker
connector.
Di sconnect each front speaker harness connector one at a ti me.
Turn the i gni ti on on.
Turn the radi o on.
Wi th the DRBI I I ௡, erase the audi o DTCs.
Cycl e the i gni ti on swi tch from off to on and wai t 10 seconds.
Wi th the DRBI I I ௡, read DTC’s.
Does the DRBI I I ௡ di spl ay POWER AMP SHUTDOWN wi th al l the front speakers
di sconnected?
Al l
Yes → Go To 3
No → Repl ace the Speaker that when di sconnected the DTC di d not
reset.
Perform BODY VERI FI CATI ON TEST - VER 1.
87
AUDIO
TEST ACTION APPLICABILITY
3 Turn the i gni ti on off.
NOTE: Perform this procedure after disconnecting each rear speaker
connector.
Di sconnect each rear speaker harness connector one at a ti me.
Turn the i gni ti on on.
Turn the radi o on.
Wi th the DRBI I I ௡, erase the audi o DTCs.
Cycl e the i gni ti on swi tch from off to on and wai t 10 seconds.
Wi th the DRBI I I ௡, read DTC’s.
Does the DRBI I I ௡ di spl ay POWER AMP SHUTDOWN wi th al l the rear speakers
di sconnected?
Al l
Yes → Go To 4
No → Repl ace the Speaker that when di sconnected the DTC di d not
reset.
Perform BODY VERI FI CATI ON TEST - VER 1.
4 Turn the i gni ti on off.
Di sconnect each front and rear speaker harness connector.
Di sconnect the Radi o harness connector.
Measure the resi stance between ground and each speaker (+) ci rcui t.
I s the resi stance bel ow 1000.0 (1K) ohms?
Al l
Yes → Repai r the speaker (+) ci rcui t for a short to ground.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Go To 5
5 Turn the i gni ti on off.
Di sconnect each front and rear speaker harness connector.
Di sconnect the Radi o harness connector.
Measure the resi stance between ground and each speaker (-) ci rcui t.
I s the resi stance bel ow 1000.0 (1K) ohms?
Al l
Yes → Repai r the speaker (-) ci rcui t for a short to ground.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Go To 6
6 Turn the i gni ti on off.
Di sconnect each front and rear speaker harness connector.
Di sconnect the Radi o harness connector.
Measure the resi stance between each speaker (+) ci rcui t and each speaker (-) ci rcui t.
I s the resi stance bel ow 1000.0 (1K) ohms for any of the measurements?
Al l
Yes → Repai r the speaker ci rcui ts shorted together.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Go To 7
7 I f there are no possi bl e causes remai ni ng, vi ew repai r. Al l
Repai r
Repl ace the Radi o.
Perform BODY VERI FI CATI ON TEST - VER 1.
88
AUDIO
POWER AMP SHUTDOWN - BASE AUDIO SYSTEM — Continued
Symptom:
POWER AMP SHUTDOWN - PREMIUMAUDIO SYSTEM
When Monitored and Set Condition:
POWER AMP SHUTDOWN - PREMIUMAUDIO SYSTEM
When Moni tored: I gni ti on i n RUN and I OD fuse i nstal l ed.
Set Condi ti on: The radi o has sensed a short on the output for more than 10 seconds.
POSSIBLE CAUSES
DETERMI NE FAULT
FRONT SHORTED SPEAKER
SUBWOOFER
REAR SHORTED SPEAKER
(+) CI RCUI T SHORTED TO GROUND
(-) CI RCUI T SHORTED TO GROUND
SPEAKER (+) & (-) CI RCUI TS SHORTED TOGETHER
SPEAKER SECTI ON OF RADI O
TEST ACTION APPLICABILITY
1 Turn the i gni ti on on.
Turn the Radi o on.
Wi th the DRBI I I ௡, erase the audi o DTC’s.
Cycl e the i gni ti on swi tch from off to on and wai t 10 seconds.
Wi th the DRBI I I ௡, read the audi o DTC’s.
Does the DRBI I I ௡ di spl ay POWER AMP SHUTDOWN?
Al l
Yes → Go To 2
No → Refer to the wi ri ng di agrams l ocated i n the servi ce i nformati on to
hel p i sol ate a possi bl e i ntermi ttent short.
Perform BODY VERI FI CATI ON TEST - VER 1.
2 Turn the i gni ti on off.
Di sconnect the Subwoofer harness connector.
Turn the i gni ti on on.
Turn the radi o on.
Wi th the DRBI I I ௡, erase the audi o DTCs.
Cycl e the i gni ti on swi tch from off to on and wai t 10 seconds.
Wi th the DRBI I I ௡, read DTC’s.
Does the DRBI I I ௡ di spl ay POWER AMP SHUTDOWN wi th the Subwoofer di scon-
nected?
Al l
Yes → Go To 3
No → Repl ace the Subwoofer i n accordance wi th the servi ce i nforma-
ti on.
Perform BODY VERI FI CATI ON TEST - VER 1.
89
AUDIO
TEST ACTION APPLICABILITY
3 Turn the i gni ti on off.
NOTE: Perform this procedure after disconnecting each front speaker
connector.
Di sconnect each front speaker harness connector one at a ti me.
Turn the i gni ti on on.
Turn the radi o on.
Wi th the DRBI I I ௡, erase the audi o DTCs.
Cycl e the i gni ti on swi tch from off to on and wai t 10 seconds.
Wi th the DRBI I I ௡, read DTC’s.
Does the DRBI I I ௡ di spl ay POWER AMP SHUTDOWN wi th al l the front speakers
di sconnected?
Al l
Yes → Go To 4
No → Repl ace the Speaker that when di sconnected the DTC di d not
reset.
Perform BODY VERI FI CATI ON TEST - VER 1.
4 Turn the i gni ti on off.
NOTE: Perform this procedure after disconnecting each rear speaker
connector.
Di sconnect each rear speaker harness connector one at a ti me.
Turn the i gni ti on on.
Turn the radi o on.
Wi th the DRBI I I ௡, erase the audi o DTCs.
Cycl e the i gni ti on swi tch from off to on and wai t 10 seconds.
Wi th the DRBI I I ௡, read DTC’s.
Does the DRBI I I ௡ di spl ay POWER AMP SHUTDOWN wi th al l the rear speakers
di sconnected?
Al l
Yes → Go To 5
No → Repl ace the Speaker that when di sconnected the DTC di d not
reset.
Perform BODY VERI FI CATI ON TEST - VER 1.
5 Turn the i gni ti on off.
Di sconnect each front and rear speaker harness connector.
Di sconnect the Radi o harness connector.
Measure the resi stance between ground and each speaker (+) ci rcui t.
I s the resi stance bel ow 1000.0 (1K) ohms?
Al l
Yes → Repai r the speaker (+) ci rcui t for a short to ground.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Go To 6
6 Turn the i gni ti on off.
Di sconnect each front and rear speaker harness connector.
Di sconnect the Radi o harness connector.
Measure the resi stance between ground and each speaker (-) ci rcui t.
I s the resi stance bel ow 1000.0 (1K) ohms?
Al l
Yes → Repai r the speaker (-) ci rcui t for a short to ground.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Go To 7
90
AUDIO
POWER AMP SHUTDOWN - PREMIUMAUDIO SYSTEM — Continued
TEST ACTION APPLICABILITY
7 Turn the i gni ti on off.
Di sconnect each front and rear speaker harness connector.
Di sconnect the Radi o harness connector.
Measure the resi stance between each speaker (+) ci rcui t and each speaker (-) ci rcui t.
I s the resi stance bel ow 1000.0 (1K) ohms for any of the measurements?
Al l
Yes → Repai r the speaker ci rcui ts shorted together.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Go To 8
8 I f there are no possi bl e causes remai ni ng, vi ew repai r. Al l
Repai r
Repl ace the Radi o.
Perform BODY VERI FI CATI ON TEST - VER 1.
91
AUDIO
POWER AMP SHUTDOWN - PREMIUMAUDIO SYSTEM — Continued
Symptom:
*POOR SOUND QUALITY
POSSIBLE CAUSES
CHECK AUDI O DTCS
CHECK SELECTED RADI O EQ CURVE
SET THE RADI O EQ CURVE
VERI FY SOUND PERFORMANCE
TEST ACTION APPLICABILITY
1 Turn the i gni ti on on.
Wi th the DRBI I I ௡, check for any audi o rel ated DTC’s.
Are any Audi o rel ated DTCs set?
Al l
Yes → Refer to the Audi o category for the rel ated symptom(s).
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Go To 2
2 Turn the i gni ti on on.
Wi th the DRBI I I ௡, enter body, I nstrument Cl uster then mi scel l aneous.
Check the radi o EQ curve setti ng and fol l ow the i nstructi ons on the DRBI I I ௡.
I s the radi o EQ curve correct for the audi o combi nati on the vehi cl e i s equi pped wi th?
Al l
Yes → Refer to the servi ce i nformati on for probl ems rel ated to poor
sound qual i ty and perform the appropri ate checks.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Go To 3
3 Turn the i gni ti on on.
Wi th the DRBI I I ௡, enter body, I nstrument Cl uster then mi scel l aneous.
Set the radi o EQ curve. Fol l ow the i nstructi ons on the DRBI I I ௡.
Cycl e the i gni ti on swi tch from off to on.
Check the radi o EQ curve setti ng.
I s the radi o EQ curve correct for the audi o combi nati on the vehi cl e i s equi pped wi th?
Al l
Yes → Refer to the servi ce i nformati on for probl ems rel ated to poor
sound qual i ty and perform the appropri ate checks.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Repl ace the I nstrument Cl uster i n accordance wi th the Servi ce
I nformati on.
Perform BODY VERI FI CATI ON TEST - VER 1.
92
AUDIO
Symptom:
*CHIME INOPERATIVE AT ALL TIMES
POSSIBLE CAUSES
I NSTRUMENT CLUSTER - CHI ME I NOPERATI VE
TEST ACTION APPLICABILITY
1 I f there are no possi bl e causes remai ni ng, vi ew repai r. Al l
Repai r
Repl ace the I nstrument Cl uster i n accordance wi th the Servi ce
I nformati on.
Perform BODY VERI FI CATI ON TEST - VER 1.
93
CHIME
Symptom:
*CHIME INOPERATIVE WITH DRIVER SEAT BELT UNFASTENED
POSSIBLE CAUSES
SEAT BELT SWI TCH STATUS WRONG
SEAT BELT SWI TCH SHORTED
SEAT BELT SWI TCH SENSE WI RE SHORT TO GROUND
I NSTRUMENT CLUSTER - SEAT BELT SWI TCH SHORTED
TEST ACTION APPLICABILITY
1 Ensure the dri vers seat bel t i s unfastened.
Wi th the DRB I I I sel ect: El ectro Mech Cl uster I nput Output.
Turn the i gni ti on on.
Read the Dri ver Bel t SW status.
Does the DRB I I I show Dri ver Bel t SW: CLOSED?
Al l
Yes → Go To 2
No → Repl ace the I nstrument Cl uster.
Perform BODY VERI FI CATI ON TEST - VER 1.
2 Di sconnect the Seat Bel t Swi tch connector.
Wi th the DRB I I I sel ect: El ectro Mech Cl uster I nput Outputs.
Turn the i gni ti on on.
Read the Dri ver Bel t Sw status.
Does the DRB I I I show Seat Bel t SW: CLOSED?
Al l
Yes → Go To 3
No → Repai r Seat Bel t swi tch pi gtai l wi ri ng for a short to ground or
repl ace the Seat Bel t buckl e assembl y.
Perform BODY VERI FI CATI ON TEST - VER 1.
3 Turn the i gni ti on off.
Remove the I nstrument Cl uster from the i nstrument panel .
Di sconnect the Seat Bel t Swi tch connector.
Measure the resi stance between ground and the Seat Bel t Swi tch Sense ci rcui t at the
I nstrument Cl uster C2 connector.
I s the resi stance bel ow 100.0 ohms?
Al l
Yes → Repai r the Seat Bel t Swi tch Sense wi re for a short to ground.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Go To 4
4 I f there are no possi bl e causes remai ni ng, vi ew repai r. Al l
Repai r
Repl ace the I nstrument Cl uster.
Perform BODY VERI FI CATI ON TEST - VER 1.
94
CHIME
Symptom:
*CHIME INOPERATIVE WITH EXTERIOR LAMPSONANDDRIVER
DOOR OPEN
POSSIBLE CAUSES
VERI FY KEY-I N I GNI TI ON, DRI VER’S DOOR OPEN CHI ME OPERATI ON
HEADLAMP SWI TCH OUTPUT OPEN
MI C - CHI ME I NOP WI TH EXTERI OR LAMPS ON
TEST ACTION APPLICABILITY
1 Turn the i gni ti on off.
Ensure the key i s i n the i gni ti on swi tch al l the way.
Open the dri ver door.
Does the chi me sound?
Al l
Yes → Go To 2
No → Refer to symptom *CHI ME I NOPERATI VE WI TH KEY I N I G-
NI TI ON, DRI VER’S DOOR OPEN i n the CHI ME category.
Perform BODY VERI FI CATI ON TEST - VER 1.
2 Turn the i gni ti on off.
Remove the I nstrument Cl uster From the I /P.
Turn the Exteri or Lamps on.
Measure the vol tage of the Headl amp Swi tch Output ci rcui t i n the I nstrument
Cl uster C1 connector.
I s the vol tage above 10.0 vol ts?
Al l
Yes → I f there are no possi bl e causes remai ni ng, repl ace the I nstrument
Cl uster.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Repai r the Headl amp Swi tch Output ci rcui t for an open.
Perform BODY VERI FI CATI ON TEST - VER 1.
95
CHIME
Symptom:
*CHIME INOPERATIVE WITH KEY IN IGNITION, DRIVER’S DOOR
OPEN
POSSIBLE CAUSES
OPEN DOOR AJAR GROUND CKT
OPEN/MI SSI NG FUSE 4
DRI VER DOOR AJAR SWI TCH
DOOR AJAR SWI TCH OUTPUT CI RCUI T OPEN
DRI VER DOOR AJAR SWI TCH SENSE CI RCUI T OPEN
I NSTRUMENT CLUSTER - DOOR AJAR
I GNI TI ON SWI TCH GROUND CI RCUI T OPEN
KEY-I N I GNI TI ON SWI TCH OPEN
KEY-I N I GNI TI ON SWI TCH SENSE CI RCUI T OPEN
I NSTRUMENT CLUSTER - KEY-I N
TEST ACTION APPLICABILITY
1 Turn the i gni ti on on.
Open the dri ver door.
Wi th the DRB, read the ЉDR DOOR AJAR SWЉ state.
Does the DRB di spl ay ЉDR DOOR AJAR SW: CLOSEDЉ?
Al l
Yes → Go To 2
No → Go To 6
2 Turn the i gni ti on off.
Di sconnect the I gni ti on Swi tch harness connector.
Note: Ensure the key is in the Ignition Switch Lock Cylinder.
Measure the resi stance of the Key-i n I gni ti on Swi tch wi th the key i n.
I s the resi stance bel ow 20 ohms?
Al l
Yes → Go To 3
No → Check the I gni ti on Lock Cyl i nder for damage. I f OK, repl ace the
I gni ti on Swi tch.
Perform BODY VERI FI CATI ON TEST - VER 1.
3 Turn the i gni ti on off.
Di sconnect the I gni ti on Swi tch harness connector.
Measure the resi stance of the ground ci rcui t i n the i gni ti on swi tch harness connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 4
No → Repai r the ground ci rcui t for an open.
Perform BODY VERI FI CATI ON TEST - VER 1.
96
CHIME
TEST ACTION APPLICABILITY
4 Turn the i gni ti on off.
Di sconnect the I gni ti on Swi tch harness connector.
Remove the I nstrument Cl uster from the I /P.
Measure the resi stance of the Key-i n I gni ti on Swi tch Sense ci rcui t between the
i gni ti on swi tch harness connector and the I nstrument Cl uster C2 connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 5
No → Repai r the key-i n i gni ti on swi tch sense ci rcui t for an open.
Perform BODY VERI FI CATI ON TEST - VER 1.
5 I f there are no possi bl e causes remai ni ng, vi ew repai r. Al l
Repai r
Repl ace the I nstrument Cl uster i n accordance wi th the Servi ce
I nformati on..
Perform BODY VERI FI CATI ON TEST - VER 1.
6 Gai n access to the Fuse Bl ock Fuse #4 and i nspect.
Was the fuse mi ssi ng or open?
Al l
Yes → Repl ace Fuse.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Go To 7
7 Usi ng a 12-vol t Test Li ght connected to 12-vol ts, test the Ground ci rcui t at fuse #4 for
conti nui ty.
Does the l i ght i l l umi nate?
Al l
Yes → Go To 8
No → Repai r the Ground ci rcui t for an open.
Perform BODY VERI FI CATI ON TEST - VER 1.
8 Rei nstal l fuse i f removed i n previ ous test.
Di sconnect the Dri ver Door Ajar Swi tch connector.
Wi th the DRBI I I ௡ i n I nputs/Outputs, read the DRV DR AJAR SW state.
Connect a jumper wi re between Sense ci rcui t and the Output ci rcui t.
Does the DRBI I I ௡ di spl ay DRV DR AJAR SW: CLOSED?
Al l
Yes → Repl ace the Dri ver Door Ajar Swi tch.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Go To 9
9 Di sconnect the Dri ver Door Ajar Swi tch connector.
Measure the resi stance of the Door Ajar Output from the ajar swi tch to the fuse.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 10
No → Repai r the Door Ajar Swi tch Output ci rcui t for an open.
Perform BODY VERI FI CATI ON TEST - VER 1.
97
CHIME
*CHIME INOPERATIVE WITH KEY IN IGNITION, DRIVER’S DOOR
OPEN — Continued
TEST ACTION APPLICABILITY
10 Remove the I nstrument Cl uster from the I /P.
Di sconnect the Dri ver Door Ajar Swi tch connector.
Measure the resi stance of the Dri ver Door Ajar Swi tch Sense ci rcui t from the Dri ver
Door Ajar swi tch to the I nstrument Cl uster C2 connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 11
No → Repai r the Dri ver Door Ajar Swi tch Sense ci rcui t for an open.
Perform BODY VERI FI CATI ON TEST - VER 1.
11 I f there are no possi bl e causes remai ni ng, vi ew repai r. Al l
Repai r
Repl ace the I nstrument Cl uster i n accordance wi th the Servi ce
I nformati on.
Perform BODY VERI FI CATI ON TEST - VER 1.
98
CHIME
*CHIME INOPERATIVE WITH KEY IN IGNITION, DRIVER’S DOOR
OPEN — Continued
Symptom:
*CHIME SOUNDS WITH DRIVER SEAT BELT FASTENED
POSSIBLE CAUSES
SEAT BELT SWI TCH STATUS WRONG
SEAT BELT SWI TCH OPEN
GROUND WI RE OPEN
SEAT BELT SWI TCH SENSE OPEN
I NSTRUMENT CLUSTER - SEAT BELT SENSE OPEN
TEST ACTION APPLICABILITY
1 Ensure the dri vers seat bel t i s fastened.
Wi th the DRB I I I sel ect: El ectro Mech Cl uster I nput/Outputs.
Turn the i gni ti on on.
Read the Dri ver Bel t SW status.
Does the DRB I I I show Dri ver Bel t SW: CLOSED?
Al l
Yes → Repl ace the I nstrument Cl uster.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Go To 2
2 Di sconnect the Seat Bel t Swi tch connector.
Turn al l i nteri or l i ghts off.
Measure the resi stance of the Ground ci rcui t i n the Seat Bel t Swi tch connector to
ground.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 3
No → Repai r the open Ground wi re.
Perform BODY VERI FI CATI ON TEST - VER 1.
3 Di sconnect the Seat Bel t Swi tch connector.
Connect a jumper wi re between Seat Bel t Swi tch Sense ci rcui t and the Ground
ci rcui t i n the Seat Bel t Swi tch connector.
Wi th the DRB I I I sel ect: El ectro Mech Cl uster I nput/Outputs.
Turn the i gni ti on on.
Read the Dri ver Bel t SW status.
Does the DRB I I I show Dri ver Bel t SW: CLOSED?
Al l
Yes → Repai r Seat Bel t swi tch pi gtai l wi ri ng or repl ace Buckl e assembl y.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Go To 4
4 Turn the i gni ti on off.
Remove the I nstrument Cl uster from the i nstrument panel .
Di sconnect the Seat Bel t Swi tch connector.
Measure the resi stance of the Seat Bel t Swi tch Sense ci rcui t between the I nstrument
Cl uster C2 connector and the Seat Bel t Swi tch connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 5
No → Repai r the open Seat Bel t Swi tch Sense wi re.
Perform BODY VERI FI CATI ON TEST - VER 1.
99
CHIME
TEST ACTION APPLICABILITY
5 I f there are no possi bl e causes remai ni ng, vi ew repai r. Al l
Repai r
Repl ace the I nstrument Cl uster.
Perform BODY VERI FI CATI ON TEST - VER 1.
100
CHIME
*CHIME SOUNDS WITH DRIVER SEAT BELT FASTENED — Continued
Symptom:
*CHIME SOUNDS WITH DRIVER’S DOOR OPEN, KEY REMOVED
POSSIBLE CAUSES
KEY-I N I GNI TI ON SWI TCH SHORTED
KEY-I N I GNI TI ON SW SENSE SHORT TO GROUND
I NSTRUMENT CLUSTER - KEY-I N I GNI TI ON SHORTED
TEST ACTION APPLICABILITY
1 Di sconnect the I gni ti on Swi tch connector.
Di d the chi me turn off?
Al l
Yes → Check the I gni ti on Lock Cyl i nder for damage. I f OK repl ace the
I gni ti on Swi tch.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Go To 2
2 Turn i gni ti on off.
Di sconnect the I gni ti on Swi tch connector.
Remove the I nstrument Cl uster from the I /P.
Measure the resi stance of the Key-i n I gni ti on Swi tch Sense ci rcui t to ground at the
I nstrument Cl uster C2 connector.
I s the resi stance bel ow 100.0 ohms?
Al l
Yes → Repai r the Key-I n I gni ti on Swi tch Sense wi re for a short to
ground..
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Go To 3
3 I f there are no possi bl e causes remai ni ng, vi ew repai r. Al l
Repai r
Repl ace the I nstrument Cl uster.
Perform BODY VERI FI CATI ON TEST - VER 1.
101
CHIME
Symptom:
*NO RESPONSE FROMAIRBAG CONTROL MODULE
POSSIBLE CAUSES
CHECKI NG FOR VOLTAGE AT ACM
GROUND CI RCUI T OPEN
OPEN PCI BUS CI RCUI T
AI RBAG CONTROL MODULE
TEST ACTION APPLICABILITY
1 Ensure that the battery i s ful l y charged.
WARNING: TO AVOID PERSONAL INJ URY OR DEATH TURN THE IGNI-
TION OFF, DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE-
FORE PROCEEDING.
Di sconnect the ACM harness connector.
Connect the appropri ate Load Tool ACM Adapter to the ACM connector.
Turn the i gni ti on on and then reconnect the Battery.
Usi ng a 12-vol t test l i ght connected to ground, probe the Fused I gni ti on Swi tch
Output (Run) Ci rcui t and the Fused I gni ti on Swi tch Output (Run/Start) Ci rcui t at
the ACM connector.
NOTE: One open ci rcui t wi l l not cause a NO RESPONSE condi ti on.
I s the test l i ght i l l umi nated on both ci rcui ts?
Al l
Yes → Go To 2
No → Repai r the Fused I gni ti on Swi tch Output (Run) and Fused
I gni ti on Swi tch Output (Run/Start) ci rcui ts for an open.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
NOTE: When reconnectingairbagsystemcomponents, theignition must be
turned off and the battery must be disconnected.
2 NOTE: Ensure there is PCI Bus communication with other modules on the
vehicle before proceeding. If not, refer to the symptomlist fromthe menu
and repair as necessary.
Warning: To avoid personal injury or death, turn the ignition Off, discon-
nect the Battery and wait 2 minutes before proceeding.
Di sconnect the Ai rbag Control Modul e harness connector.
Connect the appropri ate Load Tool ACM Adapter to the ACM connector.
Usi ng a 12-vol t test l i ght connected to 12-vol ts, probe the ground ci rcui t.
I s the test l i ght i l l umi nated?
Al l
Yes → Go To 3
No → Repai r the ground ci rcui t for an open.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
Note: When reconnectingAirbag systemcomponents, the ignition must be
turned off and the battery must be disconnected.
102
COMMUNICATION
TEST ACTION APPLICABILITY
3 Note: Ensure there is PCI Bus communication with other modules on the
vehicle before proceeding. If not, refer to the symptomlist fromthe menu
and repair as necessary.
Turn the i gni ti on off and wai t 2 mi nutes before proceedi ng.
Di sconnect the Ai rbag Control Modul e harness connector.
Connect the appropri ate Load Tool ACM Adapter to the ACM connector.
Use Scope i nput cabl e CH7058, Cabl e to Probe adapter CH7062, and the red and
bl ack test probes.
Connect the scope i nput cabl e to the channel one connector on the DRB. Attach the
red and bl ack l eads and the cabl e to probe adapter to the scope i nput cabl e.
Wi th the DRBI I I ௡ sel ect Pep Modul e Tool s.
Sel ect l ab scope.
Sel ect Li ve Data.
Sel ect 12 vol t square wave.
Press F2 for Scope.
Press F2 and use the down arrow to set vol tage range to 20 vol ts. Press F2 agai n
when compl ete.
Connect the Bl ack l ead to the chassi s ground. Connect the Red l ead to the PCI Bus
ci rcui t i n the ACM connector.
Turn the i gni ti on on.
Observe the vol tage di spl ay on the DRB Lab Scope.
Does the vol tage pul se from 0 to approxi matel y 7.5 vol ts?
Al l
Yes → Go To 4
No → Repai r the PCI Bus ci rcui t for an open.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
NOTE: When reconnectingAirbagsystemcomponents, theignition must be
turned off and the battery must be disconnected.
4 I f there are no possi bl e causes remai ni ng, vi ew repai r. Al l
Repai r
Repl ace the Ai rbag Control Modul e (ACM) i n accordance wi th the
Servi ce I nformati on.
Perform AI RBAG VERI FI CATI ON TEST - VER 1.
103
COMMUNICATION
*NO RESPONSE FROMAIRBAG CONTROL MODULE — Continued
Symptom:
*NO RESPONSE FROM CONTROLLER ANTILOCK BRAKE
POSSIBLE CAUSES
ATTEMPT TO COMMUNI CATE WI TH THE PCM
CHECK FUSE #7 I N FUSE BLOCK
OPEN GROUND CI RCUI TS
OPEN FUSED I GNI TI ON SWI TCH OUTPUT CI RCUI T
SCI TRANSMI T CI RCUI T OPEN
CONTROLLER ANTI LOCK BRAKE
TEST ACTION APPLICABILITY
1 Turn the i gni ti on on.
Wi th the DRB attempt to communi cate wi th the PCM.
Was the DRB abl e to communi cate wi th the PCM?
Al l
Yes → Go To 2
No → Refer to symptom l i st for probl ems rel ated to No Response From
PCM.
Perform ABS VERI FI CATI ON TEST - VER 1.
2 Turn the i gni ti on off.
Remove and i nspect fuse #7 i n the Fuse Bl ock.
I s the fuse open?
Al l
Yes → Refer to the wi ri ng di agrams l ocated i n the servi ce i nformati on to
hel p i sol ate a possi bl e short to ground.
Perform ABS VERI FI CATI ON TEST - VER 1.
No → Go To 3
3 Turn the i gni ti on off.
Di sconnect the CAB harness connector.
Usi ng a 12-vol t test l i ght connected to 12-vol ts, probe each ground ci rcui t.
I s the test l i ght i l l umi nated for each ci rcui t?
Al l
Yes → Go To 4
No → Repai r the ground ci rcui t for an open.
Perform ABS VERI FI CATI ON TEST - VER 1.
4 Turn the i gni ti on off.
NOTE: Ensure fuse #7 is installed in the Fuse Block.
Di sconnect the CAB harness connector.
Turn the i gni ti on on.
Usi ng a 12-vol t test l i ght connected to ground, probe the Fused I gni ti on Swi tch
Output ci rcui t.
I s the test l i ght i l l umi nated?
Al l
Yes → Go To 5
No → Repai r the Fused I gni ti on Swi tch Output ci rcui t for an open.
Perform ABS VERI FI CATI ON TEST - VER 1.
104
COMMUNICATION
TEST ACTION APPLICABILITY
5 Turn the i gni ti on off.
Di sconnect the CAB harness connector.
Measure the resi stance of the SCI Transmi t ci rcui t between the CAB connector and
the DLC.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 6
No → Repai r the SCI Transmi t ci rcui t for an open.
Perform ABS VERI FI CATI ON TEST - VER 1.
6 I f there are no possi bl e causes remai ni ng, vi ew repai r. Al l
Repai r
Repl ace the Control l er Anti l ock Brake i n accordance wi th the
Servi ce I nformati on.
Perform ABS VERI FI CATI ON TEST - VER 1.
105
COMMUNICATION
*NO RESPONSE FROM CONTROLLER ANTILOCK BRAKE — Continued
Symptom:
*NO RESPONSE FROM INSTRUMENT CLUSTER
POSSIBLE CAUSES
OPEN GROUND CI RCUI T
OPEN FUSED I GNI TI ON SWI TCH OUTPUT CI RCUI T
OPEN FUSED B+ CI RCUI T
OPEN PCI BUS CI RCUI T
I NSTRUMENT CLUSTER
TEST ACTION APPLICABILITY
1 Turn the i gni ti on off.
Turn al l l i ghts off.
Di sconnect the I nstrument Cl uster C1 harness connector.
Usi ng a 12-vol t test l i ght connected to 12-vol ts, probe the ground ci rcui t.
I s the test l i ght i l l umi nated?
Al l
Yes → Go To 2
No → Repai r the ground ci rcui t for an open.
Perform BODY VERI FI CATI ON TEST - VER 1.
2 Turn the i gni ti on off.
Di sconnect the I nstrument Cl uster C1 harness connector.
Turn the i gni ti on on.
Usi ng a 12-vol t test l i ght connected to ground, probe the Fused I gni ti on Swi tch
Output ci rcui t.
I s the test l i ght i l l umi nated?
Al l
Yes → Go To 3
No → Check the fuse i n the Fuse Bl ock for an open. Refer to the wi ri ng
di agrams. I f ok, repai r the Fused I gni ti on Swi tch Output ci rcui t
for an open.
Perform BODY VERI FI CATI ON TEST - VER 1.
3 Turn the i gni ti on off.
Di sconnect the I nstrument Cl uster C1 harness connector.
Usi ng a 12-vol t test l i ght connected to ground, probe the Fused B+ ci rcui t.
I s the test l i ght i l l umi nated?
Al l
Yes → Go To 4
No → Repai r the Fused B+ ci rcui t for an open.
Perform BODY VERI FI CATI ON TEST - VER 1.
106
COMMUNICATION
TEST ACTION APPLICABILITY
4 Note: Ensure there is PCI Bus communication with other modules on the
vehicle before proceeding. If not, refer to the symptomlist fromthe menu
and repair as necessary.
Di sconnect the I nstrument Cl uster C2 harness connector.
Use Scope i nput cabl e CH7058, Cabl e to Probe adapter CH7062, and the red and
bl ack test probes.
Connect the scope i nput cabl e to the channel one connector on the DRB. Attach the
red and bl ack l eads and the cabl e to probe adapter to the scope i nput cabl e.
Wi th the DRBI I I ௡ sel ect Pep Modul e Tool s.
Sel ect l ab scope.
Sel ect Li ve Data.
Sel ect 12 vol t square wave.
Press F2 for Scope.
Press F2 and use the down arrow to set vol tage range to 20 vol ts. Press F2 agai n
when compl ete.
Connect the Bl ack l ead to the chassi s ground. Connect the Red l ead to the PCI Bus
ci rcui t i n the I nstrument Cl uster connector.
Turn the i gni ti on on.
Observe the vol tage di spl ay on the DRB Lab Scope.
Does the vol tage pul se from 0 to approxi matel y 7.5 vol ts?
Al l
Yes → Go To 5
No → Repai r the PCI Bus ci rcui t for an open.
Perform BODY VERI FI CATI ON TEST - VER 1.
5 I f there are no possi bl e causes remai ni ng, vi ew repai r. Al l
Repai r
Repl ace the I nstrument Cl uster i n accordance wi th the servi ce
i nformati on.
Perform BODY VERI FI CATI ON TEST - VER 1.
107
COMMUNICATION
*NO RESPONSE FROM INSTRUMENT CLUSTER — Continued
Symptom:
*NO RESPONSE FROM PCM (PCI BUS)
POSSIBLE CAUSES
PCM PCI NO RESPONSE
PCI BUS CI RCUI T OPEN
POWERTRAI N CONTROL MODULE
TEST ACTION APPLICABILITY
1 Turn the i gni ti on on.
NOTE:Assoon asoneor moremodulecommunicateswith theDRB, answer
the question.
Wi th the DRBI I I ௡, enter Body then El ectro/Mechani cal Cl uster (MI C).
Wi th the DRBI I I ௡, enter Passi ve Restrai nts then Ai rbag.
Were you abl e to establ i sh communi cati ons wi th any of the modul es?
Al l
Yes → Go To 2
No → Refer to symptom PCI Bus Communi cati on Fai l ure i n the Com-
muni cati ons category.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 1.
2 Wi th the DRBI I I ௡ read PCM Di agnosti c Troubl e Codes. Thi s i s to ensure power and
grounds to the PCM are operati onal .
NOTE: If the DRBIII௡ will not read PCM DTC’s, follow the NO RESPONSE
TO PCM (SCI only) symptompath.
NOTE: If the vehicle will not start and the DRBIII௡ displays a no response
message, refer to the appropriate symptom in the powertrain diagnostic
procedures.
Turn the i gni ti on off.
Di sconnect the PCM C3 harness connector.
Use Scope i nput cabl e CH7058, Cabl e to Probe adapter CH7062, and the red and
bl ack test probes.
Connect the scope i nput cabl e to the channel one connector on the DRBI I I ௡. Attach
the red and bl ack l eads and the cabl e to probe adapter to the scope i nput cabl e.
I nstal l DRBI I I ௡ SuperCard 2 CH8361 i nto DRBI I I ௡.
Wi th the DRBI I I ௡ sel ect Pep Modul e Tool s.
Sel ect l ab scope.
Sel ect Li ve Data.
Sel ect 12 vol t square wave.
Press F2 for Scope.
Press F2 and use the down arrow to set vol tage range to 20 vol ts. Press F2 agai n
when compl ete.
Connect the Bl ack l ead to the PCM ground. Connect the Red l ead to the PCI Bus
ci rcui t i n the PCM connector.
Turn the i gni ti on on.
Observe the vol tage di spl ay on the DRBI I I ௡ Lab Scope.
Does the vol tage pul se from 0 to approxi matel y 7.5 vol ts?
Al l
Yes → Repl ace and program the Powertrai n Control Modul e i n accor-
dance wi th the Servi ce I nformati on.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 1.
No → Repai r the PCI Bus ci rcui t for an open.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 1.
108
COMMUNICATION
Symptom:
*NO RESPONSE FROM PCM (SCI ONLY)
POSSIBLE CAUSES
CHECK PCM POWERS AND GROUNDS
CONTROLLER ANTI LOCK BRAKE
SCI TRANSMI T CI RCUI T SHORTED TO VOLTAGE
TRANSMI SSI ON CONTROL MODULE
SCI RECEI VE CI RCUI T SHORTED TO VOLTAGE
SCI CI RCUI TS SHORTED TOGETHER
SCI TRANSMI T CI RCUI T SHORTED TO GROUND
SCI RECEI VE CI RCUI T SHORTED TO GROUND
SCI RECEI VE CI RCUI T OPEN
SCI TRANSMI T CI RCUI T OPEN
POWERTRAI N CONTROL MODULE
TEST ACTION APPLICABILITY
1 Perform the symptom Checki ng PCM Power and Ground Ci rcui ts i n the Dri veabi l i ty
category.
NOTE: With the DRBIII௡ in the generic scan tool mode, attempt to commu-
nicate with the PCM.
NOTE: If the DRBIII௡ can communicate with the PCM in the generic scan
tool mode, it may not be necessary to performthis step.
Di d the vehi cl e pass thi s test?
Al l
Yes → Go To 2
No → Repai r as necessary.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 1.
2 Turn the i gni ti on off.
Di sconnect the PCM harness connectors.
Di sconnect the DRB from the DLC.
Measure the resi stance between ground and the SCI Transmi t ci rcui t.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 3
No → Go To 5
3 Turn the i gni ti on off.
Di sconnect the CAB harness connector (i f equi pped).
NOTE: If vehicle is not equipped with antilock brakes, answer yes to the
question.
Measure the resi stance between ground and the SCI Transmi t ci rcui t.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 4
No → Repl ace the Control l er Anti l ock Brake i n accordance wi th the
servi ce i nformati on.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 1.
109
COMMUNICATION
TEST ACTION APPLICABILITY
4 Turn the i gni ti on off.
Di sconnect the TCM harness connector (i f equi pped).
NOTE: If vehicle is not equipped with a TCM, answer yes to the question.
Measure the resi stance between ground and the SCI Transmi t ci rcui t.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Repai r the SCI Transmi t ci rcui t for a short to ground.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 1.
No → Repl ace the Transmi ssi on Control Modul e i n accordance wi th the
servi ce i nformati on.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 1.
5 Turn the i gni ti on off.
Di sconnect the DRB from the DLC.
Di sconnect the PCM harness connectors.
Di sconnect the TCM harness connector (i f equi pped).
Di sconnect the CAB harness connector (i f equi pped).
Turn the i gni ti on on.
Measure the vol tage of the SCI Transmi t ci rcui t at the DLC connector (cav 7).
I s the vol tage above 1.0 vol t?
Al l
Yes → Repai r the SCI Transmi t ci rcui t for a short to vol tage.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 1.
No → Go To 6
6 Turn the i gni ti on off.
Di sconnect the DRB from the DLC.
Di sconnect the PCM harness connectors.
Turn the i gni ti on on.
Measure the vol tage of the SCI Recei ve ci rcui t at the DLC connector (cav 6).
I s the vol tage above 1.0 vol t?
Al l
Yes → Repai r the SCI Recei ve ci rcui t for a short to vol tage.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 1.
No → Go To 7
7 Turn the i gni ti on off.
Di sconnect the DRB from the DLC.
Di sconnect the PCM harness connectors.
Measure the resi stance between the SCI Transmi t ci rcui t and the SCI Recei ve ci rcui t
at the PCM connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Repai r the short between the SCI Transmi t and the SCI Recei ve
ci rcui ts.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 1.
No → Go To 8
8 Turn the i gni ti on off.
Di sconnect the PCM harness connectors.
Di sconnect the DRB from the DLC.
Measure the resi stance between ground and the SCI Recei ve ci rcui t.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Repai r the SCI Recei ve ci rcui t for a short to ground.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 1.
No → Go To 9
110
COMMUNICATION
*NO RESPONSE FROM PCM (SCI ONLY) — Continued
TEST ACTION APPLICABILITY
9 Turn the i gni ti on off.
Di sconnect the PCM harness connectors.
Di sconnect the DRB from the DLC.
Measure the resi stance of the SCI Recei ve ci rcui t between the PCM connector and
the DLC.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 10
No → Repai r the SCI Recei ve ci rcui t for an open.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 1.
10 Turn the i gni ti on off.
Di sconnect the PCM harness connectors.
Di sconnect the DRB from the DLC.
Measure the resi stance of the SCI Transmi t ci rcui t between the PCM connector and
the DLC.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 11
No → Repai r the SCI Transmi t ci rcui t for an open.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 1.
11 I f there are no possi bl e causes remai ni ng, vi ew repai r. Al l
Repai r
Repl ace and program the Powertrai n Control Modul e i n accor-
dance wi th the Servi ce I nformati on.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 1.
111
COMMUNICATION
*NO RESPONSE FROM PCM (SCI ONLY) — Continued
Symptom:
*NO RESPONSE FROM RADIO
POSSIBLE CAUSES
NO RESPONSE FROM RADI O
OPEN FUSED I GNI TI ON SWI TCH OUTPUT CI RCUI T
OPEN FUSED B+ CI RCUI T
RADI O GROUND CI RCUI T OPEN
OPEN PCI BUS CI RCUI T
RADI O
TEST ACTION APPLICABILITY
1 Turn the i gni ti on on.
Note: As soon as one or more module communicates with the DRB, answer
the question.
Wi th the DRB, attempt to communi cate wi th the Ai rbag Control Modul e (ACM).
Wi th the DRB, attempt to communi cate wi th the I nstrument Cl uster (MI C).
Was the DRB abl e to I /D or establ i sh communi cati ons wi th ei ther of the modul es?
Al l
Yes → Go To 2
No → Refer to the Communi cati ons category and perform the symptom
PCI Bus Communi cati on Fai l ure.
Perform BODY VERI FI CATI ON TEST - VER 1.
2 Turn the i gni ti on off.
Di sconnect the Radi o harness connector.
Turn the i gni ti on on.
Usi ng a 12-vol t test l i ght connected to ground, probe the Fused I gni ti on Swi tch
Output ci rcui t.
I s the test l i ght i l l umi nated?
Al l
Yes → Go To 3
No → Check Fuse Bl ock fuse for an open. I f ok, repai r the Fused I gni ti on
Swi tch Output ci rcui t for an open or short. Refer to the wi ri ng
di agrams l ocated i n the Servi ce I nformati on.
Perform BODY VERI FI CATI ON TEST - VER 1.
3 Turn the i gni ti on off.
Di sconnect the Radi o harness connector.
Usi ng a 12-vol t test l i ght connected to ground, probe each Fused B+ ci rcui t.
I s the test l i ght i l l umi nated for each ci rcui t?
Al l
Yes → Go To 4
No → Repai r the Fused B+ ci rcui t for an open or short. Refer to the
wi ri ng di agrams l ocated i n the Servi ce I nformati on.
Perform BODY VERI FI CATI ON TEST - VER 1.
112
COMMUNICATION
TEST ACTION APPLICABILITY
4 Turn the i gni ti on off.
Di sconnect the Radi o harness connector.
Usi ng a 12-vol t test l i ght connected to 12-vol ts, probe each ground ci rcui t.
I s the test l i ght i l l umi nated for each ci rcui t?
Al l
Yes → Go To 5
No → Repai r the ground ci rcui t for an open.
Perform BODY VERI FI CATI ON TEST - VER 1.
5 Note: Ensure there is PCI Bus communication with other modules on the
vehicle before proceeding. If not, refer to the symptomlist fromthe menu
and repair as necessary.
Di sconnect the Radi o harness connector.
Use Scope i nput cabl e CH7058, Cabl e to Probe adapter CH7062, and the red and
bl ack test probes.
Connect the scope i nput cabl e to the channel one connector on the DRB. Attach the
red and bl ack l eads and the cabl e to probe adapter to the scope i nput cabl e.
Wi th the DRBI I I ௡ sel ect Pep Modul e Tool s.
Sel ect l ab scope.
Sel ect Li ve Data.
Sel ect 12 vol t square wave.
Press F2 for Scope.
Press F2 and use the down arrow to set vol tage range to 20 vol ts. Press F2 agai n
when compl ete.
Connect the Bl ack l ead to the chassi s ground. Connect the Red l ead to the PCI Bus
ci rcui t i n the Radi o connector.
Turn the i gni ti on on.
Observe the vol tage di spl ay on the DRB Lab Scope.
Does the vol tage pul se from 0 to approxi matel y 7.5 vol ts?
Al l
Yes → Go To 6
No → Repai r the PCI Bus ci rcui t for an open.
Perform BODY VERI FI CATI ON TEST - VER 1.
6 I f there are no possi bl e causes remai ni ng, vi ew repai r. Al l
Repai r
Repl ace the Radi o.
Perform BODY VERI FI CATI ON TEST - VER 1.
113
COMMUNICATION
*NO RESPONSE FROM RADIO — Continued
Symptom:
*NO RESPONSE FROM SENTRY KEY IMMOBILIZER MODULE
POSSIBLE CAUSES
ATTEMPT TO COMMUNI CATE WI TH THE I NSTRUMENT CLUSTER
GROUND CI RCUI T OPEN
FUSED I GNI TI ON SWI TCH OUTPUT CI RCUI T OPEN
FUSED B(+) CI RCUI T OPEN
OPEN PCI BUS CI RCUI T
SENTRY KEY I MMOBI LI ZER MODULE
TEST ACTION APPLICABILITY
1 Turn the i gni ti on on.
Wi th the DRB, enter Body then El ectro/Mech Cl uster.
Was the DRB abl e to I /D or communi cate wi th the I nstrument Cl uster?
Al l
Yes → Go To 2
No → Refer to the symptom l i st for probl ems rel ated to no communi ca-
ti on wi th the I nstrument Cl uster.
Perform SKI S VERI FI CATI ON.
2 Turn the i gni ti on off.
Di sconnect the SKI M harness connector.
Usi ng a 12-vol t test l i ght connected to 12-vol ts, probe the ground ci rcui t.
I s the test l i ght i l l umi nated?
Al l
Yes → Go To 3
No → Repai r the ground ci rcui t for an open.
Perform SKI S VERI FI CATI ON.
3 Turn the i gni ti on off.
Di sconnect the SKI M harness connector.
Turn the i gni ti on on.
Usi ng a 12-vol t test l i ght connected to ground, probe the Fused I gni ti on Swi tch
Output ci rcui t.
I s the test l i ght i l l umi nated?
Al l
Yes → Go To 4
No → Repai r the Fused I gni ti on Swi tch Output ci rcui t for an open.
Perform SKI S VERI FI CATI ON.
4 Turn the i gni ti on off.
Di sconnect the SKI M harness connector.
Usi ng a 12-vol t test l i ght connected to ground, probe the Fused B(+) ci rcui t.
I s the test l i ght i l l umi nated?
Al l
Yes → Go To 5
No → Check the Fuse i n the Fuse Bl ock for an open. Refer to the wi ri ng
di agrams. I f OK, repai r the Fused B+ ci rcui t for an open.
Perform SKI S VERI FI CATI ON.
114
COMMUNICATION
TEST ACTION APPLICABILITY
5 Note: Ensure there is PCI Bus communication with other modules on the
vehicle before proceeding. If not, refer to the symptomlist fromthe menu
and repair as necessary.
Di sconnect the SKI M harness connector.
Use Scope i nput cabl e CH7058, Cabl e to Probe adapter CH7062, and the red and
bl ack test probes.
Connect the scope i nput cabl e to the channel one connector on the DRB. Attach the
red and bl ack l eads and the cabl e to probe adapter to the scope i nput cabl e.
Wi th the DRBI I I ௡ sel ect Pep Modul e Tool s.
Sel ect l ab scope.
Sel ect Li ve Data.
Sel ect 12 vol t square wave.
Press F2 for Scope.
Press F2 and use the down arrow to set vol tage range to 20 vol ts. Press F2 agai n
when compl ete.
Connect the Bl ack l ead to the chassi s ground. Connect the Red l ead to the PCI Bus
ci rcui t i n the SKI M connector.
Turn the i gni ti on on.
Observe the vol tage di spl ay on the DRB Lab Scope.
Does the vol tage pul se from 0 to approxi matel y 7.5 vol ts?
Al l
Yes → Go To 6
No → Repai r the PCI Bus ci rcui t for an open.
Perform SKI S VERI FI CATI ON.
6 I f there are no possi bl e causes remai ni ng, vi ew repai r. Al l
Repai r
Repl ace and program the Sentry Key I mmobi l i zer Modul e i n
accordance wi th the Servi ce I nformati on.
Perform SKI S VERI FI CATI ON.
115
COMMUNICATION
*NO RESPONSE FROM SENTRY KEY IMMOBILIZER MODULE —
Continued
Symptom:
*NO RESPONSE FROM TRANSMISSION CONTROL MODULE
POSSIBLE CAUSES
NO RESPONSE FROM TRANSMI SSI ON CONTROL MODULE
FUSED I GNI TI ON SWI TCH OUTPUT (RUN/ST) CI RCUI T OPEN
FUSED I GNI TI ON SWI TCH OUTPUT (START) CI RCUI T OPEN
FUSED I GNI TI ON SWI TCH OUTPUT (START) CI RCUI T SHORT
FUSED B(+) CI RCUI T OPEN
GROUND CI RCUI T(S) OPEN
OPEN PCI BUS CI RCUI T
TRANSMI SSI ON CONTROL MODULE
TEST ACTION APPLICABILITY
1 I gni ti on on, engi ne not runni ng.
Note: As soon as one or more module communicates with the DRB, answer
the question.
Wi th the DRB, attempt to communi cate wi th the Ai rbag Control Modul e (ACM).
Wi th the DRB, attempt to communi cate wi th the I nstrument Cl uster.
Was the DRB abl e to I /D or establ i sh communi cati ons wi th ei ther of the modul es?
Al l
Yes → Go To 2
No → Refer to the Body Communi cati on category and perform the
symptom PCI Bus Communi cati on Fai l ure.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
2 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the TCM harness connector.
I gni ti on on, engi ne not runni ng.
Usi ng a 12-vol t test l i ght connected to ground, check the Fused I gni ti on Swi tch
Output (Run/St) ci rcui t.
NOTE: The test light must illuminate brightly. Compare the brightness to
that of a direct connection to the battery.
Does the test l i ght i l l umi nate bri ghtl y?
Al l
Yes → Go To 3
No → Repai r the Fused I gni ti on Swi tch Output (Run/St) ci rcui t for an
open. Refer to the wi ri ng di agrams l ocati on i n the Servi ce I nfor-
mati on.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
116
COMMUNICATION
TEST ACTION APPLICABILITY
3 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the TCM harness connector.
Remove the starter rel ay from the PDC.
Usi ng a 12-vol t test l i ght connected to ground, check the Fused I gni ti on Swi tch
Output (Start) ci rcui t.
NOTE: The test light must illuminate brightly. Compare the brightness to
that of a direct connection to the battery.
Observe the test l i ght whi l e momentari l y turni ng the i gni ti on swi tch to the Start
posi ti on.
Does the test l i ght i l l umi nate bri ghtl y?
Al l
Yes → Go To 4
No → Repai r the Fused I gni ti on Swi tch Output (Start) ci rcui t for an
open. Refer to the wi ri ng di agrams l ocated i n the Servi ce I nfor-
mati on.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
4 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the TCM harness connector.
Wi th a vol tmeter i n the mi l l i vol t scal e, measure the vol tage of the Fused I gni ti on
Swi tch Output (Start) ci rcui t.
NOTE:Anoresponsecondition can exist if voltageispresent on thiscircuit
with the ignition switch in any position except for the Start position.
NOTE: Voltage up to .080 millivolts can cause this condition.
NOTE: Check for after market components that could causethis condition.
Perform thi s step wi th the I gni ti on Swi tch i n every posi ti on except for the Start
posi ti on.
I s any vol tage present?
Al l
Yes → Repai r the Fused I gni ti on Swi tch Output (Start) ci rcui t for a
short to vol tage. Refer to the wi ri ng di agrams l ocated i n the
Servi ce I nformati on.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 5
Note: Reinstall the original Starter Relay.
5 Turn the i gni ti on off.
Di sconnect the TCM harness connector.
Usi ng a 12-vol t test l i ght connected to ground, check the Fused B(+) ci rcui t.
NOTE: The test light must illuminate brightly. Compare the brightness to
that of a direct connection to the battery.
Does the test l i ght i l l umi nate bri ghtl y?
Al l
Yes → Go To 6
No → Repai r the Fused B(+) ci rcui t for an open. Refer to the wi ri ng
di agrams l ocated i n the Servi ce I nformati on.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
117
COMMUNICATION
*NORESPONSE FROMTRANSMISSION CONTROL MODULE —Continued
TEST ACTION APPLICABILITY
6 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the TCM harness connector.
Usi ng a 12-vol t test l i ght connected to 12-vol ts, check each ground ci rcui t i n the TCM
harness connector.
NOTE: The test light must illuminate brightly. Compare the brightness to
that of a direct connection to the battery.
Does the test l i ght i l l umi nate bri ghtl y at al l the ground ci rcui ts?
Al l
Yes → Go To 7
No → Repai r the Ground ci rcui t(s) for an open. Check the mai n ground
connecti on to engi ne bl ock and/or chassi s. Refer to the wi ri ng
di agrams l ocated i n the Servi ce I nformati on.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
7 Note: Ensure there is PCI Bus communication with other modules on the
vehicle before proceeding. If not, refer to the symptomlist fromthe menu
and repair as necessary.
Di sconnect the TCM harness connector.
Use Scope i nput cabl e CH7058, Cabl e to Probe adapter CH7062, and the red and
bl ack test probes.
Connect the scope i nput cabl e to the channel one connector on the DRB. Attach the
red and bl ack l eads and the cabl e to probe adapter to the scope i nput cabl e.
Wi th the DRBI I I ௡ sel ect Pep Modul e Tool s.
Sel ect l ab scope.
Sel ect Li ve Data.
Sel ect 12 vol t square wave.
Press F2 for Scope.
Press F2 and use the down arrow to set vol tage range to 20 vol ts. Press F2 agai n
when compl ete.
Connect the Bl ack l ead to the chassi s ground. Connect the Red l ead to the PCI Bus
ci rcui t i n the TCM connector.
Turn the i gni ti on on.
Observe the vol tage di spl ay on the DRB Lab Scope.
Does the vol tage pul se from 0 to approxi matel y 7.5 vol ts?
Al l
Yes → Go To 8
No → Repai r the PCI Bus ci rcui t for an open.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
8 Usi ng the schemati cs as a gui de, i nspect the wi ri ng and connectors. Repai r as
necessary. Pay parti cul ar attenti on to al l power and ground ci rcui ts.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace the Transmi ssi on Control Modul e i n accordance wi th the
servi ce i nformati on. WI TH THE DRBI I I ௡ PERFORM QUI CK
LEARN.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
118
COMMUNICATION
*NORESPONSE FROMTRANSMISSION CONTROL MODULE —Continued
Symptom:
*PCI BUS COMMUNICATION FAILURE
POSSIBLE CAUSES
WI RI NG HARNESS I NTERMI TTENT
OPEN PCI BUS CI RCUI T AT THE DATA LI NK CONNECTOR (DLC)
PCI BUS CI RCUI T SHORTED TO VOLTAGE
MODULE SHORT TO VOLTAGE
PCI BUS CI RCUI T SHORTED TO GROUND
MODULE SHORT TO GROUND
TEST ACTION APPLICABILITY
1 Note: Determinewhich modules this vehicleis equipped with beforebegin-
ning.
Note: When attempting to communicate with any of the modules on this
vehicle, the DRB will display 1 of 2 different communication errors: a NO
RESPONSE message or a BUS +/- SIGNALS OPEN message.
Turn the i gni ti on on.
Usi ng the DRB, attempt to communi cate wi th the fol l owi ng control modul es:
Ai rbag Control Modul e
SKI M (SENTRY KEY I MMOBI LI ZER)
MI C (I NSTRUMENT CLUSTER)
Was the DRBI I I ௡ abl e to communi cate wi th one or more Modul e(s)?
Al l
Yes → Go To 2
No → Go To 3
2 Turn the i gni ti on off.
Note: Visually inspect the related wiring harness. Look for any chafed,
pierced, pinched, or partially broken wires.
Note:Visuallyinspect therelatedwireharnessconnectors. Look for broken,
bent, pushed out, or corroded terminals.
Note: If the DRB can not communicate with a single module, refer to the
category list for the related symptom.
Were any probl ems found?
Al l
Yes → Repai r wi ri ng harness/connectors as necessary.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Test Compl ete.
3 Turn the i gni ti on off.
Di sconnect the PCM harness connector.
Di sconnect the DRB from the Data Li nk Connector (DLC).
Di sconnect the negati ve battery cabl e.
Measure the resi stance of the PCI Bus ci rcui t between the Data Li nk Connector
(DLC) and the PCM connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 4
No → Repai r the PCI Bus ci rcui t for an open.
Perform BODY VERI FI CATI ON TEST - VER 1.
119
COMMUNICATION
TEST ACTION APPLICABILITY
4 NOTE: Reconnect the PCM harness connector and the negative battery
cable.
Turn the i gni ti on on.
Measure the vol tage of the PCI Bus ci rcui t at the Data Li nk Connector (DLC).
I s the vol tage above 7.0 vol ts?
Al l
Yes → Go To 5
No → Go To 6
5 Turn the i gni ti on off.
Usi ng a vol tmeter, connect one end to the PCI Bus ci rcui t at the DLC, and the other
end to ground.
Note: When performingthenext stepturn theignition off (wait oneminute)
before disconnecting any module. When the module is disconnected turn
the ignition on to check for a short to voltage.
Turn the i gni ti on on.
Whi l e moni tori ng the vol tmeter, di sconnect each modul e the vehi cl e i s equi pped wi th
one at a ti me.
I s the vol tage steadi l y above 7.0 vol ts wi th al l the modul es di sconnected?
Al l
Yes → Repai r the PCI Bus ci rcui t for a short to vol tage.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Repl ace the modul e that when di sconnected the short to vol tage
was el i mi nated.
Perform BODY VERI FI CATI ON TEST - VER 1.
6 Turn the i gni ti on off.
Di sconnect the negati ve battery cabl e.
Usi ng a ohmmeter, connect one end to the PCI Bus ci rcui t at the DLC, and the other
end to ground.
Whi l e moni tori ng the ohmmeter, di sconnect each modul e the vehi cl e i s equi pped wi th
one at a ti me.
NOTE: Total bus resistance to ground thru all of the modules is typically
between 350to1000ohms. Themoremoduleson thebus, thelower thetotal
bus resistance will be.
I s the resi stance bel ow 150.0 ohms wi th al l the modul es di sconnected?
Al l
Yes → Repai r the PCI Bus ci rcui t for a short to ground.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Repl ace the modul e that when di sconnected the short to ground
was el i mi nated.
Perform BODY VERI FI CATI ON TEST - VER 1.
120
COMMUNICATION
*PCI BUS COMMUNICATION FAILURE — Continued
Symptom:
*COMPASS/TEMP MODULE WILL NOT CALIBRATE
POSSIBLE CAUSES
CALI BRATI ON PROCEDURE
COMPASS/TEMPERATURE MI RROR
TEST ACTION APPLICABILITY
1 Turn the i gni ti on off.
Perform the Compass/Temperature modul e sel f-check.
Press and hol d the Compass/Temperature Mi rror Center swi tch.
Turn the i gni ti on on and then rel ease the Center swi tch.
NOTE: The Compass/Temp module will illuminate all of the VF segments
and then display an ؆F؆ or ؆P؆.
Exi t the sel f-check by pressi ng the Center swi tch or cycl i ng the i gni ti on.
Di d the Comp/Temp modul e di spl ay an ЉFЉ duri ng the sel f-check?
Al l
Yes → Repl ace the Compass/Temperature Mi rror i n accordance wi th the
Servi ce I nformati on. NOTE: After repl acement, set the correct
compass vari ati on and cal i brate. The vehi cl e must be dri ven for
more than 2 mi nutes to update the temperature di spl ay.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Ensure that al l cal i brati on i nstructi ons have been performed
properl y. I f cal i brati on i s unsuccessful , repl ace the Comp/Temp
Mi rror i n accordance wi th the Servi ce I nformati on. NOTE: After
repl acement, set the correct compass vari ati on and cal i brate.
Perform BODY VERI FI CATI ON TEST - VER 1.
121
COMPASS/MINI-TRIP COMPUTER
Symptom:
*COMPASS/TEMPERATURE MODULE INOPERATIVE
POSSIBLE CAUSES
FUSED B(+) CI RCUI T OPEN
FUSED I GNI TI ON SWI TCH OUTPUT CI RCUI T OPEN
GROUND CI RCUI T OPEN
COMPASS/TEMPERATURE MI RROR
TEST ACTION APPLICABILITY
1 Turn the i gni ti on off.
Di sconnect the Compass/Temperature Mi rror harness connector.
Measure the vol tage between the Fused B(+) ci rcui t and ground.
I s the vol tage bel ow 10.5 vol ts?
Al l
Yes → Repai r the Fused B(+) ci rcui t for an open. I f the fuse i s open make
sure to check for a short to ground.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Go To 2
2 Turn the i gni ti on off.
Di sconnect the Compass/Temperature Mi rror harness connector.
Turn the i gni ti on on.
Measure the vol tage between the Fused I gni ti on Swi tch Output ci rcui t and ground.
I s the vol tage bel ow 10.5 vol ts?
Al l
Yes → Repai r the Fused I gni ti on Swi tch Output ci rcui t for an open. I f
the fuse i s open make sure to check for a short to ground.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Go To 3
3 Turn the i gni ti on off.
Di sconnect the Compass/Temperature Mi rror harness connector.
Measure the resi stance between ground and the Ground ci rcui t.
I s the resi stance above 5.0 ohms?
Al l
Yes → Repai r the Ground ci rcui t for an open.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Repl ace the Compass/Temperature Mi rror i n accordance wi th the
Servi ce I nformati on. NOTE: After repl acement, the vehi cl e must
be dri ven for more than 2 mi nutes to update the di spl ay.
Perform BODY VERI FI CATI ON TEST - VER 1.
122
COMPASS/MINI-TRIP COMPUTER
Symptom:
*TEMPERATURE DISPLAY INACCURATE OR INOPERATIVE
POSSIBLE CAUSES
AMBI ENT TEMPERATURE SENSOR
AMBI ENT TEMPERATURE SENSOR SI GNAL CI RCUI T OPEN
AMBI ENT TEMPERATURE SENSOR SI GNAL CI RCUI T SHORT TO GROUND
AMBI ENT TEMPERATURE SENSOR GROUND CI RCUI T OPEN
COMPASS/TEMPERATURE MI RROR
TEST ACTION APPLICABILITY
1 Turn the i gni ti on off.
Di sconnect the Ambi ent Temperature Sensor harness connector.
Measure the resi stance of the Ambi ent Temperature Sensor between pi n 1 and pi n 2.
The Ambi ent Temperature Sensor shoul d measure wi thi n the fol l owi ng val ues:
10°C (50°F) Sensor Resi stance = 17.99k - 21.81k Ohms
20°C (68°F) Sensor Resi stance = 11.37k - 13.61k Ohms
25°C (77°F) Sensor Resi stance = 9.12k - 10.88k Ohms
30°C (86°F) Sensor Resi stance = 7.37k - 8.75k Ohms
40°C (104°F) Sensor Resi stance = 4.90k - 5.75k Ohms
50°C (122°F) Sensor Resi stance = 3.33k - 3.88k Ohms
Does the Ambi ent Temperature Sensor resi stance measure between the mi n/max
speci fi cati ons?
Al l
Yes → Go To 2
No → Repl ace the Ambi ent Temperature Sensor i n accordance wi th the
Servi ce I nformati on. NOTE: After any repai r for an Ambi ent
Temperature Sensor probl em, the vehi cl e must be dri ven for more
than 2 mi nutes to update the di spl ay.
Perform BODY VERI FI CATI ON TEST - VER 1.
2 Turn the i gni ti on off.
Di sconnect the Ambi ent Temperature Sensor harness connector.
Di sconnect the Compass/Temperature Mi rror harness connector.
Measure the resi stance of the Si gnal ci rcui t between the Ambi ent Temperature
Sensor connector and the Compass/Temperature Mi rror connector.
I s the resi stance above 5.0 ohms?
Al l
Yes → Repai r the Ambi ent Temperature Sensor Si gnal ci rcui t for an
open. NOTE: After any repai r for an Ambi ent Temperature Sensor
probl em, thee vehi cl e must be dri ven for more than 2 mi nutes to
update the di spl ay.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Go To 3
123
COMPASS/MINI-TRIP COMPUTER
TEST ACTION APPLICABILITY
3 Turn the i gni ti on off.
Di sconnect the Ambi ent Temperature Sensor harness connector.
Di sconnect the Compass/Temperature Mi rror harness connector.
Measure the resi stance between ground and the Ambi ent Temperature Sensor Si gnal
ci rcui t.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Repai r the Ambi ent Temperature Sensor Si gnal ci rcui t for a short
to ground. NOTE: After any repai r for an Ambi ent Temperature
Sensor probl em, the vehi cl e must be dri ven for more than 2
mi nutes to update the di spl ay.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Go To 4
4 Turn the i gni ti on off.
Di sconnect the Ambi ent Temperature Sensor harness connector.
Di sconnect the Compass/Temperature Mi rror harness connector.
Measure the resi stance of the Sensor Ground ci rcui t between the Ambi ent Temper-
ature Sensor connector and the Compass/Temperature Mi rror connector.
I s the resi stance above 5.0 ohms?
Al l
Yes → Repai r the Ambi ent Temperature Sensor Ground ci rcui t for an
open. NOTE: After any repai r for an Ambi ent Temperature Sensor
probl em, the vehi cl e must be dri ven for more than 2 mi nutes to
update the di spl ay.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Repl ace the Compass/Temperature Mi rror i n accordance wi th the
Servi ce I nformati on. NOTE: After any repai r for an Ambi ent
Temperature Sensor probl em, the vehi cl e must be dri ven for more
than 2 mi nutes to update the di spl ay.
Perform BODY VERI FI CATI ON TEST - VER 1.
124
COMPASS/MINI-TRIP COMPUTER
*TEMPERATURE DISPLAY INACCURATE OR INOPERATIVE — Continued
Symptom:
*REAR WINDOWDEFOGGER INOPERATIVE
POSSIBLE CAUSES
REAR WI NDOW DEFOGGER GROUND CKT
REAR WI NDOW DEFOGGER GRI D OPEN
REAR WI NDOW DEFOGGER RELAY OUTPUT OPEN
FUSED I GNI TI ON SWI TCH OUTPUT (RUN) OPEN
FUSED B(+) CKT OPEN
RELAY COI L
RELAY CONTACTS
REAR WI NDOW DEFOGGER RELAY CONTROL CI RCUI T OPEN
REAR WI NDOW DEFOGGER SWI TCH SENSE CKT OPEN
REAR WI NDOW DEFOGGER SWI TCH SENSE CKT SHORTED TO GROUND
REAR WI NDOW DEFOGGER SWI TCH SENSE CKT SHORTED TO VOLTAGE
REAR WI NDOW DEFOGGER SWI TCH
I NSTRUMENT CLUSTER
TEST ACTION APPLICABILITY
1 Toggl e the Rear Defogger swi tch and l i sten to the Rear Wi ndow Defogger Rel ay i n the
PDC.
Does the rel ay cl i ck when the swi tch i s pressed?
Al l
Yes → Go To 2
No → Go To 6
2 Turn the i gni ti on off.
Open the tai l gate.
Measure resi stance between ground and the Rear Wi ndow Defogger Ground ci rcui t.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 3
No → Repai r the Rear Wi ndow Defogger Ground Ci rcui t for an open
condi ti on.
Perform BODY VERI FI CATI ON TEST - VER 1.
3 Turn the i gni ti on on.
Turn the Rear Wi ndow Defogger on.
Usi ng a 12-vol t test l i ght connected to ground, check the Rear Wi ndow Defogger
Rel ay Output ci rcui t at the defogger gri d.
Does the test l i ght i l l umi nate bri ghtl y?
Al l
Yes → Repai r the open i n the Rear Wi ndow Defogger Gri d.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Go To 4
125
ELECTRICALLY HEATED SYSTEMS
TEST ACTION APPLICABILITY
4 Remove the Rear Wi ndow Defogger Rel ay.
Turn the i gni ti on on.
Measure vol tage of the Fused B+ Ci rcui t i n the Rear Wi ndow Defogger Rel ay
connector.
I s the vol tage above 10.0 vol ts?
Al l
Yes → Go To 5
No → Repai r the open Fused B+ Ci rcui t from PDC fuse #2.
Perform BODY VERI FI CATI ON TEST - VER 1.
5 Remove the Rear Wi ndow Defogger Rel ay.
I nstal l a known good rel ay i n the Rear Wi ndow Defogger Rel ay connector.
Turn the i gni ti on on.
Check the Rear Wi ndow Defogger for proper operati on.
Does the system operate normal l y?
Al l
Yes → Repl ace the ori gi nal Rear Wi ndow Defogger Rel ay.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Repai r the Rear Wi ndow Defogger Rel ay Output Ci rcui t for an
open condi ti on.
Perform BODY VERI FI CATI ON TEST - VER 1.
6 Remove the Rear Wi ndow Defogger Rel ay from the PDC.
Turn the i gni ti on swi tch On.
Usi ng a 12-vol t test l i ght connected to ground, check the Fused I gni ti on Swi tch
Output ci rcui t at the rel ay.
Does the test l i ght i l l umi nate bri ghtl y?
Al l
Yes → Go To 7
No → Repai r the open Fused I gni ti on Swi tch Output ci rcui t from PDC
fuse #7
Perform BODY VERI FI CATI ON TEST - VER 1.
7 I nstal l a known good rel ay i n the Rear Wi ndow Defogger Rel ay.
Turn the i gni ti on on.
Check the Rear Wi ndow Defogger for proper operati on.
Does the system operate normal l y?
Al l
Yes → Repl ace the ori gi nal Rear Wi ndow Defogger Rel ay.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Go To 8
8 Turn the i gni ti on off.
Remove the Rear Wi ndow Defogger Rel ay from the PDC.
Di sconnect the I nstrument Cl uster C2 connector.
Measure the resi stance of the Rear Wi ndow Defogger Rel ay Control ci rcui t between
the I nstrument Cl uster C2 connector and the PDC.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 9
No → Repai r the Rear Wi ndow Defogger Rel ay Control Ci rcui t for an
open.
Perform BODY VERI FI CATI ON TEST - VER 1.
126
ELECTRICALLY HEATED SYSTEMS
*REAR WINDOWDEFOGGER INOPERATIVE — Continued
TEST ACTION APPLICABILITY
9 Turn the i gni ti on off.
Di sconnect the I nstrument Cl uster C2 connector.
Di sconnect the Rear Wi ndow Defogger Swi tch connector.
Turn the i gni ti on on.
Measure vol tage between the Rear Wi ndow Defogger Swi tch Sense Ci rcui t and
ground.
I s any vol tage present?
Al l
Yes → Repai r the Rear Wi ndow Swi tch Sense Ci rcui t for a short to
vol tage condi ti on.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Go To 10
10 Turn the i gni ti on off.
Di sconnect the I nstrument Cl uster C2 connector.
Di sconnect the Rear Wi ndow Defogger Swi tch connector.
Measure resi stance between ground and the Rear Wi ndow Defogger Swi tch Sense
Ci rcui t.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Repai r the Rear Wi ndow Defogger Swi tch Sense Ci rcui t for a
short to ground condi ti on.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Go To 11
11 Turn the i gni ti on off.
Di sconnect the I nstrument Cl uster C2 connector.
Di sconnect the Rear Wi ndow Defogger Swi tch.
Measure resi stance of the Rear Wi ndow Defogger Swi tch Sense ci rcui t from the
I nstrument Cl uster C2 connector to the Defogger swi tch connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 12
No → Repai r the Rear Wi ndow Defogger Swi tch Sense Ci rcui t for an
open condi ti on.
Perform BODY VERI FI CATI ON TEST - VER 1.
12 Turn the i gni ti on off.
Rei nstal l the Rear Wi ndow Defogger Rel ay.
Reconnect the I nstrument Cl uster C2 connector.
Di sconnect the Rear Wi ndow Defogger Swi tch connector.
Turn the i gni ti on on.
Connect a jumper wi re between the Rear Wi ndow Defogger Swi tch Sense ci rcui t i n
the Defogger Swi tch connector to ground and l i sten for the rel ay to cl i ck.
Does the Defogger Rel ay cl i ck?
Al l
Yes → Repl ace the Rear Wi ndow Defogger Swi tch.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Repl ace the I nstrument Cl uster.
Perform BODY VERI FI CATI ON TEST - VER 1.
127
ELECTRICALLY HEATED SYSTEMS
*REAR WINDOWDEFOGGER INOPERATIVE — Continued
Symptom:
*REAR WINDOW DEFOGGER SWITCH INDICATOR LAMP INOP-
ERATIVE
POSSIBLE CAUSES
FUSED REAR WI NDOW DEFOGGER RELAY OUTPUT CKT SHORTED TO GROUND
FUSE BLOCK FUSE #17
FUSED REAR WI NDOW DEFOGGER RELAY OUTPUT CKT OPEN
DEFOGGER SWI TCH
TEST ACTION APPLICABILITY
1 I nspect Fuse Bl ock fuse #17.
I s Fuse Bl ock fuse #17 open?
Al l
Yes → Go To 2
No → Go To 3
2 Turn the i gni ti on off.
Di sconnect the Rear Defogger Swi tch.
Measure resi stance of the Fused Rear Wi ndow Defogger Rel ay Output ci rcui t to
ground.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Repai r the Fused Rear Wi ndow Defogger Rel ay Output ci rcui t for
a short to ground condi ti on.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Repl ace Fuse Bl ock fuse #17.
Perform BODY VERI FI CATI ON TEST - VER 1.
3 Turn the i gni ti on off.
Di sconnect the Rear Defogger Swi tch.
Remove the Rear Wi ndow Defogger Rel ay.
Ensure that Fuse Bl ock fuse #17 i s i nstal l ed.
Measure resi stance of the Fused Rear Wi ndow Defogger Rel ay Output ci rcui t from
the rel ay output termi nal to the Defogger Swi tch connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Repl ace the Rear Wi ndow Defogger Swi tch.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Repai r the Fused Rear Wi ndow Defogger Rel ay Output ci rcui t for
an open condi ti on.
Perform BODY VERI FI CATI ON TEST - VER 1.
128
ELECTRICALLY HEATED SYSTEMS
Symptom:
ACM MESSAGE NOT REC’D BY MIC
When Monitored and Set Condition:
ACM MESSAGE NOT REC’D BY MIC
When Moni tored: Wi th the i gni ti on i n the Run/Start posi ti on, I nstrument Cl uster i n
power-up state.
Set Condi ti on: The I nstrument Cl uster detects l oss of communi cati on wi th the Ai r Bag
Control Modul e (ACM).
POSSIBLE CAUSES
ACM MESSAGE NOT RECEI VED
TEST ACTION APPLICABILITY
1 Turn the i gni ti on on.
NOTE: Ensure the Instrument Cluster communicates on the PCI Bus.
Wi th the DRBI I I ௡, sel ect Body, El ectro/Mech Cl uster, then read DTCs.
Does the DRBI I I ௡ di spl ay ACM Message Not Rec’d by MI C?
Al l
Yes → Refer to the COMMUNI CATI ON category and perform the ap-
propri ate symptom.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Test Compl ete.
129
INSTRUMENT CLUSTER
Symptom:
AIR BAG LAMP CIRCUIT OPEN
When Monitored and Set Condition:
AIR BAG LAMP CIRCUIT OPEN
When Moni tored: Wi th the i gni ti on i n the Run/Start posi ti on, I nstrument Cl uster i n
power-up state.
Set Condi ti on: The I nstrument Cl uster performs an i ndi cator check when the i ndi cator i s
commanded on or off by the ACM. I f an open l amp fai l ure i s detected, the Cl uster sends thi s
meesage to the ACM.
POSSIBLE CAUSES
I NSTRUMENT CLUSTER
TEST ACTION APPLICABILITY
1 Turn the i gni ti on on.
NOTE: Ensure the Instrument Cluster and the Air Bag Control Module
communicate on the PCI Bus.
NOTE: TheAirbag indicator can only be turned on or off by theACM. The
Instrument Cluster reports theindicator status totheACMon thePCI Bus.
Wi th the DRBI I I ௡, read DTCs.
Does the DRBI I I ௡ di spl ay Ai r Bag Lamp Ci rcui t Open?
Al l
Yes → Repl ace and confi gure the I nstrument Cl uster i n accordance wi th
the Servi ce I nformati on.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Test Compl ete.
130
INSTRUMENT CLUSTER
Symptom:
AIR BAG LAMP CIRCUIT SHORT
When Monitored and Set Condition:
AIR BAG LAMP CIRCUIT SHORT
When Moni tored: Wi th the i gni ti on i n the Run/Start posi ti on, the I nstrument Cl uster i n
power-up state.
Set Condi ti on: The I nstrument Cl uster performs an i ndi cator check when the i ndi cator i s
commanded on by the ACM. I f a shorted l amp fai l ure i s detected, the Cl uster sends thi s
message to the ACM.
POSSIBLE CAUSES
I NSTRUMENT CLUSTER
TEST ACTION APPLICABILITY
1 Turn the i gni ti on on.
NOTE: Ensure the Instrument Cluster and the Air Bag Control Module
communicate on the PCI Bus.
NOTE: TheAirbag indicator can only be turned on or off by theACM. The
Instrument Cluster reportsthestatusof theindicator totheACMonthePCI
Bus.
Wi th the DRBI I I ௡, read DTCs.
Does the DRBI I I ௡ di spl ay Ai r Bag Lamp Ci rcui t Shorted?
Al l
Yes → Repl ace and confi gure the I nstrument Cl uster i n accordance wi th
the Servi ce I nformati on.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Test Compl ete.
131
INSTRUMENT CLUSTER
Symptom:
CHECKSUM FAILURE
When Monitored and Set Condition:
CHECKSUM FAILURE
When Moni tored: I nstrument Cl uster detects battery connecti on.
Set Condi ti on: I nstrument Cl uster fai l s EEPROM checksum test. (The I nstrument
Cl uster performs an EEPROM checksum as a conti nuous sel f test to veri fy functi onal i ty.)
POSSIBLE CAUSES
I NSTRUMENT CLUSTER
TEST ACTION APPLICABILITY
1 Turn the i gni ti on on.
Wi th the DRBI I I ௡, sel ect Body, then El ectro/Mech Cl uster, read DTCs.
Does the DRBI I I ௡ di spl ay Checksum Fai l ure?
Al l
Yes → Repl ace and confi gure the I nstrument Cl uster i n accordance wi th
the Servi ce I nformati on.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Test Compl ete.
132
INSTRUMENT CLUSTER
Symptom:
PANEL DIMMER OPEN
When Monitored and Set Condition:
PANEL DIMMER OPEN
When Moni tored: The I nstrument Cl uster detects battery vol tage i nput on the Headl amp
Swi tch Output ci rcui t.
Set Condi ti on: The I nstrument Cl uster detects the Panel Lamp Di mmer Si gnal ci rcui t
resi stance i s greater than 9250 ohms for fi ve seconds. Duri ng an open ci rcui t condi ti on, the
VF di spl ay and general panel i l l umi nati on wi l l defaul t to ful l i ntensi ty.
POSSIBLE CAUSES
I NTERMI TTENT CONDI TI ON
PANEL LAMP DI MMER SI GNAL CI RCUI T OPEN
MULTI -FUNCTI ON SWI TCH
MULTI -FUNCTI ON SWI TCH GROUND CI RCUI T OPEN
I NSTRUMENT CLUSTER
TEST ACTION APPLICABILITY
1 Turn the i gni ti on on.
Wi th the DRBI I I ௡, erase DTCs.
Cycl e the i gni ti on.
Wi th the DRBI I I ௡, read DTCs.
Does the DRBI I I ௡ di spl ay Panel Di mmer Open?
Al l
Yes → Go To 2
No → The condi ton i s not present at thi s ti me. Moni tor DRBI I I ௡
parameters whi l e wi ggl i ng the rel ated wi re harness. Refer to any
Techni cal Servi ce Bul l eti ns (TSB) that may appl y. Vi sual l y i n-
spect the rel ated wi ri ng harness and connector termi nal s.
Perform BODY VERI FI CATI ON TEST - VER 1.
2 Turn the i gni ti on off.
Di sconnect the I nstrument Cl uster C2 harness connector.
Di sconnect the Mul ti -Functi on Swi tch harness connector.
Check connectors - Cl ean/repai r as necessary.
Measure the resi stance of the Panel Lamp Di mmer Si gnal ci rcui t.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 3
No → Repai r the Panel Lamp Di mmer Si gnal ci rcui t for an open.
Perform BODY VERI FI CATI ON TEST - VER 1.
133
INSTRUMENT CLUSTER
TEST ACTION APPLICABILITY
3 Turn the i gni ti on off.
Di sconnect the Mul ti -Functi on Swi tch harness connector.
Check connectors - Cl ean/repai r as necessary.
Measure the resi stance of the Mul ti -Functi on Swi tch between termi nal pi n 7 and
termi nal pi n 8.
Does the resi stance measure above 9250 ohms?
Al l
Yes → Repl ace the Mul ti -Functi on Swi tch i n accordance wi th the Servi ce
I nformati on.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Go To 4
4 Turn the i gni ti on off.
Di sconnect the Mul ti -Functi on Swi tch harness connector.
Check connectors - Cl ean/repai r as necessary.
Measure the resi stance between ground and the Mul ti -Functi on Swi tch Ground
ci rcui t.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Repl ace and confi gure the I nstrument Cl uster i n accordance wi th
the Servi ce I nformati on.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Repai r the Mul ti -Functi on Swi tch Ground ci rcui t for an open.
Perform BODY VERI FI CATI ON TEST - VER 1.
134
INSTRUMENT CLUSTER
PANEL DIMMER OPEN — Continued
Symptom:
PCM MESSAGE NOT REC’D BY MIC
When Monitored and Set Condition:
PCM MESSAGE NOT REC’D BY MIC
When Moni tored: Wi th the i gni ti on i n the Run/Start posi ti on, I nstrument Cl uster i n
power-up state.
Set Condi ti on: The I nstrument Cl uster detects l oss of communi cati on wi th Powertrai n
Control Modul e (PCM). .
POSSIBLE CAUSES
PCM MESSAGE NOT REC’D BY MI C
TEST ACTION APPLICABILITY
1 Turn the i gni ti on on.
NOTE: Ensure the Instrument Cluster communicates on the PCI Bus.
Wi th the DRBI I I ௡, sel ect Body, El ectro/Mech Cl uster, then read DTCs.
Does the DRBI I I ௡ di spl ay NO RESPONSE FROM PCM (PCI )?
Al l
Yes → Refer to the COMMUNI CATI ON category and perform the ap-
propri ate symptom.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Test Compl ete.
135
INSTRUMENT CLUSTER
Symptom:
SKIM MESSAGE NOT REC’D BY MIC
When Monitored and Set Condition:
SKIM MESSAGE NOT REC’D BY MIC
When Moni tored: Wi th the i gni ti on i n the Run/Start posi ti on, I nstrument Cl uster i n
power-up state.
Set Condi ti on: The I nstrument Cl uster detects l oss of communi cati on wi th the Sentry
Key I mmobi l i zer Modul e (SKI M). .
POSSIBLE CAUSES
SKI M MESSAGE NOT RECEI VED
TEST ACTION APPLICABILITY
1 Turn the i gni ti on on.
NOTE: Ensure the Instrument Cluster communicates on the PCI Bus.
Wi th the DRBI I I ௡, sel ect Body, El ectro/Mech Cl uster, then read DTCs.
Does the DRBI I I ௡ di spl ay SKI M Message Not Rec’d by MI C?
Al l
Yes → Refer to the COMMUNI CATI ON category and perform the ap-
propri ate symptom.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Test Compl ete.
136
INSTRUMENT CLUSTER
Symptom:
*؆NO BUS؆ IN VF DISPLAY
POSSIBLE CAUSES
PCI BUS MESSAGES NOT REC’D BY MI C
I NSTRUMENT CLUSTER
TEST ACTION APPLICABILITY
1 Turn the i gni ti on on.
Wi th the DRBI I I ௡, sel ect J1850 Modul e Scan.
Does the DRBI I I ௡ di spl ay MI C i n the J1850 Modul e Scan?
Al l
Yes → Repl ace the I nstrument Cl uster i n accordance wi th the Servi ce
I nformati on.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Refer to the COMMUNI CATI ON category and perform the appro-
pri ate symptom.
Perform BODY VERI FI CATI ON TEST - VER 1.
137
INSTRUMENT CLUSTER
Symptom:
*؆NO FUSE؆ IN VF DISPLAY
POSSIBLE CAUSES
FUSED B(+) CI RCUI T SHORT TO GROUND
FUSED B(+) CI RCUI T OPEN
I NSTRUMENT CLUSTER
TEST ACTION APPLICABILITY
1 Turn the i gni ti on off.
I nspect the #24 fuse i n the Power Di stri buti on Center.
I f the fuse i s open, repl ace wi th proper rated fuse.
Turn the i gni ti on on for one mi nute.
Turn the i gni ti on off.
I nspect the #24 fuse i n the Power Di stri buti on Center.
I s the fuse open?
Al l
Yes → Repai r the Fused B(+) ci rcui t for a short to ground.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Go To 2
2 Turn the i gni ti on off.
Di sconnect the I nstrument Cl uster C1 harness connector.
Check connectors - Cl ean/repai r as necessary.
Measure the vol tage between the Fused B(+) ci rcui t and ground.
I s the vol tage above 10.5 vol ts?
Al l
Yes → Repl ace and confi gure the I nstrument Cl uster i n accordance wi th
the Servi ce I nformati on.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Repai r the Fused B(+) ci rcui t for an open.
Perform BODY VERI FI CATI ON TEST - VER 1.
138
INSTRUMENT CLUSTER
Symptom:
*4WD INDICATOR INOPERATIVE
POSSIBLE CAUSES
I NTERMI TTENT CONDI TI ON
TRANSFER CASE SWI TCH - EXCEPT OFF-ROAD PACKAGE
4WD I NDI CATOR CI RCUI T OPEN
TRANSFER CASE SWI TCH GROUND CI RCUI T OPEN - EXCEPT OFF-ROAD PACKAGE
TRANSFER CASE SWI TCH - OFF-ROAD PACKAGE
TRANSFER CASE POSI TI ON SENSOR I NPUT CI RCUI T OPEN
TRANSFER CASE SWI TCH GROUND CI RCUI T OPEN - OFF-ROAD PACKAGE
I NSTRUMENT CLUSTER - EXCEPT OFF-ROAD PACKAGE
I NSTRUMENT CLUSTER - OFF-ROAD PACKAGE
TEST ACTION APPLICABILITY
1 I s vehi cl e equi pped wi th the opti onal Off-Road Package? Al l
Yes → Go To 2
No → Go To 6
2 Perform the I nstrument Cl uster sel f-test.
Turn the i gni ti on off.
Press and hol d the Tri p Reset button.
Turn the i gni ti on on.
Observe the 4WD i ndi cator duri ng the sel f-test.
NOTE: TheInstrument Cluster self-test can beinitiated usingtheDRBIII௡.
Di d the 4WD i ndi cator i l l umi nate duri ng the sel f-test?
Al l
Yes → Go To 3
No → Repl ace and confi gure the I nstrument Cl uster i n accordance wi th
the Servi ce I nformati on.
Perform BODY VERI FI CATI ON TEST - VER 1.
3 Turn the i gni ti on on, Transfer Case Shi ft Lever i n 2H.
Wi th the DRBI I I ௡ i n I nputs/Outputs, read the 4WD Swi tch state.
Pl ace the Transfer Case Shi ft Lever i n 4H or 4L whi l e observi ng the 4WD Swi tch
State.
Di d the Does the DRBI I I ௡ di spl ay 4H or 4L?
Al l
Yes → The condi ti on i s not present at thi s ti me. Moni tor DRBI I I ௡
parameters whi l e wi ggl i ng the rel ated wi re harness. Refer to any
Techni cal Servi ce Bul l eti ns (TSB) that may appl y. Vi sual l y i n-
spect the rel ated wi ri ng harness and connector termi nal s.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Go To 4
139
INSTRUMENT CLUSTER
TEST ACTION APPLICABILITY
4 Turn the i gni ti on off.
Di sconnect the Transfer Case Swi tch harness connector.
Connect a jumper wi re between cavi ty 1 and cavi ty 2.
Turn the i gni ti on on.
Wi th the DRBI I I ௡, read the 4WD Swi tch i nput.
Does the DRBI I I ௡ di spl ay ЉCl osed?Љ
Al l
Yes → Repl ace the Transfer Case Swi tch i n accordance wi th the Servi ce
I nformati on.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Go To 5
5 Turn the i gni ti on off.
Di sconnect the Transfer Case Swi tch harness connector.
Di sconnect the PCM C1 harness connector.
Measure the resi stance of the Transfer Case Posi ti on Sensor I nput ci rcui t between
the T/Case Swi tch connector and the PCM C1 connector.
I s the resi stance above 5.0 ohms?
Al l
Yes → Repai r the Transfer Case Posi ti on Sensor I nput ci rcui t for an
open.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Repai r the Transfer Case Swi tch Ground ci rcui t for an open.
Perform BODY VERI FI CATI ON TEST - VER 1.
6 Turn the i gni ti on on.
Wi th the DRBI I I ௡, sel ect Body, MI C, then I nputs/Outputs.
Move the transfer case shi ft l ever from the 2H to the 4H or 4L posi ti on.
Does the DRBI I I ௡ di spl ay 4WD Swi tch ЉCl osedЉ wi th the shi ft l ever i n the 4H or 4L
posi ti on?
Al l
Yes → Repl ace and confi gure the I nstrument Cl uster i n accordance wi th
the Servi ce I nformati on.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Go To 7
7 Turn the i gni ti on off.
Di sconnect the Transfer Case Swi tch harness connector.
Connect a jumper wi re between cavi ty A and cavi ty B.
Turn the i gni ti on on.
Wi th the DRBI I I ௡, read the 4WD Swi tch i nput.
Does the DRBI I I ௡ di spl ay ЉCl osedЉ.
Al l
Yes → Repl ace the Transfer Case Swi tch i n accordance wi th the Servi ce
I nformati on.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Go To 8
140
INSTRUMENT CLUSTER
*4WD INDICATOR INOPERATIVE — Continued
TEST ACTION APPLICABILITY
8 Turn the i gni ti on off.
Di sconnect the Transfer Case Swi tch harness connector.
Connect a jumper wi re between the 4WD I ndi cator ci rcui t and ground.
Turn the i gni ti on on.
Wi th the DRBI I I ௡, read the 4WD Swi tch state.
Does the DRBI I I ௡ di spl ay ЉCl osedЉ?
Al l
Yes → Go To 9
No → Repai r the 4WD I ndi cator ci rcui t for an open.
Perform BODY VERI FI CATI ON TEST - VER 1.
9 Turn the i gni ti on off.
Di sconnect the Transfer Case Swi tch harness connector.
Measure the resi stance between ground and the Transfer Case Swi tch Ground
ci rcui t.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → The condi ti on i s not present at thi s ti me. Moni tor DRBI I I ௡
parameters whi l e wi ggl i ng the rel ated wi re harness. Refer to any
Techni cal Servi ce Bul l eti ns (TSB) that may appl y. Vi sual l y i n-
spect the rel ated wi ri ng harness and connector termi nal s.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Repai r the Transfer Case Swi tch Ground ci rcui t for an open.
Perform BODY VERI FI CATI ON TEST - VER 1.
141
INSTRUMENT CLUSTER
*4WD INDICATOR INOPERATIVE — Continued
Symptom:
*ABS INDICATOR INOPERATIVE
POSSIBLE CAUSES
ABS DTC
I NSTRUMENT CLUSTER
TEST ACTION APPLICABILITY
1 NOTE:TheInstrument Cluster ABSIndicator will not illuminateduringthe
cluster Self Test. The indicator is controlled by PCI Bus messages received
fromthe CAB.
NOTE: The CAB will command the ABS Indicator on when the ignition is
cycled to the Run/Start position.
Wi th the DRBI I I ௡, read DTCs.
Does the DRBI I I ௡ di spl ay any ABS DTCs?
Al l
Yes → Refer to the Anti -Lock Brake System category and perform the
appropri ate symptom.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Repl ace the I nstrument Cl uster i n accordance wi th the Servi ce
I nformati on.
Perform BODY VERI FI CATI ON TEST - VER 1.
142
INSTRUMENT CLUSTER
Symptom:
*AIR BAG INDICATOR INOPERATIVE
POSSIBLE CAUSES
I NSTRUMENT CLUSTER
AI R BAG I NDI CATOR DTC
TEST ACTION APPLICABILITY
1 NOTE: TheInstrument Cluster Air BagIndicator will not illuminateduring
the cluster Self Test. The indicator is controlled by PCI Bus messages
received fromtheAir Bag Control Module (ACM).
NOTE: TheACMwill command theindicator on when theignition is cycled
to the Run/Start position.
Wi th the DRBI I I ௡, sel ect Body, then MI C, read DTCs.
Does the DRBI I I ௡ di spl ay Ai r Bag Lamp Open or Ai r Bag Lamp Shorted?
Al l
Yes → Refer to the Servi ce I nformati on and perform the appropri ate
symptom.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Repl ace the I nstrument Cl uster i n accordance wi th the Servi ce
I nformati on.
Perform BODY VERI FI CATI ON TEST - VER 1.
143
INSTRUMENT CLUSTER
Symptom:
*ALL GAUGES INOPERATIVE
POSSIBLE CAUSES
NO RESPONSE - PCI BUS
NO RESPONSE - PCI BUS - I NSTRUMENT CLUSTER
NO RESPONSE - PCI BUS - POWERTRAI N CONTROL MODULE
FUSED I GNI TI ON SWI TCH OUTPUT CI RCUI T SHORT TO GROUND
FUSED I GNI TI ON SWI TCH OUTPUT CI RCUI T OPEN
GROUND CI RCUI T OPEN
I NSTRUMENT CLUSTER
TEST ACTION APPLICABILITY
1 Turn the i gni ti on on.
Wi th the DRBI I I ௡, sel ect System Moni tors, then J1850 Modul e Scan.
Does the DRBI I I ௡ di spl ay MI C PRESENT on the BUS?
Al l
Yes → Go To 2
No → Refer to the COMMUNI CATI ON category and perform the appro-
pri ate symptom.
Perform BODY VERI FI CATI ON TEST - VER 1.
2 Turn the i gni ti on on.
Wi th the DRBI I I ௡, sel ect Body, MI C, MODULE DI SPLAY.
Does the DRBI I I ௡ di spl ay NO RESPONSE from MI C?
Al l
Yes → Refer to symptom *NO CLUSTER BUS MESSAGE i n the Com-
muni cati on category.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Go To 3
3 Turn the i gni ti on on.
Wi th the DRBI I I ௡, sel ect Body, MI C, SYSTEM TESTS, PCM Moni tor.
Does the DRBI I I ௡ di spl ay PCM I NACTI VE ON THE BUS?
Al l
Yes → Refer to the symptom l i st for probl ems rel ated to *NO RE-
SPONSE FROM THE POWERTRAI N CONTROL MODULE.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Go To 4
144
INSTRUMENT CLUSTER
TEST ACTION APPLICABILITY
4 Turn the i gni ti on off.
I nspect the #10 Fuse i n the Fuse Bl ock.
I f the fuse i s open, repl ace wi th proper rated fuse.
Turn the i gni ti on on for one mi nute.
Turn the i gni ti on off.
I nspect the #10 Fuse i n the Fuse Bl ock.
I s the fuse open?
Al l
Yes → Repai r the Fused I gni ti on Swi tch Output ci rcui t for a short to
ground.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Go To 5
5 Turn the i gni ti on off.
Di sconnect the I nstrument Cl uster C1 harness connector.
Check connectors - Cl ean/repai r as necessary.
Turn the i gni ti on on.
Measure the vol tage between the Fused I gni ti on Swi tch Output ci rcui t and ground.
I s the vol tage above 10.5 vol ts?
Al l
Yes → Go To 6
No → Repai r the Fused I gni ti on Swi tch Output ci rcui t for an open.
Perform BODY VERI FI CATI ON TEST - VER 1.
6 Turn the i gni ti on off.
Di sconnect the I nstrument Cl uster C1 harness connector.
Check connectors - Cl ean/repai r as necessary.
Measure the resi stance between ground and the I nstrument Cl uster Ground ci rcui t.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Repl ace and confi gure the I nstrument Cl uster i n accordance wi th
the Servi ce I nformati on.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Repai r the I nstrument Cl uster Ground ci rcui t for an open.
Perform BODY VERI FI CATI ON TEST - VER 1.
145
INSTRUMENT CLUSTER
*ALL GAUGES INOPERATIVE — Continued
Symptom:
*ANY PCI BUS INDICATOR INOPERATIVE
POSSIBLE CAUSES
NO RESPONSE - PCI BUS
NO RESPONSE - I NSTRUMENT CLUSTER
NO RESPONSE - POWERTRAI N CONTROL MODULE
I NOPERATI VE I NDI CATOR
I NSTRUMENT CLUSTER
TEST ACTION APPLICABILITY
1 Turn the i gni ti on on.
Wi th the DRBI I I ௡, sel ect System Moni tors, then J1850 Modul e Scan.
Does the DRBI I I ௡ di spl ay MI C PRESENT on the Bus?
Al l
Yes → Go To 2
No → Refer to the COMMUNI CATI ON category and perform the appro-
pri ate symptom.
Perform BODY VERI FI CATI ON TEST - VER 1.
2 Turn the i gni ti on on.
Wi th the DRBI I I ௡, Sel ect Body, MI C, then MODULE DI SPLAY.
Does the DRBI I I ௡ di spl ay NO RESPONSE from MI C?
Al l
Yes → Refer to the symptom l i st for probl ems rel ated to *NO RE-
SPONSE FROM THE I NSTRUMENT CLUSTER
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Go To 3
3 Turn the i gni ti on on.
Wi th the DRBI I I ௡, sel ect Body, MI C, SYSTEM TESTS, PCM MONI TOR.
Does the DRBI I I ௡ di spl ay PCM I NACTI VE on the BUS?
Al l
Yes → Refer to the symptom l i st for probl ems rel ated to *NO RE-
SPONSE FROM THE POWERTRAI N CONTROL MODULE
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Go To 4
4 NOTE:Diagnoseandrepair anyPCMDTCsbeforeproceedingwiththistest.
Perform the I nstrument Cl uster Sel f Test.
Observe the i ndi cator i n questi on duri ng the Sel f Test.
Di d the i ndi cator i l l umi nate?
Al l
Yes → Refer to the appropri ate Servi ce I nformati on category to di agnose
the rel ated system.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Repl ace the I nstrument Cl uster i n accordance wi th the Servi ce
I nformati on.
Perform BODY VERI FI CATI ON TEST - VER 1.
146
INSTRUMENT CLUSTER
Symptom:
*AXLE LOCK INDICATOR PROBLEMS
POSSIBLE CAUSES
DTC PRESENT
AXLE LOCKER SWI TCH FUSED B(+) CI RCUI T OPEN
AXLE LOCKER SWI TCH GROUND CI RCUI T OPEN
FRONT LOCKER REQUEST CI RCUI T OPEN
REAR LOCKER REQUEST CI RCUI T OPEN
AXLE LOCK SWI TCH
I NTERMI TTENT CONDI TI ON
I NSTRUMENT CLUSTER
TEST ACTION APPLICABILITY
1 NOTE: Thefollowingtests areto diagnosean inoperativeAxleLock indica-
tor. If theAxleLock indicator flashes, theEnableconditions havenot been
met to lock the axle, or an axle mechanical fault exists.
NOTE: The Front Axle Lock and Rear Axle Lock indicators can NOT be
diagnosed using the Instrument Cluster self test.
Wi th the DRBI I I ௡, read DTCs.
Are any ABS, PCM, VSS, or Transfer Case DTCs present?
Al l
Yes → Refer to DRI VEABI LI TY or TRANSMI SSI ON/TRANSFER CASE
i nformati on for the rel ated symptom(s).
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Go To 2
2 Sel ect the i noperati ve i ndi cator. Al l
Rear Axl e Lock I ndi cator
Go To 3
Front Axl e Lock I ndi cator
Go To 8
3 Perform the Axl e Locker test.
Turn the i gni ti on on.
Pl ace transfer case i n 4WD Lo and vi sual l y confi rm by observi ng the 4WD i ndi cator.
Dri ve the vehi cl e at l ess than 10 MPH (16 km/h).
Press the Axl e Lock swi tch once.
Di d the Rear Axl e Lock i ndi cator i l l umi nate?
Al l
Yes → The condi ti on i s not present at thi s ti me. Moni tor DRBI I I ௡
parameters whi l e wi ggl i ng the rel ated wi re harness. Refer to any
Techni cal Servi ce Bul l eti ns(TSB) that may appl y. Vi sual l y i nspect
the rel ated wi ri ng harness and connector termi nal s.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Go To 4
147
INSTRUMENT CLUSTER
TEST ACTION APPLICABILITY
4 Pl ace the transfer case i n 4WD Lo.
Dri ve the vehi cl e at l ess than 2.5 MPH (4 km/h).
Wi th the DRBI I I ௡ i n I nputs/Outputs, read the Enabl e 1 state, (shoul d read LOW).
Wi th the DRBI I I ௡ i n I nputs/Outputs, read the Rear Lock Request state.
Press the Axl e Lock swi tch once.
Di d the Rear Lock Request change state?
Al l
Yes → Repl ace and confi gure the I nstrument Cl uster i n accordance wi th
the Servi ce I nformati on.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Go To 5
5 Turn the i gni ti on off.
Di sconnect the Axl e Lock Swi tch harness connector.
Measure the vol tage between the Fused B(+) ci rcui t and ground.
I s the vol tage bel ow 10.5 vol ts?
Al l
Yes → Repai r the Axl e Locker Swi tch Fused B(+) ci rcui t for an open.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Go To 6
6 Turn the i gni ti on off.
Di sconnect the Axl e Lock Swi tch harness connector.
Measure the resi stance between ground and the Axl e Locker Swi tch Ground ci rcui t.
I s the resi stance above 5.0 ohms?
Al l
Yes → Repai r the Axl e Locker Swi tch Ground ci rcui t for an open.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Go To 7
7 Turn the i gni ti on off.
Di sconnect the Axl e Locker Swi tch harness connector.
Di sconnect the I nstrument Cl uster C1 harness connector.
Measure the resi stance of the Rear Locker Request ci rcui t between the Axl e Locker
Swi tch connector and the I nstrument Cl uster C1 connector.
I s the resi stance above 5.0 ohms?
Al l
Yes → Repai r the Rear Locker Request ci rcui t for an open.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Repl ace the Axl e Lock Swi tch i n accordance wi th the Servi ce
I nformati on.
Perform BODY VERI FI CATI ON TEST - VER 1.
148
INSTRUMENT CLUSTER
*AXLE LOCK INDICATOR PROBLEMS — Continued
TEST ACTION APPLICABILITY
8 Pl ace transfer case i n 4WD Lo and dri ve vehi cl e at l ess than 2.5 MPH (4 km/h).
Press the Axl e Locker Swi tch once to l ock the rear axl e.
Wi th the DRBI I I ௡ i n I nputs/Outputs, ensure that the Enabl e 1 and Enabl e 2 states
both read LOW.
Wi th the DRBI I I ௡ i n I nputs/Outputs, ensure that the Rear Lock Request and Rear
Lock Return states both read LOCKED.
Press the Axl e Locker Swi tch agai n.
Di d the Front Axl e Lock i ndi cator i l l umi nate?
Al l
Yes → The condi ti on i s not present at thi s ti me. Moni tor DRBI I I ௡
parameters whi l e wi ggl i ng the rel ated wi re harness. Refer to any
Techni cal Servi ce Bul l eti ns(TSB) that may appl y. Vi sual l y i nspect
the rel ated wi ri ng harness and connector termi nal s.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Go To 9
9 Pl ace the vehi cl e i n 4WD Lo, operate vehi cl e at 2.5 MPH (4 km/h) or l ess.
Wi th the DRBI I I ௡ i n I nputs/Outputs, ensure that the Enabl e 1 and Enabl e 2 states
read LOW.
The Rear Axl e Lock i ndi cator must be i l l umi nated.
Wi th the DRBI I I ௡ i n I nputs/Outputs, read the Front Lock Request state.
Press the Axl e Locker Swi tch.
Di d the Front Axl e Lock Request change state?
Al l
Yes → Repl ace and confi gure the I nstrument Cl uster i n accordance wi th
the Servi ce I nformati on.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Go To 10
10 Turn the i gni ti on off.
Di sconnect the Axl e Locker Swi tch harness connector.
Di sconnect the I nstrument Cl uster C2 harness connector.
Measure the resi stance of the Front Locker Request ci rcui t between the Axl e Locker
Swi tch connector and the I nstrument Cl uster C2 connector.
I s the resi stance above 5.0 ohms?
Al l
Yes → Repai r the Front Locker Request ci rcui t for an open.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Repl ace the Axl e Lock Swi tch i n accordance wi th the Servi ce
I nformati on.
Perform BODY VERI FI CATI ON TEST - VER 1.
149
INSTRUMENT CLUSTER
*AXLE LOCK INDICATOR PROBLEMS — Continued
Symptom:
*BRAKE WARNING INDICATOR ALWAYS ON
POSSIBLE CAUSES
BRAKE WARNI NG I NDI CATOR CI RCUI T SHORT TO GROUND
BRAKE WARNI NG I NDI CATOR SWI TCH
PARK BRAKE SWI TCH
TEST ACTION APPLICABILITY
1 NOTE: Ensure that the Base brake systemfunctions properly and that the
Brake Master Cylinder is filled with proper amount of fluid.
NOTE: If equipped, diagnose and repair any ABS DTCs before continuing
with this test.
Turn the i gni ti on off.
Di sconnect the Park Brake Swi tch harness connector.
Turn the i gni ti on on and observe the Brake Warni ng I ndi cator.
Does the Brake Warni ng I ndi cator remai n i l l umi nated?
Al l
Yes → Go To 2
No → Repl ace the Park Brake Swi tch i n accordance wi th the Servi ce
I nformati on.
Perform BODY VERI FI CATI ON TEST - VER 1.
2 Turn the i gni ti on off.
Di sconnect the Brake Warni ng I ndi cator Swi tch harness connector.
Connect a jumper wi re between cavi ty 1 and cavi ty 2.
Turn the i gni ti on on and observe the Brake Warni ng I ndi cator.
Does the Brake Warni ng I ndi cator remai n i l l umi nated?
Al l
Yes → Repai r the Brake Warni ng I ndi cator ci rcui t for a short to ground.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Repl ace the Brake Warni ng I ndi cator Swi tch i n accordance wi th
the Servi ce I nformati on.
Perform BODY VERI FI CATI ON TEST - VER 1.
150
INSTRUMENT CLUSTER
Symptom:
*BRAKE WARNING INDICATOR INOPERATIVE
POSSIBLE CAUSES
BRAKE WARNI NG I NDI CATOR CI RCUI T SHORT TO VOLTAGE
BRAKE WARNI NG I NDI CATOR CI RCUI T OPEN
BRAKE WARNI NG I NDI CATOR SWI TCH
PARK BRAKE SWI TCH
I NSTRUMENT CLUSTER
TEST ACTION APPLICABILITY
1 Turn the i gni ti on off.
Perform the I nstrument Cl uster Sel f Test.
Di d the Brake Warni ng I ndi cator i l l umi nate duri ng the Sel f Test?
Al l
Yes → Go To 2
No → Repl ace the I nstrument Cl uster i n accordance wi th the Servi ce
I nformati on.
Perform BODY VERI FI CATI ON TEST - VER 1.
2 Turn the i gni ti on off.
Di sconnect the I nstrument Cl uster C2 harness connector.
Check connectors - Cl ean/repai r as necessary.
Measure the vol tage between the Brake Warni ng I ndi cator ci rcui t and ground.
I s there any vol tage present?
Al l
Yes → Repai r the Brake Warni ng I ndi cator ci rcui t for a short to vol tage.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Go To 3
3 NOTE: Ensurethat theInstrument Cluster harnessconnector isconnected.
Turn the i gni ti on off.
Di sconnect the Brake Warni ng I ndi cator Swi tch (Pressure Swi tch) harness connec-
tor.
Connect a jumper wi re between cavi ty 1 and cavi ty 2.
Di sconnect the Park Brake Swi tch harness connector.
Connect a jumper wi re between the Brake Warni ng I ndi cator ci rcui t and ground.
Turn the i gni ti on on and observe the Brake Warni ng I ndi cator.
Does the Brake Warni ng I ndi cator i l l umi nate?
Al l
Yes → Repl ace the Park Brake Swi tch i n accordance wi th the Servi ce
I nformati on.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Go To 4
151
INSTRUMENT CLUSTER
TEST ACTION APPLICABILITY
4 Turn the i gni ti on off.
Di sconnect the I nstrument Cl uster C2 harness connector.
Di sconnect the Park Brake Swi tch harness connector.
Di sconnect the Brake Warni ng I ndi cator Swi tch harness connector.
Connect a jumper wi re between cavi ty 1 and cavi ty 2.
Measure the resi stance of the Brake Warni ng I ndi cator ci rcui t.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Repl ace the Brake Warni ng I ndi cator Swi tch i n accordance wi th
the Servi ce I nformati on.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Repai r the Brake Warni ng I ndi cator ci rcui t for an open.
Perform BODY VERI FI CATI ON TEST - VER 1.
152
INSTRUMENT CLUSTER
*BRAKE WARNING INDICATOR INOPERATIVE — Continued
Symptom:
*FOG LAMP INDICATOR INOPERATIVE - DOMESTIC
POSSIBLE CAUSES
FOG LAMP I NDI CATOR CI RCUI T OPEN
I NSTRUMENT CLUSTER
TEST ACTION APPLICABILITY
1 NOTE: Ensure that the Fog Lamps operate properly. If not, refer to EXTE-
RIOR LIGHTING in the Service Information.
NOTE: The Headlamps must be on Low Beamfor indicator to operate.
Turn the i gni ti on off.
Di sconnect the I nstrument Cl uster.
Check connectors - Cl ean/repai r as necessary.
Turn the Headl amps on and actuate the Fog Lamps.
Usi ng a 12-vol t test l i ght connected to ground, check the Fog Lamp I ndi cator ci rcui t.
Does the test l i ght i l l umi nate bri ghtl y?
Al l
Yes → Repl ace the I nstrument Cl uster i n accordance wi th the Servi ce
I nformati on.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Repai r the Fog Lamp I ndi cator ci rcui t for an open.
Perform BODY VERI FI CATI ON TEST - VER 1.
153
INSTRUMENT CLUSTER
Symptom:
*HIGH BEAM INDICATOR INOPERATIVE
POSSIBLE CAUSES
HI GH BEAM I NDI CATOR CI RCUI T OPEN
I NDI CATOR BULB
I NSTRUMENT CLUSTER
TEST ACTION APPLICABILITY
1 NOTE:Ensurethat theHeadlampHighBeamsoperateproperly. If not, refer
to the Exterior Lighting Service Information.
Turn the i gni ti on off.
Di sconnect the I nstrument Cl uster C1 harness connector.
Check connectors - Cl ean/repai r as necessary.
Turn the Headl amps on and actuate the Hi gh Beams.
NOTE: Ensure that the Fog Lamps are not actuated (Domestic vehicles
only).
Usi ng a 12-vol t test l i ght connected to ground, back probe the Hi gh Beam I ndi cator
ci rcui t.
Does the test l i ght i l l umi nate bri ghtl y?
Al l
Yes → Go To 2
No → Repai r the Di mmer Swi tch Hi gh Beam Output ci rcui t for an open.
Perform BODY VERI FI CATI ON TEST - VER 1.
2 Turn the i gni ti on off.
Di sconnect the I nstrument Cl uster.
Check connectors - Cl ean/repai r as necessary.
Remove and i nspect the Hi gh Beam I ndi cator bul b.
I s the i ndi cator bul b fi l ament open?
Al l
Yes → Repl ace the Hi gh Beam I ndi cator Bul b i n accordance wi th the
Servi ce I nformati on.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Repl ace the I nstrument Cl uster i n accordance wi th the Servi ce
I nformati on.
Perform BODY VERI FI CATI ON TEST - VER 1.
154
INSTRUMENT CLUSTER
Symptom:
*ONE GAUGE INOPERATIVE
POSSIBLE CAUSES
I NTERMI TTENT CONDI TI ON
POWERTRAI N CONTROL MODULE DTC PRESENT
I NSTRUMENT CLUSTER
TEST ACTION APPLICABILITY
1 Turn the i gni ti on on.
Wi th the DRBI I I ௡, read DTCs.
NOTE: The PCM will not store any DTCs regarding Oil Pressure concerns.
NOTE: If Oil Pressure gauge readings are in question and the gauge tests
good, a mechanical oil pressure gauge must be attached to the engine.
Does the DRBI I I ௡ di spl ay any PCM DTCs?
Al l
Yes → Refer to the DRI VEABI LI TY category and perform the appropri -
ate symptom.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Go To 2
2 Turn the i gni ti on off.
Perform the I nstrument Cl uster Sel f Test.
Observe the gauge i n questi on whi l e the I nstrument Cl uster performs the Sel f Test.
The gauges shoul d posi ti on at the fol l owi ng cal i brati on poi nts:
Speedometer: 20mph (40km/h BUX), 55mph (80km/h BUX), 75mph (120km/h BUX)
Tachometer: 2000, 5000
Fuel : Empty Stop, E, 1/2, F, Ful l Stop
Temperature: Lo, Mi d Lo, Mi d Hi gh, Hi gh
Oi l Pressure: 0, 40, 60,
Vol t: Off, 9, 12, 14, 16, 19
Di d the gauge i n questi on operate properl y?
Al l
Yes → The condi ti on i s not present at thi s ti me. Moni tor DRBI I I ௡
parameters whi l e wi ggl i ng the rel ated wi re harness. Refer to any
Techni cal Servi ce Bul l eti ns (TSB) that may appl y. Vi sual l y i n-
spect the rel ated wi ri ng harness and connector termi nal s.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Repl ace and confi gure the I nstrument Cl uster i n accordance wi th
the Servi ce I nformati on.
Perform BODY VERI FI CATI ON TEST - VER 1.
155
INSTRUMENT CLUSTER
Symptom:
*PANEL DIMMNG INOPERATIVE
POSSIBLE CAUSES
I NSTRUMENT CLUSTER PANEL DI MMI NG DTC
PARK LAMP FEED CI RCUI T OPEN
I LLUMI NATI ON BULB
I NSTRUMENT CLUSTER
TEST ACTION APPLICABILITY
1 NOTE:Ensurethat thePark/Headlampsoperateproperlybeforecontinuing
with this test.
NOTE: Ensure that other Instrument Cluster functions operate properly
before continuing with this test.
Turn the i gni ti on on.
Wi th the DRBI I I ௡, sel ect Body, El ectro/Mech Cl uster, read DTCs.
Does the DRBI I I ௡ di spl ay PANEL DI MMER OPEN?
Al l
Yes → Refer to PANEL DI MMER OPEN DTC i n the Servi ce I nforma-
ti on.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Go To 2
2 Turn the i gni ti on off.
Di sconnect the I nstrument Cl uster C1 harness connector.
Check connectors - Cl ean/repai r as necessary.
Turn the Park l amps on.
Measure the vol tage between the Park Lamp Feed ci rcui t and ground.
I s the vol tage above 10.5 vol ts?
Al l
Yes → Go To 3
No → Repai r the Park Lamp Feed ci rcui t for an open.
Perform BODY VERI FI CATI ON TEST - VER 1.
3 Turn the i gni ti on off.
Di sconnect the I nstrument Cl uster C1 harness connector.
Check connectors - Cl ean/repai r as necessary.
Remove and i nspect the i noperati ve i l l umi nati on bul b(s).
I s the i l l umi nati on bul b fi l ament open?
Al l
Yes → Repl ace the I nstrument Cl uster I l l umi nati on Bul b(s) i n accor-
dance wi th the Servi ce I nformati on.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Repl ace the I nstrument Cl uster i n accordance wi th the Servi ce
I nformati on.
Perform BODY VERI FI CATI ON TEST - VER 1.
156
INSTRUMENT CLUSTER
Symptom:
*REAR FOG LAMP INDICATOR INOPERATIVE - BUX ONLY
POSSIBLE CAUSES
REAR FOG LAMP I NDI CATOR CI RCUI T OPEN
I NSTRUMENT CLUSTER
TEST ACTION APPLICABILITY
1 NOTE: Ensure that the Rear Fog Lamp operates properly. If not, refer to
EXTERIOR LIGHTING in the Service Information.
NOTE: Headlamps must be turned on for Rear Fog Lamp and indicator to
operate.
Turn the i gni ti on off.
Di sconnect the I nstrument Cl uster.
Check connectors - Cl ean/repai r as necessary.
Turn on the Headl amps and Rear Fog Lamp.
Usi ng a 12-vol t test l i ght connected to ground, check the Rear Fog Lamp I ndi cator
ci rcui t.
Does the test l i ght i l l umi nate bri ghtl y?
Al l
Yes → Repl ace the I nstrument Cl uster i n accordance wi th the Servi ce
I nformati on.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Repai r the Fog Lamp I ndi cator ci rcui t for an open.
Perform BODY VERI FI CATI ON TEST - VER 1.
157
INSTRUMENT CLUSTER
Symptom:
*SEAT BELT INDICATOR NOT OPERATING PROPERLY
POSSIBLE CAUSES
SEAT BELT SWI TCH SENSE CI RCUI T SHORT TO GROUND
SEAT BELT SWI TCH SENSE CI RCUI T OPEN
SEAT BELT SWI TCH GROUND CI RCUI T OPEN
SEAT BELT SWI TCH
SEAT BELT SWI TCH SENSE CI RCUI T SHORT TO VOLTAGE
I NSTRUMENT CLUSTER
TEST ACTION APPLICABILITY
1 Turn the i gni ti on on.
Wi th the DRBI I I ௡ i n I nputs/Outputs, read the Dri ver Bel t Swi tch state whi l e
buckl i ng and unbuckl i ng the Seat Bel t.
Does the DRBI I I ௡ di spl ay Open whi l e the bel t i s buckl ed and Cl osed whi l e
unbuckl ed?
Al l
Yes → Go To 2
No → Go To 3
2 Turn the i gni ti on off.
Perform the I nstrument Cl uster Sel f Test whi l e observi ng the Seat Bel t I ndi cator.
Di d the Seat Bel t I ndi cator i l l umi nate duri ng the Sel f Test?
Al l
Yes → Test Compl ete.
No → Repl ace the I nstrument Cl uster i n accordance wi th the Servi ce
I nformati on.
Perform BODY VERI FI CATI ON TEST - VER 1.
3 Turn the i gni ti on off.
Di sconnect the I nstrument Cl uster C2 harness connector.
Check connectors - Cl ean/repai r as necessary.
NOTE: Ensure that the Seat Belt is buckled.
Measure the vol tage between the Seat Bel t Swi tch Sense ci rcui t and ground.
I s there any vol tage present?
Al l
Yes → Repai r the Seat Bel t Swi tch Sense ci rcui t for a short to vol tage.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Go To 4
4 Turn the i gni ti on off.
Di sconnect the Seat Bel t Swi tch harness connector.
Di sconnect the I nstrument Cl uster C2 harness connector.
Check connectors - Cl ean/repai r as necessary.
Measure the resi stance between ground and the Seat Bel t Swi tch Sense ci rcui t.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Repai r the Seat Bel t Swi tch Sense ci rcui t for a short to ground.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Go To 5
158
INSTRUMENT CLUSTER
TEST ACTION APPLICABILITY
5 Turn the i gni ti on off.
Di sconnect the Seat Bel t Swi tch harness connector.
Di sconnect the I nstrument Cl uster C2 harness connector.
Check connectors - Cl ean/repai r as necessary.
Measure the resi stance of the Seat Bel t Swi tch Sense ci rcui t.
I s the resi stance above 5.0 ohms?
Al l
Yes → Repai r the Seat Bel t Swi tch Sense ci rcui t for an open.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Go To 6
6 Turn the i gni ti on off.
Di sconnect the Seat Bel t Swi tch harness connector.
Check connectors - Cl ean/repai r as necessary.
Measure the resi stance between ground and the Seat Bel t Swi tch Ground ci rcui t.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Repl ace the Seat Bel t Swi tch i n accordance wi th the Servi ce
I nformati on.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Repai r the Seat Bel t Swi tch Ground ci rcui t for an open.
Perform BODY VERI FI CATI ON TEST - VER 1.
159
INSTRUMENT CLUSTER
*SEAT BELT INDICATOR NOT OPERATING PROPERLY — Continued
Symptom:
*SPEEDOMETER INACCURATE OR INOPERATIVE
POSSIBLE CAUSES
PCM DTC PRESENT
I NCORRECT CONFI GURATI ON
I NTERMI TTENT CONDI TI ON
I NSTRUMENT CLUSTER
TEST ACTION APPLICABILITY
1 Wi th the DRBI I I ௡, read DTCs.
Are any Powertrai n DTCs present?
Al l
Yes → Refer to DRI VEABI LI TY for the rel ated symptom(s).
No → Go To 2
2 Wi th the DRBI I I ௡, ensure that the I nstrument Cl uster i s correctl y confi gured for Ti re
Si ze, Axl e Type, and Transfer Case Type.
Are the I nstrument Cl uster confi gurati ons correct?
Al l
Yes → Go To 3
No → Usi ng the DRBI I I ௡, sel ect Mi scel l aneous, Confi gure Cl uster for
the correct Ti re Si ze, Axl e Type, and Transfer Case Type. Wi th the
DRBI I I ௡, erase DTCs.
3 Turn the i gni ti on off.
Perform the I nstrument Cl uster sel f test.
Press and hol d the Tri p Reset button.
Turn the i gni ti on on.
Observe the Speedometer duri ng the sel f test.
NOTE: The sel f test can al so be i ni ti ated usi ng the DRBI I I ௡.
The Speedometer shoul d pause at the fol l owi ng cal i brati on poi nts:
Cal Poi nt 1: 20 MPH (40km/h Canada/BUX) (40 MPH Aus/Japan)
Cal Poi nt 2: 55 MPH (80 km/h Canada/BUX) (80 MPH Aus/Japan)
Cal Poi nt 3: 75 MPH (120 km/h Canada/BUX) (120 MPH Aus/Japan)
Di d the Speedometer pause at the correct cal i brati on poi nts?
Al l
Yes → The condi ti on i s not present at thi s ti me. Moni tor DRBI I I ௡
parameters whi l e wi ggl i ng the rel ated wi re harness. Refer to any
Techni cal Servi ce Bul l eti ns (TSB) that may appl y. Vi sual l y i n-
spect the rel ated wi ri ng harness and connector termi nal s.
No → Repl ace and confi gure the I nstrument Cl uster i n accordance wi th
the Servi ce I nformati on.
160
INSTRUMENT CLUSTER
Symptom:
*VF DISPLAY INOPERATIVE
POSSIBLE CAUSES
I NSTRUMENT CLUSTER
TEST ACTION APPLICABILITY
1 NOTE:Ensurethat all other Instrument Cluster functionsoperateproperly.
Turn the i gni ti on off.
Perform the I nstrument Cl uster Sel f Test.
Di d any or al l of the VF di spl ay fai l to operate?
Al l
Repai r
Repl ace and confi gure the I nstrument Cl uster i n accordance wi th
the Servi ce I nformati on.
Perform BODY VERI FI CATI ON TEST - VER 1.
161
INSTRUMENT CLUSTER
Symptom:
*VF ODOMETER INOPERATIVE WITH DOOR OPEN
POSSIBLE CAUSES
DEFECTI VE FUSE
DOOR AJAR SENSE CI RCUI T SHORT TO VOLTAGE
AJAR SWI TCH
DOOR AJAR SWI TCH SENSE CI RCUI T OPEN
DOOR AJAR SWI TCH GROUND CI RCUI T OPEN
I NSTRUMENT CLUSTER
TEST ACTION APPLICABILITY
1 Turn the i gni ti on off.
I nspect the #4 fuse i n the Fuse Bl ock.
I f the fuse i s open, repl ace wi th proper rated fuse.
NOTE: Ensure that the ignition is in the off position.
Open the door(s).
I nspect the #4 fuse i n the Fuse Bl ock.
I s the fuse open?
Al l
Yes → Go To 2
No → Go To 3
2 Turn the i gni ti on off.
Di sconnect the I nstrument Cl uster C2 harness connector.
Check connectors - Cl ean/repai r as necessary.
Measure the vol tage between the Door Ajar Swi tch Sense ci rcui t and ground.
NOTE: This test will work for either the Driver or Passenger Door Ajar
Switch Sense circuit.
I s there any vol tage present?
Al l
Yes → Repai r the Door Ajar Swi tch Sense ci rcui t for a short to vol tage.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Go To 3
3 Turn the i gni ti on off.
Di sconnect the Door Ajar Swi tch harness connector.
NOTE: This test will work for the Driver or Passenger Door Ajar Switch.
Connect a jumper wi re between cavi ty 1 and cavi ty 3.
Does the VF Odometer i l l umi nate?
Al l
Yes → Repl ace the i noperati ve Door Ajar Swi tch i n accordance wi th the
Servi ce I nformati on.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Go To 4
162
INSTRUMENT CLUSTER
TEST ACTION APPLICABILITY
4 Turn the i gni ti on off.
Di sconnect the Door Ajar Swi tch harness connector.
Connect a jumper wi re between the Door Ajar Swi tch Sense ci rcui t and ground.
NOTE: This test will work for the Driver or Passenger Door Ajar Switch
Sense circuit.
Does the VF di spl ay i l l umi nate?
Al l
Yes → Go To 5
No → Repai r the Door Ajar Swi tch Sense ci rcui t for an open.
Perform BODY VERI FI CATI ON TEST - VER 1.
5 Turn the i gni ti on off.
Di sconnect the Door Ajar Swi tch harness connector.
Check connectors - Cl ean/repai r as necessary.
Measure the resi stance between ground and the Door Ajar Swi tch Ground ci rcui t.
NOTE: This test will work for the Driver or Passenger Door Ajar Switch.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Repl ace the I nstrument Cl uster i n accordance wi th the Servi ce
I nformati on.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Repai r the Door Ajar Swi tch Ground ci rcui t for an open.
Perform BODY VERI FI CATI ON TEST - VER 1.
163
INSTRUMENT CLUSTER
*VF ODOMETER INOPERATIVE WITH DOOR OPEN — Continued
Symptom:
*COURTESY LAMPS INOPERATIVE - ALL LAMPS
POSSIBLE CAUSES
FUSED B+ CI RCUI T OPEN
I NSTRUMENT CLUSTER - COURTESY LAMP OPEN
COURTESY LAMP FEED CI RCUI T OPEN
I NTERMI TTENT CONDI TI ON
TEST ACTION APPLICABILITY
1 Remove the dome l amp l ens.
Remove and ensure the bul b i s good.
Usi ng a 12-vol t test l i ght connected to ground, check the Fused B+ ci rcui t.
Does the test l i ght i l l umi nate bri ghtl y?
Al l
Yes → Go To 2
No → Repai r the Fused B+ Ci rcui t for an open condi ti on.
Perform BODY VERI FI CATI ON TEST - VER 1.
2 Di sconnect the I nstrument Cl uster.
Connect a jumper wi re between the Courtesy Lamp Feed Ci rcui t and ground.
Observe the Dome Lamp.
Does the test l i ght i l l umi nate bri ghtl y?
Al l
Yes → Repl ace the I nstrument Cl uster.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Go To 3
3 Remove the dome l amp bul b.
Di sconnect the I nstrument Cl uster.
Connect a jumper wi re between the Courtesy Lamp Feed Ci rcui t i n the I nstrument
Cl uster connector and ground.
Measure resi stance of the Courtesy Lamp Feed Ci rcui t from the Dome Lamp to the
I nstrument Cl uster connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Repai r the Courtesy Lamp Feed Ci rcui t for an open condi ti on.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → The condi ti on that caused thi s symptom i s currentl y not present.
I nspect the rel ated wi ri ng for a possi bl e i ntermi ttent condi ti on.
Look for any chafed, pi erced, pi nched or parti al l y broken wi res.
Perform BODY VERI FI CATI ON TEST - VER 1.
164
INTERIOR LIGHTING
Symptom:
*COURTESY LAMPS ON AT ALL TIMES
POSSIBLE CAUSES
DRI VERS DOOR AJAR SWI TCH
DRI VERS DOOR AJAR SWI TCH SENSE CI RCUI T SHORT TO GROUND
I NSTRUMENT CLUSTER
PANEL LAMPS DI MMER SI GNAL CI RCUI T SHORT TO GROUND
MULTI FUNCTI ON SWI TCH
DOOR AJAR SWI TCH OPEN
PASSENGER DOOR AJAR SWI TCH SENSE CI RCUI T SHORT TO GROUND
COURTESY LAMP DRI VER CI RCUI T SHORT TO GROUND
I NSTRUMENT CLUSTER
TEST ACTION APPLICABILITY
1 Cl ose al l the doors.
Turn the Panel Lamps Di mmer Swi tch to the MI D posi ti on.
Wi th the DRBI I I ௡, read the El ectro/Mech Cl uster, I /O’s.
Does the DRBI I I ௡ read CLOSED?
Al l
Yes → Go To 2
No → Go To 6
2 Open the Dri vers door.
Di sconnect the Dri ver Door Ajar Swi tch connector.
Wi th the DRBI I I ௡ sel ect: Body, El ectro/Mech Cl uster, I nput/Output.
Read the: Drv Door Ajar Sw - state.
Does the DRBI I I ௡ show: Open?
Al l
Yes → Repl ace the Dri vers Door Ajar Swi tch.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Go To 3
3 Turn the i gni ti on off.
Di sconnect the Dri ver Door Ajar Swi tch connector.
Di sconnect the I nstrument Cl uster connector.
Measure resi stance of the Dri ver Door Ajar Swi tch Sense Ci rcui t from the door ajar
swi tch connector to ground.
I s the resi stance bel ow 100.0 ohms?
Al l
Yes → Repai r the Dri vers Door Ajar Swi tch Sense Ci rcui t for a short to
ground condi ti on.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Go To 4
165
INTERIOR LIGHTING
TEST ACTION APPLICABILITY
4 Turn the Panel Lamps Di mmer to the MI D posi ti on.
Remove the I nstrument Cl uster.
Measure the resi stance between ground and the Panel Lamps Di mmer Si gnal Ci rcui t
i n the C2 connector.
I s the resi stance bel ow 100.0 ohms?
Al l
Yes → Go To 5
No → Repl ace the I nstrument Cl uster.
Perform BODY VERI FI CATI ON TEST - VER 1.
5 Di sconnect the I nstrument Cl uster.
Di sconnect the Mul ti functi on Swi tch connector.
Measure the resi stance of the Panel Lamps Di mmer Si gnal Ci rcui t i n the i nstrument
cl uster connector to ground.
I s the resi stance bel ow 200.0 ohms?
Al l
Yes → Repai r the Panel Lamps Di mmer Si gnal Ci rcui t for a short to
ground condi ti on.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Repl ace the Mul ti functi on Swi tch.
Perform BODY VERI FI CATI ON TEST - VER 1.
6 Cl ose al l the passenger doors.
Wi th the DRBI I I ௡ sel ect: Body, El ectro/Mech Cl uster, I nput /Output.
Read the, Pas Door Ajar Sw - state.
Remove the passenger door ajar swi tch and observe the DRBI I I ௡.
Di d the DRBI I I ௡ change states to read: Pas Door Ajar Sw: Open?
Al l
Yes → Repl ace the appl i cabl e open Door Ajar Swi tch.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Go To 7
7 Turn the i gni ti on off.
Di sconnect the passenger door ajar swi tch.
Di sconnect the I nstrument Cl uster connector.
Measure the resi stance of the Passenger Door Ajar Ci rcui t i n the Passenger Door
Ajar Swi tch connector.
I s the resi stance bel ow 100.0 ohms?
Al l
Yes → Repai r the Passenger Door Ajar Swi tch Sense Ci rcui t for a short
to ground condi ti on.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Go To 8
8 Turn the Panel Lamps Di mmer to the MI D posi ti on.
Di sconnect the I nstrument Cl uster Connector.
Measure the resi stance between ground and the Courtesy Lamp Dri ver Ci rcui t.
I s the resi stance bel ow 100.0 ohms?
Al l
Yes → Repai r the Courtesy Lamp Dri ver Ci rcui t for a short to ground
condi ti on.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Repl ace the I nstrument Cl uster.
Perform BODY VERI FI CATI ON TEST - VER 1.
166
INTERIOR LIGHTING
*COURTESY LAMPS ON AT ALL TIMES — Continued
Symptom:
*ILLUMINATED ENTRY INOPERATIVE
POSSIBLE CAUSES
COURTESY LAMPS OPERATI ONAL
I NTERMI TTENT CONDI TI ON
I LLUMI NATED ENTRY NOT ENABLED
TEST ACTION APPLICABILITY
1 Check the Courtesy Lamps for proper operati on.
Do the Courtesy Lamps operate properl y from the Door Ajar Swi tches?
Al l
Yes → Go To 2
No → Refer to Symptom l i st for probl ems rel ated to COURTESY
LAMPS I NOPERATI VE.
Perform BODY VERI FI CATI ON TEST - VER 1.
2 Wi th the DRBI I I ௡ sel ect: ENABLE I LLUMI NATED ENTRY.
Wi th the DRBI I I ௡, read the I LLUMI NATED ENTRY status.
Does the DRBI I I ௡ di spl ay ENABLED?
Al l
Yes → The condi ti on that caused thi s symptom i s currentl y not present.
I nspect the rel ated wi ri ng harness for a possi bl e i ntermi ttent
condi ti on. Look for any chafed, pi erced, pi nched or parti al l y
broken wi res.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Wi th the DRB, enabl e the I l l umi nated Entry.
Perform BODY VERI FI CATI ON TEST - VER 1.
167
INTERIOR LIGHTING
Verification Tests
42RLE TRANSMISSION VERIFICATION TEST - VER 1 APPLICABILITY
1. Connect the DRBI I I ௡ to the Data Li nk Connector (DLC).
2. Reconnect any di sconnected components.
3. Wi th the DRBI I I ௡, erase al l Transmi ssi on DTC’s, al so erase the PCM DTC’s.
4. NOTE: EraseDTC P0700in thePCMtoturn theMalfunction Indicator Lamp(MIL)
off after making Transmission repairs.
5. Wi th the DRBI I I ௡, di spl ay Transmi ssi on Temperature. Start and run the engi ne unti l the
Transmi ssi on Temperature i s HOT - above 43° C or 110° F.
6. Check the Transmi ssi on Fl ui d and adjust i f necessary. Refer to the Servi ce i nformati on for
the Fl ui d Fi l l procedure.
7. NOTE: If theTransmission Control Moduleor theTransmission has been repaired
or replaced it is necessary toperformtheDRBIII௡ Quick Learn Procedureand reset
the ؆Pinion Factor؆
8. Road test the vehi cl e. Wi th the DRBI I I ௡, moni tor the engi ne RPM. Make 15 to 20 1-2, 2-3,
3-4 upshi fts. Perform these shi fts from a standi ng start to 45 MPH wi th a constant throttl e
openi ng of 20 to 25 degrees.
9. Bel ow 25 MPH, make 5 to 8 wi de open throttl e ki ckdowns to 1st gear. Al l ow at l east 5 seconds
each i n 2nd and 3rd gear between each ki ckdown.
10. For a speci fi c DTC, dri ve the vehi cl e to the Symptom’s When Moni tored/When Set
condi ti ons to veri fy the DTC repai r.
11. I f equi pped wi th AutoSti ck௡, up-shi ft and down-shi ft several ti mes usi ng the AutoSti ck௡
feature duri ng the road test.
12. NOTE:UsetheEATXOBDII Task Manager torunGoodTriptimeineachgear, this
will confirmthe repair and to ensure that the DTC has not re-matured.
13. Check for Di agnosti c Troubl e Codes (DTC’s) duri ng the road test. I f a DTC sets duri ng the
road test , return to the Symptom l i st and perform the appropri ate Symptom.
Were there any Di agnosti c Troubl e Codes (DTCs) set duri ng the road test?
Al l
Yes → Refer to the Symptom Li st for appropri ate Symptom(s).
No → Repai r i s compl ete.
ABS VERIFICATION TEST - VER 1 APPLICABILITY
1. Turn the i gni ti on off.
2. Connect al l previ ousl y di sconnected components and connectors.
3. Ensure al l accessori es are turned off and the battery i s ful l y charged.
4. Ensure that the I gni ti on i s on, and wi th the DRBI I I , erase al l Di agnosti c Troubl e Codes from
ALL modul es. Start the engi ne and al l ow i t to run for 2 mi nutes and ful l y operate the system
that was mal functi oni ng.
5. Turn the i gni ti on off and wai t 5 seconds. Turn the i gni ti on on and usi ng the DRBI I I , read
DTC’s from ALL modul es.
6. I f any Di agnosti c Troubl e Codes are present, return to Symptom l i st and troubl eshoot new
or recurri ng symptom.
7. NOTE: For Sensor Signal and Pump Motor faults, theCAB must senseall 4wheels
at 25 km/h (15 mph) before it will extinguish theABS Indicator.
8. I f there are no DTC’s present after turni ng i gni ti on on, road test the vehi cl e for at l east 5
mi nutes. Perform several anti l ock braki ng stops.
9. Caution: Ensure braking capability is available before road testing.
10. Agai n, wi th the DRBI I I ௡ read DTC’s. I f any DTC’s are present, return to Symptom l i st.
11. I f there are no Di agnosti c Troubl e Codes (DTC’s) present, and the customer’s concern can no
l onger be dupl i cated, the repai r i s compl ete.
Are any DTC’s present or i s the ori gi nal concern sti l l present?
Al l
Yes → Repai r i s not compl ete, refer to appropri ate symptom.
No → Repai r i s compl ete.
168
VERIFICATION TESTS
AIRBAG VERIFICATION TEST - VER 1 APPLICABILITY
1. Remove any speci al tool s or jumper wi res and reconnect al l previ ousl y di sconnected
components - except the Battery.
2. WARNING: TOAVOID PERSONAL INJ URY OR DEATH, TURN THE IGNITION ON,
THEN RECONNECT THE BATTERY.
3. Connect the DRBI I I ௡ to the Data Li nk Connector - use the most current software avai l abl e.
4. Use the DRBI I I ௡ and erase the stored codes i n al l ai rbag system modul es.
5. Turn the i gni ti on off, and wai t 15 seconds, then turn the i gni ti on on.
6. Wai t one mi nute, and read acti ve codes and i f there are none present read the stored codes.
7. Note: I f equi pped wi th Ai rbag On - Off swi tch, read the DTC’s i n al l swi tch posi ti ons.
8. Note: Read the DTC’s i n al l ai rbag system rel ated modul es.
9. I f the DRBI I I ௡ shows any acti ve or stored codes, return to the Symptom l i st and fol l ow path
speci fi ed for that troubl e code. I f no acti ve or stored codes are present, the repai r i s compl ete.
Are any DTC’s present or i s the ori gi nal condi ti on sti l l present?
Al l
YES
Repai r i s not compl ete, refer to appropri ate symptom l i st.
NO
Repai r i s compl ete.
BODY VERIFICATION TEST - VER 1 APPLICABILITY
1. Di sconnect al l jumper wi res and reconnect al l previ ousl y di sconnected components and
connectors.
2. NOTE: If the SKIM or PCM was replaced, refer to the service information for
proper programming procedures.
3. NOTE: If theMIC was replaced, configurenewcluster with TireSize, Axle, T-Case
Type, and EQ Setting.
4. Ensure al l accessori es are turned off and the battery i s ful l y charged.
5. Wi th the DRBI I I ௡, record and erase al l DTC’s from ALL modul es. Start and run the engi ne
for 2 mi nutes. Operate al l functi ons of the system that caused the ori gi nal concern.
6. Turn the i gni ti on off and wai t 5 seconds. Turn the i gni ti on on and usi ng the DRBI I I ௡, read
DTC’s from ALL modul es.
Are any DTCs present or i s the ori gi nal condi ti on sti l l present?
Al l
Yes → Repai r i s not compl ete, refer to the appropri ate symptom.
No → Repai r i s compl ete.
169
VERIFICATION TESTS
Verification Tests — Continued
POWERTRAIN VERIFICATION TEST VER - 1 APPLICABILITY
1. I nspect the vehi cl e to ensure that al l engi ne components are properl y i nstal l ed and
connected. Reassembl e and reconnect components as necessary.
2. I nspect the engi ne oi l for contami nati on. I f oi l contami nati on i s suspected, change the oi l and
fi l ter.
3. I f the PCM was not repl aced ski p steps 4 through 6 and conti nue wi th the veri fi cati on.
4. I f the PCM was repl aced the correct VI N and mi l eage must be programmed or a DTC wi l l set
i n the ABS and Ai r Bag modul es. I n addi ti on, i f the vehi cl e i s equi pped wi th Sentry Key
I mmobi l i zer Modul e (SKI M), Secret Key data must be updated to enabl e start.
5. For ABS and Ai r Bag systems: Enter correct VI N and Mi l eage i n PCM. Erase codes i n ABS
and Ai r Bag modul es.
6. For SKI M theft al arm: Connect DRBI I I ௡ to data l i nk conn. Go to Theft Al arm, SKI M, Mi sc.
and pl ace SKI M i n secured access mode, by usi ng the appropri ate PI N code for thi s vehi cl e.
Sel ect Update the Secret Key data. Data wi l l be transferred from SKI M to PCM
7. Attempt to start the engi ne.
8. I f the condi ti ons cannot be dupl i cated, erase al l DTCs.
I s the vehi cl e sti l l unabl e to start and/or are there any DTCs or symptoms remai ni ng?
Al l
Yes → Check for any rel ated Techni cal Servi ce Bul l eti ns and/or refer to the
appropri ate Symptom l i st (Di agnosti c Procedure).
No → Repai r i s compl ete.
SKIS VERIFICATION APPLICABILITY
1. Reconnect al l previ ousl y di sconnected components and connectors.
2. Obtai n the vehi cl e’s uni que Personal I denti fi cati on Number (PI N) assi gned to i t’s ori gi nal
SKI M. Thi s number can be obtai ned from the vehi cl e’s i nvoi ce or Chrysl er’s Customer Center
(1-800-992-1997).
3. NOTE: When entering the PIN, care should be taken because the SKIM will only
allow3consecutiveattemptstoenter thecorrect PIN. If 3consecutiveincorrect PINs
are entered, the SKIM will Lock Out the DRB for 1 hour.
4. To exi t Lock Out mode, the i gni ti on key must remai n i n the Run posi ti on conti nual l y for 1
hour. Turn off al l accessori es and connect a battery charger i f necessary.
5. Wi th the DRB, sel ect Theft Al arm, SKI M and Mi scel l aneous. Then, sel ect the desi red
procedure and fol l ow the steps that wi l l be di spl ayed.
6. I f the SKI M has been repl aced, ensure al l of the vehi cl e i gni ti on keys are programmed to the
new SKI M.
7. NOTE:Prior toreturningvehicletothecustomer, performamodulescantobesure
that all DTCs are erased. Erase any DTCs that are found.
8. Wi th the DRB, erase al l DTCs. Perform 5 i gni ti on key cycl es l eavi ng the key on for at l east
90 seconds per cycl e.
9. Wi th the DRB, read the SKI M DTCs.
Are there any SKI M DTCs?
Al l
Yes → Repai r i s not compl ete, refer to appropri ate symptom.
No → Repai r i s compl ete.
170
VERIFICATION TESTS
Verification Tests — Continued
8.0 SYSTEM COMPONENT LOCATIONS
8. 1 DATA LINK CONNECTOR
8. 2 AIRBAG
8. 2. 1 DRIVER AIRBAG MODULE & CLOCKSPRING
C
O
M
P
O
N
E
N
T
L
O
C
A
T
I
O
N
S
171
COMPONENT LOCATIONS
8. 2. 2 DRIVER/PASSENGER AIRBAG MODULES & MECHANICAL INSTRUMENT CLUSTER
8. 2. 3 AIRBAG CONTROL MODULE AND PASSENGER AIRBAG ON/OFF SWITCH
C
O
M
P
O
N
E
N
T
L
O
C
A
T
I
O
N
S
172
COMPONENT LOCATIONS
8. 2 AIRBAG (Continued)
8. 3 FUSE BLOCK
8. 4 INSTRUMENT CLUSTER
8. 4. 1 FRONT VIEW
C
O
M
P
O
N
E
N
T
L
O
C
A
T
I
O
N
S
173
COMPONENT LOCATIONS
8. 4. 2 REAR VIEW
8. 5 POWER DISTRIBUTION CENTER (PDC)
C
O
M
P
O
N
E
N
T
L
O
C
A
T
I
O
N
S
174
COMPONENT LOCATIONS
8. 4 INSTRUMENT CLUSTER (Continued)
8. 6 POWERTRAIN CONTROL MODULE
C
O
M
P
O
N
E
N
T
L
O
C
A
T
I
O
N
S
175
COMPONENT LOCATIONS
NOTES
176
9.0 CONNECTOR PINOUTS
AIRBAG CONTROL MODULE - YELLOW 22 WAY
CAV CIRCUIT FUNCTION
1 R45 18DG/LB DRIVER SQUIB 1 LINE 2
2 R43 18BK/LB DRIVER SQUIB 1 LINE 1
3 - -
4 - -
5 R42 18BK/YL PASSENGER SQUIB 1 LINE 1
6 R44 18DG/YL PASSENGER SQUIB 1 LINE 2
7 - -
8 R166 18LG/BR (PAD) PASSENGER AIRBAG INDICATOR DRIVER
9 - -
10 Z6 18BK/PK GROUND
11 R65 18LG/OR (PAD) PASSENGER AIRBAG MUX SWITCH SENSE
12 - -
13 - -
14 - -
15 - -
16 - -
17 F14 18LG/YL FUSED IGNITION SWITCH OUTPUT (RUN)
18 D25 18VT/YL PCI BUS
19 - -
20 F23 18DB/YL FUSED IGNITION SWITCH OUTPUT (RUN)
21 - -
22 R66 18YL/LG (PAD) PASSENGER AIRBAG MUX SWITCH RETURN
AMBIENT TEMPERATURE SENSOR - GRAY 2 WAY
CAV CIRCUIT FUNCTION
1 G31 20VT/LG AMBIENT TEMPERATURE SENSOR SIGNAL
2 G32 20BK/LB SENSOR GROUND
BRAKE WARNING INDICATOR SWITCH - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 G9 20GY/BK BRAKE WARNING INDICATOR DRIVER
2 G99 20GY/WT BRAKE WARNING INDICATOR DRIVER
C
O
N
N
E
C
T
O
R
P
I
N
O
U
T
S
177
CONNECTOR PINOUTS
CLOCKSPRING C2 - YELLOW 2 WAY
CAV CIRCUIT FUNCTION
1 R45 18DG/LB DRIVER SQUIB 1 LINE 2
2 R43 18BK/LB DRIVER SQUIB 1 LINE 1
COMPASS/TEMPERATURE MIRROR - BLACK 7 WAY
CAV CIRCUIT FUNCTION
1 G5 20DB/WT FUSED IGNITION SWITCH OUTPUT (RUN-START)
2 Z2 20BK/LG GROUND
3 L1 20VT/BK BACK-UP LAMP FEED
4 G31 20VT/LG AMBIENT TEMPERATURE SENSOR SIGNAL
5 G32 20BK/LB SENSOR GROUND
6 M2 20YL COURTESY LAMPS DRIVER
7 M1 20PK/WT FUSED B(+)
CONTROLLER ANTILOCK BRAKE - 25 WAY
CAV CIRCUIT FUNCTION
1 B1 18YL/DB RIGHT REAR WHEEL SPEED SENSOR (-)
2 B3 18LG/DB LEFT REAR WHEEL SPEED SENSOR (-)
3 B7 18WT RIGHT FRONT WHEEL SPEED SENSOR (+)
4 B9 18RD LEFT FRONT WHEEL SPEED SENSOR (+)
5 - -
6 B41 18YL/VT G-SWITCH NO. 1 SENSE
7 B42 18TN/WT G-SWITCH NO. 2 SENSE
8 Z22 12BK/PK GROUND
9 A20 12RD/DB FUSED B(+)
10 B4 18LG LEFT REAR WHEEL SPEED SENSOR (+)
11 B8 18RD/DB LEFT FRONT WHEEL SPEED SENSOR (-)
12 L50 18WT/TN BRAKE LAMP SWITCH OUTPUT
13 B43 18PK/OR G-SWITCH TEST SIGNAL
14 - -
15 - -
16 G83 18GY/BK ABS RELAY CONTROL
17 B2 18YL RIGHT REAR WHEEL SPEED SENSOR (+)
18 B6 18WT/DB RIGHT FRONT WHEEL SPEED SENSOR (-)
19 - -
20 D21 18PK SCI TRANSMIT
21 - -
22 - -
23 F20 18VT/WT FUSED IGNITION SWITCH OUTPUT (RUN)
24 Z22 12BK/PK GROUND
25 A10 12RD/DG FUSED B(+)
C
O
N
N
E
C
T
O
R
P
I
N
O
U
T
S
178
CONNECTOR PINOUTS
DATA LINK CONNECTOR - BLACK 16 WAY
CAV CIRCUIT FUNCTION
1 - -
2 D25 20VT/YL PCI BUS
3 - -
4 Z2 20BK/LG GROUND
5 Z12 20BK/TN GROUND
6 D32 20LG/WT SCI RECEIVE
7 D21 20PK SCI TRANSMIT
8 - -
9 D23 20WT/BR FLASH PROGRAM ENABLE
10 - -
11 - -
12 - -
13 - -
14 D20 20LG/PK SCI RECEIVE
15 - -
16 M1 20PK/WT FUSED B(+)
DRIVER AIRBAG SQUIB 1 - YELLOW 2 WAY
CAV CIRCUIT FUNCTION
1 R45 18DG/LB DRIVER SQUIB 1 LINE 2
2 R43 18BK/LB DRIVER SQUIB 1 LINE 1
C
O
N
N
E
C
T
O
R
P
I
N
O
U
T
S
179
CONNECTOR PINOUTS
C
O
N
N
E
C
T
O
R
P
I
N
O
U
T
S
180
CONNECTOR PINOUTS
FUSES (FUSE/RELAY BLOCK)
FUSE
NO.
AMPS FUSED CIRCUIT FUNCTION
1 20A F33 18PK/RD FUSED B(+)
1 20A F33 20PK/RD FUSED B(+)
2 20A F32 18PK/DB FUSED B(+)
3 20A X13 16BK/RD (SUBWOOFER) FUSED B(+)
4 10A Z1 20BK DOOR AJ AR SWITCH OUTPUT
5 10A F23 18DB/YL FUSED IGNITION SWITCH OUTPUT (RUN)
6 20A V23 18BR/PK (HARD TOP) FUSED IGNITION SWITCH OUTPUT (RUN)
7 10A F20 20VT/WT FUSED IGNITION SWITCH OUTPUT (RUN)
8 10A F24 20RD/DG FUSED IGNITION SWITCH OUTPUT (RUN)
9 10A F14 18LG/YL FUSED IGNITION SWITCH OUTPUT (RUN)
9 10A F14 18LG/YL (PAD) FUSED IGNITION SWITCH OUTPUT (RUN)
10 10A G5 20DB/WT FUSED IGNITION SWITCH OUTPUT (RUN-START)
10 10A G5 20DB/WT FUSED IGNITION SWITCH OUTPUT (RUN-START)
11 10A F12 20RD/LG FUSED IGNITION SWITCH OUTPUT (RUN-START)
12 10A F15 20DB FUSED IGNITION SWITCH OUTPUT (RUN-START)
12 10A F15 20DB FUSED IGNITION SWITCH OUTPUT (RUN-START)
13 10A L5 20BK/GY FUSED IGNITION SWITCH OUTPUT (RUN-START)
14 10A X12 20PK FUSED IGNITION SWITCH OUTPUT (RUN-START)
15 10A F81 20DB/RD (HARD TOP) FUSED REAR WINDOW DEFOGGER RELAY OUTPUT
16 10A L22 20LG/DG (EXPORT) FUSED IGNITION SWITCH OUTPUT (RUN-START)
16 10A L22 20LG/DG (EXPORT) DIMMER SWITCH LOW BEAM OUTPUT
17 25A V6 16PK/BK FUSED IGNITION SWITCH OUTPUT (RUN-START)
17 25A V6 16PK/BK FUSED IGNITION SWITCH OUTPUT (RUN-START)
18 20A F38 16LB/WT FUSED IGNITION SWITCH OUTPUT (RUN)
19 20A - -
20 20A T141 18YL/RD FUSED IGNITION SWITCH OUTPUT (START)
20 20A T141 18YL/RD FUSED IGNITION SWITCH OUTPUT (START)
IGNITION SWITCH - 10 WAY
CAV CIRCUIT FUNCTION
1 A1 18RD FUSED B(+)
2 A21 18DB IGNITION SWITCH OUTPUT (RUN-START)
3 F22 12WT/PK IGNITION SWITCH OUTPUT (RUN-ACC)
4 F30 12RD/PK FUSED B(+)
5 G26 20LB KEY-IN IGNITION SWITCH SENSE
6 A41 18YL IGNITION SWITCH OUTPUT (START)
7 A31 18BK/DG IGNITION SWITCH OUTPUT (RUN-ACC)
8 A22 14BK/OR IGNITION SWITCH OUTPUT (RUN)
9 A2 14PK/BK FUSED B(+)
10 Z1 16BK GROUND
C
O
N
N
E
C
T
O
R
P
I
N
O
U
T
S
181
CONNECTOR PINOUTS
INSTRUMENT CLUSTER C1 - 12 WAY
CAV CIRCUIT FUNCTION
1 L61 18GY LEFT TURN SIGNAL
2 L60 18TN RIGHT TURN SIGNAL
3 G34 16RD/GY (LHD) HIGH BEAM INDICATOR DRIVER
3 L3 16RD/OR (RHD) HIGH BEAM INDICATOR DRIVER
4 L39 16LB (EXCEPT EX-
PORT)
FOG LAMP FEED
4 L38 16BR/WT (EXPORT) REAR FOG LAMP FEED
5 L7 18BK/YL HEADLAMP SWITCH OUTPUT
6 G305 20VT/LG (OFF-ROAD
PACKAGE)
REAR LOCKER REQUEST
7 G301 20VT/LB (OFF-ROAD
PACKAGE)
REAR LOCKER INDICATOR SWITCH SENSE
8 Z2 18BK/LG GROUND
9 G303 20VT/DG (OFF-ROAD
PACKAGE)
LOCKER ENABLE SIGNAL 2
10 D23 20WT/BR -
11 G5 20DB/WT FUSED IGNITION SWITCH OUTPUT (RUN-START)
12 M1 20PK/WT FUSED B(+)
INSTRUMENT CLUSTER C2 - 16 WAY
CAV CIRCUIT FUNCTION
1 C80 20DB/WT (HARD TOP) REAR WINDOW DEFOGGER SWITCH SENSE
2 G10 20LG/RD SEAT BELT SWITCH SENSE
3 G76 20TN/YL PASSENGER DOOR AJ AR SWITCH SENSE
4 G75 20TN DRIVER DOOR AJ AR SWITCH SENSE
5 M2 20YL COURTESY LAMP FEED
6 E2 20OR PANEL LAMPS FEED
7 C81 20LB/WT (HARD TOP) REAR WINDOW DEFOGGER RELAY CONTROL
8 G19 20LG/OR (ABS) ABS WARNING INDICATOR DRIVER
9 G99 20GY/WT BRAKE WARNING INDICATOR DRIVER
10 G304 20VT/DB (OFF-ROAD
PACKAGE)
FRONT LOCKER REQUEST
11 G107 20BK/RD (4X4) 4WD INDICATOR
12 D25 20VT/YL PCI BUS
13 G26 20LB KEY-IN IGNITION SWITCH SENSE
14 G302 20RD/WT (OFF-
ROAD PACKAGE)
LOCKER ENABLE SIGNAL 1
15 E19 20RD PANEL LAMPS DIMMER SIGNAL
16 G300 20VT/WT (OFF-ROAD
PACKAGE)
FRONT LOCKER INDICATOR SWITCH SENSE
LEFT FRONT SPEAKER - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 X53 18DG LEFT FRONT SPEAKER (+)
2 X55 18BR/RD LEFT FRONT SPEAKER (-)
C
O
N
N
E
C
T
O
R
P
I
N
O
U
T
S
182
CONNECTOR PINOUTS
LEFT REAR SPEAKER - BLACK 3 WAY
CAV CIRCUIT FUNCTION
1 X57 20BR/LB LEFT REAR SPEAKER (-)
2 - -
3 X51 18BR/YL LEFT REAR SPEAKER (+)
PASSENGER AIRBAG ON-OFF SWITCH (LHD) - 6 WAY
CAV CIRCUIT FUNCTION
1 F14 18LG/YL FUSED IGNITION SWITCH OUTPUT (RUN)
2 R166 18LG/BR PASSENGER AIRBAG INDICATOR DRIVER
3 R65 18LG/OR PASSENGER AIRBAG MUX SWITCH SENSE
4 - -
5 - -
6 R66 18YL/LG PASSENGER AIRBAG MUX SWITCH RETURN
PASSENGER AIRBAG SQUIB 1 - YELLOW 2 WAY
CAV CIRCUIT FUNCTION
A R44 18DG/YL PASSENGER SQUIB 1 LINE 2
B R42 18BK/YL PASSENGER SQUIB 1 LINE 1
C
O
N
N
E
C
T
O
R
P
I
N
O
U
T
S
183
CONNECTOR PINOUTS
C
O
N
N
E
C
T
O
R
P
I
N
O
U
T
S
184
CONNECTOR PINOUTS
FUSES (PDC)
FUSE
NO.
AMPS FUSED CIRCUIT FUNCTION
1 40A A111 12RD/LB FUSED B(+)
2 40A A4 12BK/PK FUSED B(+)
3 40A A6 12RD/BK FUSED B(+)
4 40A A16 12GY (2.4L) FUSED B(+)
5 20A A30 16RD/WT (A/T) FUSED B(+)
6 30A A2 14PK/BK FUSED B(+)
7 - - -
8 40A A10 12RD/DG (ABS) FUSED B(+)
9 30A A14 14RD/WT FUSED B(+)
9 30A A14 14RD/WT FUSED B(+)
10 40A A3 12RD/WT FUSED B(+)
11 - - -
12 30A A20 12RD/DB (ABS) FUSED B(+)
13 40A F30 12RD/PK FUSED B(+)
14 - - -
15 50A M1 16PK/WT FUSED B(+)
15 50A M1 20PK/WT (ABS) FUSED B(+)
16 15A A142 14DG/PK AUTOMATIC SHUT DOWN RELAY OUTPUT
16 15A F142 18OR/DG AUTOMATIC SHUT DOWN RELAY OUTPUT
17 20A F70 16PK/BK FUSED B(+)
18 20A F31 18VT FUSED B(+)
18 20A F31 18VT FUSED B(+)
19 20A F39 16PK/LG (FRONT FOG LAMPS) FUSED B(+)
20 15A F60 16RD/WT FUSED B(+)
21 10A A17 20RD/GY FUSED B(+)
22 20A A1 18RD FUSED B(+)
23 20A A61 18DG/BK FUSED B(+)
24 20A A88 18RD/DB (OFF-ROAD PACKAGE) FUSED B(+)
25 - - -
26 10A M1 20PK/WT FUSED B(+)
27 20A L9 18BK/WT FUSED B(+)
28 20A F42 18DG/LG AUTOMATIC SHUT DOWN RELAY OUTPUT
28 20A A142 14DG/PK AUTOMATIC SHUT DOWN RELAY OUTPUT
REAR WINDOW DEFOGGER RELAY (IN PDC)
CAV CIRCUIT FUNCTION
C1 A4 12BK/PK FUSED B(+)
C2 C81 20LB/WT REAR WINDOW DEFOGGER RELAY CONTROL
C3 C15 12BK/WT REAR WINDOW DEFOGGER RELAY OUTPUT
C4 F20 20VT/WT FUSED IGNITION SWITCH OUTPUT (RUN)
C5 - -
C
O
N
N
E
C
T
O
R
P
I
N
O
U
T
S
185
CONNECTOR PINOUTS
POWERTRAIN CONTROL MODULE C1 - BLACK 32 WAY
CAV CIRCUIT FUNCTION
1 K18 18RD/YL (4.0L) IGNITION COIL NO. 3 DRIVER
2 F15 18DB/WT FUSED IGNITION SWITCH OUTPUT (RUN-START)
3 - -
4 K4 18BK/LB SENSOR GROUND 1
5 - -
6 T41 18BK/WT PARK/NEUTRAL POSITION SWITCH SENSE
7 K19 18BK/GY IGNITION COIL NO. 1 DRIVER
8 K24 18GY/BK CRANKSHAFT POSITION SENSOR SIGNAL
9 - -
10 K60 18YL/BK IDLE AIR CONTROL NO. 2 DRIVER
11 K40 18BR/WT IDLE AIR CONTROL NO. 3 DRIVER
12 K10 18DB/OR (2.4L) POWER STEERING PRESSURE SWITCH SENSE
13 T141 18YL/RD FUSED IGNITION SWITCH OUTPUT (START)
14 - -
15 K21 18BK/RD INTAKE AIR TEMPERATURE SENSOR SIGNAL
16 K2 18TN/BK ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
17 K7 18OR 5V SUPPLY
18 K44 18TN/YL CMP SIGNAL
19 K39 18GY/RD IDLE AIR CONTROL NO. 1 DRIVER
20 K59 18VT/BK IDLE AIR CONTROL NO. 4 DRIVER
21 - -
22 A14 14RD/WT FUSED B(+)
23 K22 18OR/DB THROTTLE POSITION SENSOR SIGNAL
24 K41 18BK/DG OXYGEN SENSOR 1/1 SIGNAL
25 K141 18TN/WT OXYGEN SENSOR 1/2 SIGNAL
26 K241 18LG/RD (4.0L EX-
CEPT EXPORT/4.0L J APAN
LOW EMISSION VEHICLE)
OXYGEN SENSOR 2/1 SIGNAL
27 K1 18DG/RD MAP SIGNAL
28 - -
29 K341 18TN/WT (4.0L EX-
CEPT EXPORT/4.0L J APAN
LOW EMISSION VEHICLE)
OXYGEN SENSOR 2/2 SIGNAL
30 - -
31 Z12 14BK/TN GROUND
32 Z12 14BK/TN GROUND
C
O
N
N
E
C
T
O
R
P
I
N
O
U
T
S
186
CONNECTOR PINOUTS
POWERTRAIN CONTROL MODULE C2 - WHITE 32 WAY
CAV CIRCUIT FUNCTION
1 - -
2 - -
3 - -
4 K11 18WT/DB FUEL INJ ECTOR NO. 1 DRIVER
5 K13 18YL/WT FUEL INJ ECTOR NO. 3 DRIVER
6 K38 18GY (4.0L) FUEL INJ ECTOR NO. 5 DRIVER
7 - -
8 - -
9 K17 18DB/TN IGNITION COIL NO. 2 DRIVER
10 K20 18DG GENERATOR FIELD
11 - -
12 K58 18BR/DB (4.0L) FUEL INJ ECTOR NO. 6 DRIVER
13 - -
14 - -
15 K12 18TN FUEL INJ ECTOR NO. 2 DRIVER
16 K14 18LB/BR FUEL INJ ECTOR NO. 4 DRIVER
17 - -
18 - -
19 C18 18DB (2.4L) A/C PRESSURE SIGNAL
20 - -
21 - -
22 - -
23 G60 18GY/YL ENGINE OIL PRESSURE SIGNAL
24 - -
25 - -
26 - -
27 G7 18WT/OR VEHICLE SPEED SENSOR SIGNAL
28 - -
29 - -
30 - -
31 K6 18VT/WT 5V SUPPLY
32 - -
C
O
N
N
E
C
T
O
R
P
I
N
O
U
T
S
187
CONNECTOR PINOUTS
POWERTRAIN CONTROL MODULE C3 - GRAY 32 WAY
CAV CIRCUIT FUNCTION
1 C13 18DB/OR (A/C) A/C COMPRESSOR CLUTCH RELAY CONTROL
2 C24 18DB/PK (2.4L) LOW SPEED RADIATOR FAN RELAY CONTROL
3 K51 18DB/YL AUTOMATIC SHUT DOWN RELAY CONTROL
4 V36 18TN/RD (SPEED
CONTROL)
SPEED CONTROL VACUUM SOLENOID CONTROL
5 V35 18LG/RD (SPEED
CONTROL)
SPEED CONTROL VENT SOLENOID CONTROL
6 - -
7 - -
8 K99 18BR/OR OXYGEN SENSOR 1/1 HEATER CONTROL
9 K512 18RD/YL (4.0L) OXYGEN SENSOR DOWNSTREAM HEATER RELAY CONTROL
10 K106 18WT/DG LEAK DETECTION PUMP SOLENOID CONTROL
11 V32 18YL/RD (SPEED
CONTROL)
SPEED CONTROL ON/OFF SWITCH SENSE
12 A142 14DG/PK AUTOMATIC SHUT DOWN RELAY OUTPUT
13 T10 18YL/DG (A/T) TORQUE MANAGEMENT REQUEST SENSE
14 K107 18OR LEAK DETECTION PUMP SWITCH SENSE
15 K118 18PK/YL BATTERY TEMPERATURE SENSOR SIGNAL
16 K299 18BR/WT OXYGEN SENSOR HEATER CONTROL
17 - -
18 - -
19 K31 18BR FUEL PUMP RELAY CONTROL
20 K52 18PK/BK EVAP/PURGE SOLENOID CONTROL
21 C27 18DB (2.4L) HIGH SPEED RADIATOR FAN RELAY CONTROL
22 C21 18DB/OR (A/C) A/C SWITCH SENSE
23 C90 18LG (A/C) A/C SELECT INPUT
24 K29 18WT/PK BRAKE LAMP SWITCH SENSE
25 K125 18WT/DB GENERATOR SOURCE
26 K226 18DB/LG (4.0L) FUEL LEVEL SENSOR SIGNAL
27 D21 18PK SCI TRANSMIT
28 - -
29 D32 18LG/WT SCI RECEIVE
30 D25 18VT/YL PCI BUS
31 - -
32 V37 18RD/LB (SPEED
CONTROL)
SPEED CONTROL SWITCH SIGNAL
C
O
N
N
E
C
T
O
R
P
I
N
O
U
T
S
188
CONNECTOR PINOUTS
RADIO - GRAY 22 WAY
CAV CIRCUIT FUNCTION
1 F60 16RD/WT FUSED B(+)
2 X12 20PK FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
3 E2 20OR PANEL LAMPS DRIVER
4 - -
5 - -
6 - -
7 X54 18VT RIGHT FRONT SPEAKER (+)
8 X56 18DB RIGHT FRONT SPEAKER (-)
9 X55 18BR/RD LEFT FRONT SPEAKER (-)
10 X53 18DG LEFT FRONT SPEAKER (+)
11 Z9 16BK GROUND
12 F60 16RD/WT FUSED B(+)
13 X16 20LG RADIO 12V OUTPUT
14 D25 20VT/YL PCI BUS
15 - -
16 - -
17 - -
18 X51 18BR/YL LEFT REAR SPEAKER (+)
19 X57 18BR/LB LEFT REAR SPEAKER (-)
20 X58 18DB/PK RIGHT REAR SPEAKER (-)
21 X52 18DB/WT RIGHT REAR SPEAKER (+)
22 Z9 16BK GROUND
REAR WINDOW DEFOGGER SWITCH (HARD TOP) - 4 WAY
CAV CIRCUIT FUNCTION
1 Z1 20BK GROUND
2 C80 20DB/WT REAR WINDOW DEFOGGER SWITCH SENSE
3 F81 20DB/RD FUSED REAR WINDOW DEFOGGER RELAY OUTPUT
4 E2 20OR FUSED PANEL LAMPS DIMMER SWITCH SIGNAL
RIGHT FRONT SPEAKER - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 X54 18VT RIGHT FRONT SPEAKER (+)
2 X56 18DB RIGHT FRONT SPEAKER (-)
RIGHT REAR SPEAKER - BLACK 3 WAY
CAV CIRCUIT FUNCTION
1 X58 20DB/PK RIGHT REAR SPEAKER (-)
2 - -
3 X52 20DB/WT RIGHT REAR SPEAKER (+)
C
O
N
N
E
C
T
O
R
P
I
N
O
U
T
S
189
CONNECTOR PINOUTS
SEAT BELT SWITCH (EXCEPT LHD EXPORT) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 G10 20LG/RD SEAT BELT SWITCH SENSE
2 Z1 20BK GROUND
SENTRY KEY IMMOBILIZER MODULE - BLACK 6 WAY
CAV CIRCUIT FUNCTION
1 - -
2 D25 20VT/YL PCI BUS
3 - -
4 F15 20DB FUSED IGNITION SWITCH OUTPUT (RUN-START)
5 Z1 20BK GROUND
6 F33 20PK/RD FUSED B(+)
SUBWOOFER - 12 WAY
CAV CIRCUIT FUNCTION
1 X54 18VT RIGHT FRONT SPEAKER (+)
2 X56 18DB RIGHT FRONT SPEAKER (-)
3 X53 18DG LEFT FRONT SPEAKER (+)
4 X55 18BR/RD LEFT FRONT SPEAKER (-)
5 X16 20LG RADIO 12V OUTPUT
6 X13 16BK/RD FUSED IGNITION SWITCH OUTPUT
7 X52 18GY/DB RIGHT REAR SPEAKER (+)
8 X58 18DB/PK RIGHT REAR SPEAKER (-)
9 X51 18BR/YL LEFT REAR SPEAKER (+)
10 X57 18BR/LB LEFT REAR SPEAKER (-)
11 - -
12 Z9 16BK/WT GROUND
C
O
N
N
E
C
T
O
R
P
I
N
O
U
T
S
190
CONNECTOR PINOUTS
TRANSMISSION CONTROL MODULE - 60 WAY
CAV CIRCUIT FUNCTION
1 T1 18LG/BK TRS T1 SENSE
2 - -
3 T3 18VT TRS T3 SENSE
4 - -
5 - -
6 K24 18GY/BK CRANKSHAFT POSITION SENSOR SIGNAL
7 D21 18PK SCI TRANSMIT
8 T141 18YL/RD FUSED IGNITION SWITCH OUTPUT (START)
9 T9 18OR/BK OVERDRIVE PRESSURE SWITCH SENSE
10 T10 18YL/DG TORQUE MANAGEMENT REQUEST SENSE
11 F15 18DB/WT FUSED IGNITION SWITCH OUTPUT (RUN-START)
12 K22 18OR/DB THROTTLE POSITION SENSOR SIGNAL
13 T13 18DB/BK SPEED SENSOR GROUND
14 T14 18LG/WT OUTPUT SPEED SENSOR SIGNAL
15 K30 18PK TRANSMISSION CONTROL RELAY CONTROL
16 T16 16RD TRANSMISSION CONTROL RELAY OUTPUT
17 T16 16RD TRANSMISSION CONTROL RELAY OUTPUT
18 T56 18DG/LB OVERDRIVE OFF SWITCH INDICATOR
19 T19 16WT 2-4 SOLENOID CONTROL
20 T20 16LB LOW/REVERSE SOLENOID CONTROL
21 - -
22 - -
23 - -
24 - -
25 - -
26 - -
27 - -
28 - -
29 - -
30 - -
31 - -
32 - -
33 - -
34 - -
35 - -
36 - -
37 - -
38 - -
39 - -
40 - -
41 T411 18WT/PK TRS T41 SENSE
42 T42 16VT/WT TRS T42 SENSE
43 D25 18VT/YL PCI BUS
44 - -
45 - -
46 D20 18LG SCI RECEIVE
47 T47 18YL/BK 2-4 PRESSURE SWITCH SENSE
48 - -
49 T6 18OR/WT OVERDRIVE OFF SWITCH SENSE
50 T50 18DG LOW/REVERSE PRESSURE SWITCH SENSE
51 K4 18BK/LB SENSOR GROUND 1
52 T52 18RD/BK INPUT SPEED SENSOR SIGNAL
53 Z112 16BK GROUND
54 T54 18VT TRANSMISSION TEMPERATURE SENSOR SIGNAL
55 - -
56 A30 16RD/WT FUSED B(+)
57 Z113 16BK/YL GROUND
58 - -
59 T59 16PK UNDERDRIVE SOLENOID CONTROL
60 T60 16BR OVERDRIVE SOLENOID CONTROL
C
O
N
N
E
C
T
O
R
P
I
N
O
U
T
S
191
CONNECTOR PINOUTS
NOTES
192
10.0 SCHEMATIC DIAGRAMS
10. 1 AIRBAG SYSTEM
S
C
H
E
M
A
T
I
C
D
I
A
G
R
A
M
S
193
SCHEMATIC DIAGRAMS
10. 2 AUDIO SYSTEM
10. 2. 1 BASE AUDIO SYSTEM
S
C
H
E
M
A
T
I
C
D
I
A
G
R
A
M
S
194
SCHEMATIC DIAGRAMS
10. 2. 2 PREMIUM AUDIO SYSTEM
S
C
H
E
M
A
T
I
C
D
I
A
G
R
A
M
S
195
SCHEMATIC DIAGRAMS
10. 3 CHIME SYSTEM
10. 4 COMPASS/TEMPERATURE MIRROR
S
C
H
E
M
A
T
I
C
D
I
A
G
R
A
M
S
196
SCHEMATIC DIAGRAMS
10. 5 INSTRUMENT CLUSTER
S
C
H
E
M
A
T
I
C
D
I
A
G
R
A
M
S
197
SCHEMATIC DIAGRAMS
10. 5. 1 INSTRUMENT CLUSTER/AXLE LOCKER SYSTEM
S
C
H
E
M
A
T
I
C
D
I
A
G
R
A
M
S
198
SCHEMATIC DIAGRAMS
10. 5 INSTRUMENT CLUSTER (Continued)
10. 6 INTERIOR LIGHTING
S
C
H
E
M
A
T
I
C
D
I
A
G
R
A
M
S
199
SCHEMATIC DIAGRAMS
10. 7 REAR DEFOGGER
S
C
H
E
M
A
T
I
C
D
I
A
G
R
A
M
S
200
SCHEMATIC DIAGRAMS
10. 8 VEHICLE COMMUNICATIONS
S
C
H
E
M
A
T
I
C
D
I
A
G
R
A
M
S
201
SCHEMATIC DIAGRAMS
TABLE OF CONTENTS
1.0 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.1 SYSTEM COVERAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.2 SIX-STEP TROUBLESHOOTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . .1
2.0 IDENTIFICATION OF SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
3.0 SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION . . . . . . . . . . . . . . . . . . . . . .1
3.1 TEVES MARK 20I SYSTEM DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
3.1.1 PEDAL FEEL/VEHICLE CHARACTERISTICS. . . . . . . . . . . . . . . . . . . . .2
3.1.2 SYSTEM COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
3.1.3 ABS AND BRAKE WARNING INDICATORS. . . . . . . . . . . . . . . . . . . . . .2
3.1.4 CONTROLLER ANTILOCK BRAKE (CAB) . . . . . . . . . . . . . . . . . . . . . . .2
3.1.5 HYDRAULIC CONTROL UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
3.1.6 RELAYS/SWITCHES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
3.1.7 SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
3.2 DIAGNOSTIC TROUBLE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
3.2.1 SYSTEM INITIALIZATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
3.2.2 DIAGNOSTIC MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
3.2.3 INTERMITTENT DIAGNOSTIC TROUBLE CODES . . . . . . . . . . . . . . . .4
3.3 AXLE LOCK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
3.3.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
3.3.2 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
3.4 USING THE DRBIIIா . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
3.5 DRBIIIா ERROR MESSAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
3.5.1 DRBIIIா DOES NOT POWER UP (BLANK SCREEN) . . . . . . . . . . . . . .5
3.5.2 DISPLAY IS NOT VISIBLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
4.0 DISCLAIMERS, SAFETY WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
4.1 DISCLAIMERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
4.2 SAFETY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
4.2.1 TECHNICIAN SAFETY INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . .6
4.2.2 VEHICLE PREPARATION FOR TESTING. . . . . . . . . . . . . . . . . . . . . . . .6
4.2.3 SERVICING SUB-ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
4.2.4 DRBIIIா SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
4.3 WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
4.3.1 VEHICLE DAMAGE WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
4.3.2 ROAD TESTING A COMPLAINT VEHICLE. . . . . . . . . . . . . . . . . . . . . . .7
4.4 DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
5.0 REQUIRED TOOLS AND EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
6.0 GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
7.0 DIAGNOSTIC INFORMATION AND PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
BRAKES (CAB)
CAB POWER FEED CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
CONTROLLER FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
G-SWITCH NOT PROCESSABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
LEFT FRONT SENSOR CIRCUIT FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
LEFT REAR SENSOR CIRCUIT FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
i
TABLE OF CONTENTS - Continued
RIGHT FRONT SENSOR CIRCUIT FAILURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
RIGHT REAR SENSOR CIRCUIT FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
LEFT FRONT SENSOR SIGNAL FAILURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
LEFT REAR SENSOR SIGNAL FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
RIGHT FRONT SENSOR SIGNAL FAILURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
RIGHT REAR SENSOR SIGNAL FAILURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
PUMP MOTOR NOT WORKING PROPERLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
SYSTEM OVER VOLTAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
SYSTEM UNDER VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
*ABS WARNING INDICATOR ALWAYS ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
*ABS WARNING INDICATOR INOPERATIVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
*BRAKE LAMP SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
*FRONT AXLE LOCK INDICATOR REMAINS FLASHING. . . . . . . . . . . . . . . . . . . . . . .38
*NO RESPONSE FROM CONTROLLER ANTILOCK BRAKE . . . . . . . . . . . . . . . . . . . .40
*REAR AXLE LOCK INDICATOR REMAINS FLASHING . . . . . . . . . . . . . . . . . . . . . . . .42
*REAR AXLE LOCK INOPERATIVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
VERIFICATION TESTS
VERIFICATION TESTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
8.0 COMPONENT LOCATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
8.1 CONTROLLER ANTILOCK BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
8.2 DATA LINK CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
8.3 G-SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
8.4 FUSES & RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
8.5 WHEEL SPEED SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
8.6 WHEEL SPEED SENSOR CONNECTORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
8.7 BRAKE SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
8.7.1 PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
8.7.2 BRAKE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
9.0 CONNECTOR PINOUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
AXLE LOCK SWITCH (OFF-ROAD PACKAGE) - 8 WAY. . . . . . . . . . . . . . . . . . . . . . . .53
BRAKE LAMP SWITCH - GRAY 6 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
BRAKE WARNING INDICATOR SWITCH - BLACK 2 WAY . . . . . . . . . . . . . . . . . . . . . .53
C115 (OFF-ROAD PACKAGE) - BLACK (ENGINE SIDE) . . . . . . . . . . . . . . . . . . . . . . .53
C115 (OFF-ROAD PACKAGE) - BLACK (FRONT FEEDBACK OVERLAY SIDE). . . . .54
C116 (OFF-ROAD PACKAGE) - LT GRAY (ENGINE SIDE) . . . . . . . . . . . . . . . . . . . . . .54
C116 (OFF-ROAD PACKAGE) - LT GRAY (REAR FEEDBACK OVERLAY SIDE) . . . .54
CLUTCH PEDAL POSITION SWITCH (M/T) - BLACK 2 WAY. . . . . . . . . . . . . . . . . . . .54
CONTROLLER ANTILOCK BRAKE - 25 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
DATA LINK CONNECTOR - BLACK 16 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
FRONT LOCKER INDICATOR SWITCH (OFF-ROAD PACKAGE) - BLACK 2 WAY . .56
FRONT LOCKER PUMP (OFF-ROAD PACKAGE) - LT GRAY 3 WAY . . . . . . . . . . . . .56
G-SWITCH (LHD) - 3 WAY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
INSTRUMENT CLUSTER C1 - 12 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
INSTRUMENT CLUSTER C2 - 16 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
LEFT FRONT WHEEL SPEED SENSOR - 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
LEFT FRONT WHEEL SPEED SENSOR (SENSOR SIDE) - 2 WAY . . . . . . . . . . . . . .57
LEFT REAR WHEEL SPEED SENSOR - 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
LEFT REAR WHEEL SPEED SENSOR (SENSOR SIDE) - 2 WAY. . . . . . . . . . . . . . . .58
ii
TABLE OF CONTENTS - Continued
FUSES (PDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
FRONT LOCKER RELAY (IN PDC/OFF-ROAD PACKAGE). . . . . . . . . . . . . . . . . . . . . .60
REAR LOCKER RELAY (IN PDC/OFF-ROAD PACKAGE) . . . . . . . . . . . . . . . . . . . . . . .60
REAR LOCKER INDICATOR SWITCH (OFF-ROAD PACKAGE) - BLACK 2 WAY. . . .61
REAR LOCKER PUMP (OFF-ROAD PACKAGE) - LT GRAY 3 WAY . . . . . . . . . . . . . .61
RIGHT FRONT WHEEL SPEED SENSOR - BLACK 2 WAY . . . . . . . . . . . . . . . . . . . . .61
RIGHT FRONT WHEEL SPEED SENSOR (SENSOR SIDE) - 2 WAY . . . . . . . . . . . . .62
RIGHT REAR WHEEL SPEED SENSOR - BLACK 2 WAY . . . . . . . . . . . . . . . . . . . . . .62
RIGHT REAR WHEEL SPEED SENSOR (SENSOR SIDE) - 2 WAY . . . . . . . . . . . . . .62
VEHICLE SPEED SENSOR - BLACK 3 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
10.0 SCHEMATIC DIAGRAMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
10.1 TEVES MARK 20I CONTROLLER ANTILOCK BRAKE - ABS. . . . . . . . . . . . . . .65
10.2 AXLE LOCK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
iii
NOTES
iv
1.0 INTRODUCTION
The procedures contai ned i n thi s manual i ncl ude
al l the speci fi cati ons, i nstructi ons, and graphi cs
needed to di agnose the TJ Chassi s system prob-
l ems: Teves Mark 20i Anti l ock Braki ng System
(ABS) and Axl e Lock. The di agnosti cs i n thi s man-
ual are based on the fai l ure condi ti on or symptom
bei ng present at ti me of di agnosi s.
Fol l ow the recommendati ons bel ow when choos-
i ng your di agnosti c path.
1. Fi rst make sure the DRBI I I ௡ i s communi cati ng
wi th the CAB. I f the DRBI I I ௡ di spl ays a ‘‘No
Response’’ condi ti on, you must di agnose that
fi rst.
2. Read DTC’s (di agnosti c troubl e codes) wi th the
DRBI I I ௡.
3. I f no DTC’s are present, i denti fy the customer
compl ai nt.
4. Once the DTC or customer compl ai nt i s i denti -
fi ed, l ocate the matchi ng test i n the Tabl e of
Contents and begi n to di agnose the symptom.
Al l component l ocati on vi ews are i n Secti on 8.0.
Al l connector pi nouts are i n Secti on 9.0. Al l sche-
mati cs are i n Secti on 10.0.
An asteri sk (*) pl aced before the symptom de-
scri pti on i ndi cates a customer compl ai nt.
When repai rs are requi red, refer to the appropri -
ate servi ce manual for the proper removal and
repai r procedure.Di agnosti c procedures change every
year. New di agnosti c systems may be added; carryover
systems may be enhanced. READ THI S MANUAL
BEFORE TRYI NG TO DI AGNOSE A VEHI CLE DI -
AGNOSTI C TROUBLE CODE. I t i s recommended
that you revi ew the enti re manual to become fami l i ar
wi th al l new and changed di agnosti c procedures.
After usi ng thi s book, i f you have any comments
or recommendati ons, pl ease fi l l out the form at the
back of the book and mai l i t back to us.
1. 1 SYSTEM COVERAGE
Thi s di agnosti c manual covers the Teves Mark
20i Anti l ock Braki ng System (ABS) found on the
Jeep Wrangl er. Di agnosi s of the Axl e Lock i s cov-
ered i n thi s manual .
1. 2 SIX-STEP TROUBLESHOOTING
PROCEDURE
Di agnosi s of the anti l ock brake system i s done i n
si x basi c steps:
• veri fi cati on of compl ai nt
• veri fi cati on of any rel ated symptoms
• symptom anal ysi s
• probl em i sol ati on
• repai r of i sol ated probl em
• veri fi cati on of proper operati on
2.0 IDENTIFICATION OF
SYSTEM
Vehi cl es equi pped wi th the Teves Mark 20i an-
ti l ock brake system can be i denti fi ed by the pres-
ence of the hydraul i c control uni t (HCU) l ocated
under the hood near the power brake booster. Vehi -
cl es equi pped wi th Axl e Lock can be i denti fi ed by
the presence of the Axl e Lock Swi tch l ocated on the
l ower center of the i nstrument panel .
3.0 SYSTEM DESCRIPTION AND
FUNCTIONAL OPERATION
3. 1 TEVES MARK 20I SYSTEM
DESCRIPTION
An el ectroni c control modul e i s used to moni tor
wheel speeds and to modul ate (control ) hydraul i c
pressure i n each brake channel to prevent wheel
l ock-up duri ng braki ng.
Duri ng a non-ABS stop, the system functi ons as a
standard front/rear spl i t confi gurati on. The pri -
mary hydraul i c system suppl i es brake fl ui d pres-
sure to the front brakes, and the secondary hydrau-
l i c system suppl i es the rear brakes. A conventi onal
combi nati on/proporti oni ng val ve i s used.
Duri ng an ABS stop, the system sti l l uses the
front/rear hydraul i c spl i t; however, the brakes sys-
tem pressure i s further spl i t i nto three control
channel s. Duri ng ABS operati on, the front wheel s
are control l ed i ndependentl y and are on two sepa-
rate control channel s. The rear wheel s are con-
trol l ed together through one control channel . By
usi ng a separate control channel for each front
wheel , more steeri ng control i s mai ntai ned duri ng
maxi mum braki ng.
Duri ng an anti l ock stop, ‘‘wheel l ock-up’’ does not
necessari l y mean that the wheel has l ocked, i t
means onl y that the wheel i s turni ng sl ower than
the vehi cl e speed. Thi s i s cal l ed ‘‘wheel sl i p’’ and i s
i ndi cated as a percentage. 0% sl i p means that the
wheel i s rol l i ng free and 100% sl i p means that the
wheel i s l ocked. The anti l ock system mai ntai ns an
average of approxi matel y 20% wheel sl i p.
I t i s i mportant to remember that the anti l ock
brake system does not shorten the vehi cl e stoppi ng
di stance under al l dri vi ng condi ti ons, but provi des
i mproved control of the vehi cl e whi l e stoppi ng.
Vehi cl e stoppi ng di stance i s sti l l dependent on ve-
hi cl e speed, wei ght, ti res, road surface, and other
factors.
1
GENERAL INFORMATION
3. 1. 1 PEDAL FEEL/VEHICLE
CHARACTERISTICS
There are several pedal feel /vehi cl e characteri s-
ti cs that are consi dered normal for anti l ock braki ng
that may requi re further expl anati on.
When stoppi ng condi ti ons acti vate the anti l ock
brakes, the dri ver may feel some vi brati ons/
pul sati ons i n the brake pedal and may hear the
sol enoi d val ves cl i cki ng and the pump motor run-
ni ng. The vi brati ons/pul sati ons are caused by the
i sol ati ng, bui l di ng and decayi ng of brake fl ui d pres-
sure wi thi n the brake l i nes. The ABS prevents
compl ete wheel l ock-up, but some wheel sl i p i s
requi red for the best braki ng performance. Thi s sl i p
may resul t i n some ti re chi rpi ng, dependi ng on the
road surface. Thi s chi rpi ng shoul d not be i nter-
preted as total wheel l ock-up. Total wheel l ock-up
l eaves bl ack ti re marks on dry pavement. Anti l ock
braki ng may l eave some l i ght marks.
At the end of an ABS stop, the ABS system may
not functi on bel ow 5 Km/h (3 mph). There may be a
sl i ght brake pedal drop anyti me the ABS i s deacti -
vated.
I n case of braki ng on a bumpy surface, the ABS
modul e may detect wheel l ocki ng tendenci es due to
wheel hop and cycl e ABS. I n that event the brake
pedal may pul sate wi th a percei ved l oss of decel er-
ati on. ABS braki ng may al so be acti vated at ti mes
whi l e on dry pavement wi th sand, gravel , or other
l oose debri s on the road.
I t shoul d be noted that the pul sati ng pedal feel
characteri sti c wi l l not i l l umi nate the brake warni ng
i ndi cators or set a di agnosti c troubl e code that i s
stored i n the Control l er Anti l ock Brake (CAB).
When i nvesti gati ng a hard pedal feel , i nspect the
sensor and tone wheel teeth for chi ps/broken teeth,
damaged sensor pol e ti ps, excessi ve runout of the
tone wheel , or excessi ve gap.
3. 1. 2 SYSTEM COMPONENTS
Antilock Brake System
• control l er anti l ock brake (CAB)
• vacuum booster
• master cyl i nder (w/center val ves)
• hydraul i c control uni t (HCU)
val ve bl ock assembl y: 6 val ve sol enoi ds (3 i nl et
val ves, 3 outl et val ves), 3
accumul ators
• pump/motor assembl y: 1 motor
2 pumps
• G (accel erati on) swi tch
• 1 proporti oni ng val ve
• 4 wheel speed sensor/tone wheel assembl i es
• ABS warni ng i ndi cator
• fuses and wi ri ng harness
• fl ui d reservoi r (i ntegral part of master cyl i nder
assembl y)
3. 1. 3 ABS AND BRAKE WARNING
INDICATORS
The amber ABS warni ng i ndi cator i s l ocated i n
the i nstrument cl uster. I t i s used to i nform the
dri ver that the anti l ock functi on has been turned off
due to a system mal functi on. On a TJ model the
warni ng i ndi cator i s control l ed by the CAB and the
ABS rel ay. The CAB control s the i ndi cator by di -
rectl y groundi ng the ABS rel ay control ci rcui t. The
ABS rel ay grounds the i ndi cator ci rcui t when i t i s
de-energi zed.
The red brake warni ng i ndi cator i s l ocated i n the
i nstrument cl uster. I t can be acti vated by appl i ca-
ti on of the parki ng brake, l ow brake fl ui d l evel or by
turni ng the i gni ti on swi tch to the start posi ti on.
3. 1. 4 CONTROLLER ANTILOCK BRAKE
(CAB)
The control l er anti l ock brake (CAB) i s a
mi croprocessor-based devi ce that moni tors wheel
speeds and control s the anti l ock functi ons.
The pri mary functi ons of the CAB are:
• moni tor wheel speeds
• detect wheel l ocki ng tendenci es
• control fl ui d pressure modul ati on to the brakes
duri ng anti l ock stop operati on
• moni tor the system for proper operati on
• provi de communi cati on to the DRBI I I ௡ whi l e i n
di agnosti c mode
• control the ABS rel ay
• store di agnosti c i nformati on i n non-vol ati l e mem-
ory
The CAB conti nuousl y moni tors the speed of each
wheel . When a wheel l ocki ng tendency i s detected,
the CAB wi l l command the appropri ate val ve i n the
HCU to modul ate brake fl ui d pressure to that
wheel . Brake pedal posi ti on i s mai ntai ned duri ng
an anti l ock stop by bei ng a cl osed system wi th the
use of three accumul ators. The CAB conti nues to
control pressure i n i ndi vi dual hydraul i c ci rcui ts
unti l a wheel l ocki ng tendency i s no l onger present.
The CAB turns on the pump/motor duri ng an an-
ti l ock stop.
The anti l ock brake system i s constantl y moni -
tored by the CAB for proper operati on. I f the CAB
detects a system mal functi on, i t can di sabl e the
anti l ock system and turn on the ABS warni ng
i ndi cator. I f the anti l ock functi on i s di sabl ed, the
system wi l l revert to standard base brake system
operati on.
2
GENERAL INFORMATION
The CAB i nputs i ncl ude the fol l owi ng:
• four wheel speed sensors
• brake l amp swi tch
• i gni ti on swi tch
• battery vol tage
• di agnosti c communi cati on
• G swi tch (accel erati on swi tch)
The CAB outputs i ncl ude the fol l owi ng:
• si x val ve/sol enoi d dri vers
• pump/motor actuati on
• ABS warni ng i ndi cator control
• di agnosti c communi cati on
3. 1. 5 HYDRAULIC CONTROL UNIT
The hydraul i c control uni t (HCU) contai ns the
val ve bl ock assembl y, three accumul ators, and the
pump/motor assembl y.
Valve Block Assembly: The val ve bl ock assem-
bl y contai ns 6 val ves wi th three i nl et val ves and
three outl et val ves. The i nl et val ves are spri ng-
l oaded i n the open posi ti on and the outl et val ves are
spri ng l oaded i n the cl osed posi ti on. Duri ng an
anti l ock stop, these val ves are cycl ed to mai ntai n
the proper sl i p rati o for each channel . I f a wheel
l ocks, the i nl et val ve i s cl osed to prevent any further
pressure i ncrease. Then the outl et val ve i s opened
to rel ease the pressure to the accumul ators unti l
the wheel i s no l onger sl i ppi ng. Once the wheel i s no
l onger sl i ppi ng, the outl et val ve i s cl osed and the
i nl et val ve i s opened to reappl y pressure. I f the
wheel i s decel erati ng wi thi n i ts predetermi ned l i m-
i ts (proper sl i p rati o), both val ves wi l l cl ose to hol d
the pressure constant.
Pump/Motor Assembly: The pump/motor as-
sembl y provi des the extra amount of fl ui d needed
duri ng anti l ock braki ng. The pump i s suppl i ed fl ui d
that i s rel eased to the accumul ators when the outl et
val ve i s opened duri ng an anti l ock stop. The pump
i s al so used to drai n the accumul ator ci rcui ts after
the anti l ock stop i s compl ete. The pump i s operated
by an i ntegral el ectri c motor. Thi s motor i s con-
trol l ed by the CAB. The CAB turns on the motor
when an anti l ock stop i s detected. The pump con-
ti nues to run duri ng the anti l ock stop and i s turned
off approxi matel y 3-5 seconds after the stop i s
compl ete. The pump mechani sm consi sts of two
opposi ng pi stons operated by an eccentri c cam. One
pi ston suppl i es the pri mary hydraul i c ci rcui t. The
opposi ng pi ston suppl i es the secondary hydraul i c
ci rcui t. I n operati on, one pi ston draws fl ui d from
the accumul ators. The opposi ng pi ston pumps fl ui d
to the val ve body sol enoi ds. The CAB moni tors the
pump/motor operati on.
Accumulators: The accumul ators provi de tem-
porary fl ui d storage duri ng an anti l ock stop and are
drai ned by the pump/motor.
3. 1. 6 RELAYS/SWITCHES
Relays: The ABS Rel ay i s l ocated i n the power
di stri buti on center (PDC). When the rel ay i s de-
energi zed, i t suppl i es a ground to turn on the ABS
warni ng i ndi cator. The ABS rel ay i s control l ed by
the CAB. The CAB energi zes the rel ay when i t
recei ves an i gni ti on i nput si gnal .
3. 1. 7 SENSORS
Wheel Speed Sensors and Tone Wheels: One
wheel speed sensor (WSS i s l ocated at each wheel
and sends a smal l AC si gnal to the Control l er
Anti l ock Brake (CAB). Thi s vol tage i s generated by
magneti c i nducti on when a toothed sensor ri ng
(tone wheel ) passes by a stati onary magneti c sensor
(wheel speed sensor). The CAB converts the AC
si gnal s i nto di gi tal si gnal s for each wheel .
The front wheel sensor i s attached to a boss i n the
steeri ng knuckl e. The tone wheel i s an i ntegral part
of the front axl e shaft. The rear speed sensor i s
mounted i n the cal i per adapter pl ate (rear di sc onl y)
and the rear tone wheel i s an i ntegral part of the
rear rotor hub. The front wheel speed sensor ai r gap
i s NOT adjustabl e. The correct front wheel speed
sensor ai r gap i s from 0.40mm to 1.3mm (0.016Љ to
0.051Љ). Preferred rear sensor ai r gap for drum
brake systems i s 1.1mm (0.043Љ). Acceptabl e ai r gap
range i s 0.92mm to 1.275mm (0.036Љ to 0.050Љ). Al l
wheel speed sensors have a resi stance between 900
and 1300 ohms.
Correct anti l ock system operati on i s dependent
on correct wheel speed si gnal s from the wheel speed
sensors. The vehi cl e’s wheel s and ti res shoul d al l be
the same si ze and type. I n addi ti on, the ti res shoul d
be i nfl ated to the recommended pressures for opti -
mum system operati on. Vari ati ons i n wheel and ti re
si ze or si gni fi cant vari ati ons i n i nfl ati on pressure
can produce i naccurate wheel speed si gnal s; how-
ever, the system wi l l conti nue to functi on when
usi ng the mi ni -spare. When dri ven over rough road
surfaces, the rear wheel speed sensor si gnal s may
be errati c and cause a fal se troubl e code.
G (Acceleration) Switch: The CAB moni tors
the accel erati on swi tch at al l ti mes. The swi tch
assembl y contai ns three mercury swi tches that
moni tor vehi cl e decel erati on rates (G-force). Sud-
den, rapi d changes i n vehi cl e and wheel decel era-
ti on rate tri gger the swi tch, sendi ng a si gnal to the
CAB. The swi tch assembl y responds to three decel -
erati on rates; two for forward braki ng and one for
rearward braki ng.
3
GENERAL INFORMATION
3. 2 DIAGNOSTIC TROUBLE CODES
The Teves Mark 20i Anti l ock Brake System (ABS)
modul e may report any of the fol l owi ng di agnosti c
troubl e codes:
• Control l er Fai l ure
• G Swi tch Not Processabl e
• Left Front Sensor Ci rcui t Fai l ure
• Left Front Sensor Si gnal Fai l ure
• Left Rear Sensor Ci rcui t Fai l ure
• Left Rear Sensor Si gnal Fai l ure
• CAB Power Feed Ci rcui t
• System Over vol tage
• System Under vol tage
• Pump Motor Not Worki ng Properl y
• Ri ght Front Sensor Ci rcui t Fai l ure
• Ri ght Front Sensor Si gnal Fai l ure
• Ri ght Rear Sensor Ci rcui t Fai l ure
• Ri ght Rear Sensor Si gnal Fai l ure
Di agnosti c troubl e codes are retai ned i n memory
unti l erased usi ng the DRBI I I ௡, or automati cal l y
erased after 255 key cycl es.
3. 2. 1 SYSTEM INITIALIZATION
System i ni ti al i zati on starts when the key i s
turned to RUN. At thi s poi nt, the CAB performs a
compl ete sel f-check of al l el ectri cal components i n
the anti l ock brake systems.
At around 19 km/h (12 mi l es per hour), the pump
motor i s bri efl y acti vated to ensure operati on, and
wheel speed sensor ci rcui try i s checked. I f the brake
pedal i s appl i ed when the vehi cl e reaches 19 km/h
(12 mph), thi s check wi l l be del ayed unti l 40 km/h
(25 mph). I f, duri ng the dynami c test, the brake
pedal i s appl i ed, the dri ver may feel the test
through brake pedal pul sati ons. Thi s i s a normal
condi ti on. Throughout the remai nder of the dri ve
cycl e, ongoi ng tests are performed, and the CAB
moni tors ABS ci rcui ts for conti nui ty.
I f any component causes a di agnosti c troubl e code
duri ng system i ni ti al i zati on or dynami c check, the
CAB wi l l i l l umi nate the ABS warni ng i ndi cator.
3. 2. 2 DIAGNOSTIC MODE
To enter di agnosti c mode, vehi cl e speed must be
bel ow 10 km/h (6 mph), a ‘‘no response’’ message
wi l l be di spl ayed by the DRBI I I ௡. The fol l owi ng are
characteri sti cs of di agnosti c mode:
• The ABS warni ng i ndi cator wi l l fl ash. I f a hard
di agnosti c troubl e code i s present, such as a
Speed Sensor Ci rcui t or Si gnal Fai l ure troubl e
code or CAB Power Feed Ci rcui t di agnosti c trou-
bl e code, the i ndi cator wi l l be i l l umi nated wi thout
bl i nki ng and l i mi ted di agnosti c operati ons onl y
wi l l be avai l abl e unti l the di agnosti c troubl e code
condi ti on i s corrected.
• Anti l ock operati on i s di sabl ed.
3. 2. 3 INTERMITTENT DIAGNOSTIC
TROUBLE CODES
I f the mal functi on i s not present whi l e perform-
i ng a test procedure, the di agnosti c procedures wi l l
not l ocate the probl em. I n thi s case, the code can
onl y suggest an area to i nspect. Check for the
fol l owi ng:
• l oose or corroded connecti ons
• damaged components (sensors, tone wheel s espe-
ci al l y)
• damaged wi ri ng
• excessi ve axl e shaft runout
• brake system hydraul i c l eaks
• base brake system probl ems, non-ABS rel ated.
I f no obvi ous probl ems are found, erase di agnosti c
troubl e codes and, wi th the key on, wi ggl e the wi re
harness and connectors. Recheck for codes peri odi -
cal l y as you work through the system. Thi s proce-
dure may uncover an i ntermi ttent or di ffi cul t to
l ocate mal functi on.
3. 3 AXLE LOCK
3. 3. 1 GENERAL
For thi s vehi cl e, the Axl e Lock has no dedi cated
modul e control l er. A manual swi tch l ocated on the
i nstrument panel control s the system. No DTC’s
wi l l occur for thi s system.
3. 3. 2 DESCRIPTION
The axl e l ock has the abi l i ty to l ock the front and
rear axl e di fferenti al s. The system components are
the i nstrument cl uster, axl e l ock swi tch, front and
rear l ocker rel ays, front and rear l ocker pumps, and
l ocker i ndi cator swi tches. To operate both l ockers
three requi rements need to be met:
1. i gni ti on i n the ON posi ti on
2. transfer case range sensor i ndi cati ng 4 “LOW”
range
3. vehi cl e speed l ess than 16km/h (10 mph)
The 16km/h (10 mph) engagement i s for engage-
ment onl y. Al l axl es wi l l remai n l ocked i f vehi cl e
speed does not exceed 72 km/h (45 mph).
The i nstrument cl uster has the control l ogi c that
moni tors these requi rements. I f the requi rements
are not met the axl e l ock swi tch wi l l be di sabl ed.
The axl e l ock swi tch recei ves the enabl e si gnal s
from the i nstrument cl uster. Any subsequent down-
4
GENERAL INFORMATION
ward press of the axl e l ock swi tch wi l l operate the
front l ocker rel ay and front l ocker pump. The fi rst
downward press on the axl e l ock swi tch l ocks the
rear axl e, the second downward press l ocks the
front axl e (rear i s sti l l l ocked), the thi rd downward
press unl ocks the front axl e (rear i s sti l l l ocked), the
fourth downward press l ocks the front axl e (rear
axl e i s sti l l l ocked). An upward press on the axl e
l ock swi tch at any ti me wi l l unl ock any axl e that i s
currentl y l ocked.
The enabl ed axl e l ock swi tch energi zes the l ocker
rel ay and vol tage i s sent to the l ocker pump to
suppl y 5 psi of ai r to the axl e al l owi ng the di fferen-
ti al to l ock up. The “axl e l ock” i ndi cator on the
i nstrument cl uster fl ashes duri ng the transi ti on
state. The i nstrument cl uster i s seeki ng l ock feed-
back from the l ocki ng i ndi cator swi tch. Wi th a
successful l ock request the “axl e l ock” i ndi cator wi l l
be i l l umi nated and a chi me wi l l sound.
I f an axl e i s engaged the axl e l ock swi tch remai ns
enabl ed unti l al l axl es are unl ocked, regardl ess i f
the key i s removed from the i gni ti on swi tch. I f the
i gni ti on key i s removed and ei ther axl e i s l ocked the
i nstrument cl uster “axl e l ock” i ndi cator to the cor-
respondi ng axl e wi l l fl ash and the chi me wi l l sound
three ti mes to al ert of battery di scharge. Fl ashi ng
“axl e l ock” i ndi cators wi l l conti nue unti l axl es are
unl ocked. Once the axl es have been l ocked i t wi l l
remai n l ocked unti l one of the fol l owi ng happens:
1. an upward press of the axl e l ock swi tch for al l
l ocked axl es or downward press for front axl e
onl y
2. transfer case i s shi fted out of 4 “LOW” range
3. vehi cl e speed exceeds 72 km/h (45 mph)
4. l oss of battery power
3. 4 USING THE DRBIIIா
Refer to the DRBI I I ௡ user ’s gui de for i nstructi ons
and assi stance wi th readi ng di agnosti c troubl e
codes, erasi ng troubl e codes and other DRBI I I ௡
functi ons.
3. 5 DRBIIIா ERROR MESSAGES
Under normal operati on, the DRBI I I ௡ wi l l di s-
pl ay one of onl y two error messages:
– User–Requested WARM Boot or User–Re-
quested COLD Boot
Thi s i s a sampl e of such an error message di spl ay:
ver: 2.14
date: 26 Jul 93
fi l e: key_i tf.cc
date: Jul 26 1993
l i ne: 548
err: 0x1
User-Requested COLD Boot
Press MORE to swi tch between thi s di spl ay
and the appl i cati on screen.
Press F4 when done noti ng i nformati on.
3. 5. 1 DRBIIIா DOES NOT POWER UP
(BLANK SCREEN)
I f the LED’s do not l i ght or no sound i s emi tted at
start up, check for l oose cabl e connecti ons or a bad
cabl e. Check the vehi cl e battery vol tage (data l i nk
16-way connector cavi ty 16). A mi ni mum of 11 vol ts
i s requi red to adequatel y power the DRBI I I ௡. Al so,
check for a good ground at the DLC.
I f al l connecti ons are proper between the
DRBI I I ௡ and the vehi cl e or other devi ces, and the
vehi cl e battery i s ful l y charged, and i noperati ve
DRBI I I ௡ may be the resul t of faul ty cabl e or vehi cl e
wi ri ng.
3. 5. 2 DISPLAY IS NOT VISIBLE
Low temperatures wi l l affect the vi si bi l i ty of the
di spl ay. Adjust the contrast to compensate for thi s
condi ti on.
4.0 DISCLAIMERS, SAFETY
WARNINGS
4. 1 DISCLAIMERS
Al l i nformati on, i l l ustrati ons, and speci fi cati ons
contai ned i n thi s manual are based on the l atest
5
GENERAL INFORMATION
i nformati on avai l abl e at the ti me of publ i cati on.
The ri ght i s reserved to make changes at any ti me
wi thout noti ce.
4. 2 SAFETY
4. 2. 1 TECHNICIAN SAFETY INFORMATION
WARNING: ENGINES PRODUCE CARBON
MONOXIDE THAT IS ODORLESS, CAUSES
SLOWER REACTION TIME, AND CAN LEAD
TO SERIOUS INJURY. WHEN THE ENGINE IS
OPERATING, KEEP SERVICE AREAS WELL
VENTILATED OR ATTACH THE VEHICLE
EXHAUST SYSTEM TO THE SHOP EXHAUST
REMOVAL SYSTEM.
Set the parki ng brake and bl ock the wheel s before
testi ng or repai ri ng the vehi cl e. I t i s especi al l y
i mportant to bl ock the wheel s on front-wheel dri ve
vehi cl es; the parki ng brake does not hol d the dri ve
wheel s.
When servi ci ng a vehi cl e al ways wear eye protec-
ti on and remove any metal jewel ry such as watch-
bands or bracel ets that mi ght make an i nadvertent
el ectri cal contact.
Addi ti onal safety procedures can be found i n the
servi ce manual . Fol l owi ng these procedures i s very
i mportant to avoi d i njury.
4. 2. 2 VEHICLE PREPARATION FOR
TESTING
Make sure the vehi cl e bei ng tested has a ful l y
charged battery. I f i s does not, fal se di agnosti c
troubl e codes or error messages may occur.
4. 2. 3 SERVICING SUB-ASSEMBLIES
Some components of the anti l ock brake system
are i ntended to be servi ced i n assembl y onl y. At-
tempti ng to remove or repai r certai n system sub-
components may resul t i n personal i njury and/or
i mproper system operati on. Onl y those components
wi th approved repai r and i nstal l ati on procedures i n
the servi ce manual shoul d be servi ced.
4. 2. 4 DRBIIIா SAFETY INFORMATION
WARNING: EXCEEDING THE LIMITS OF THE
DRBIIIா MULTIMETER IS DANGEROUS. IT
CAN EXPOSE YOU TO SERIOUS OR
POSSIBLY FATAL INJURY. CAREFULLY
READ AND UNDERSTAND THE CAUTIONS
AND THE SPECIFICATION LIMITS.
• Fol l ow the vehi cl e manufacturer ’s servi ce speci -
fi cati ons at al l ti mes.
• Do not use the DRBI I I ௡ i f i t has been damaged.
• Do not use the test l eads i f the i nsul ati on i s
damaged or i f metal i s exposed.
• To avoi d el ectri cal shock, do not touch the test
l eads, ti ps or the ci rcui t bei ng tested.
• Choose the proper range and functi on for the
measurement. Do not try vol tage or current mea-
surements that may exceed the rated capaci ty.
• Do not exceed the l i mi ts shown i n the tabl e bel ow:
FUNCTION INPUT LIMIT
Vol ts 0 - 500 peak vol ts AC
0 - 500 vol ts DC
Ohms (resi stance)* 0 - 1.12 megohms
Frequency Measured
Frequency Generated
0 - 10 kHz
Temperature -50 - 600°C
-58 - 1100°F
* Ohms cannot be measured i f vol tage i s present.
Ohms can be measured onl y i n a non-powered
ci rcui t.
• Vol tage between any termi nal and ground must
not exceed 500v DC or 500v peak AC.
• Use cauti on when measuri ng vol tage above 25v
DC or 25v AC.
• Use the l ow current shunt to measure ci rcui ts up
to 10A. Use the hi gh current cl amp to measure
ci rcui ts exceedi ng 10A.
• When testi ng for the presence of vol tage or cur-
rent, make sure the meter i s functi oni ng cor-
rectl y. Take a readi ng of a known vol tage or
current before accepti ng a zero readi ng.
• When measuri ng current, connect the meter i n
seri es wi th the l oad.
• Di sconnect the l i ve test l ead before di sconnecti ng
the common test l ead.
• When usi ng the meter functi on, keep the
DRBI I I ௡ away from spark pl ug or coi l wi res to
avoi d measuri ng error from outsi de i nterference.
4. 3 WARNING
4. 3. 1 VEHICLE DAMAGE WARNINGS
Before di sconnecti ng any control modul e, make
sure the i gni ti on i s OFF. Fai l ure to do so coul d
damage the modul e.
When testi ng vol tage or conti nui ty at any control
modul e, use the termi nal si de (not the wi re end) of
the connector. Do not pi erce wi re i nsul ati on; thi s
wi l l damage i t and eventual l y cause i t to fai l be-
cause of corrosi on.
6
GENERAL INFORMATION
Be careful when performi ng el ectri cal tests so as
to prevent acci dental shorti ng of termi nal s. Such
mi stakes can damage fuses or components. Al so, a
second code coul d be set, maki ng di agnosi s of the
ori gi nal probl em more di ffi cul t.
4. 3. 2 ROAD TESTING A COMPLAINT
VEHICLE
Some compl ai nts wi l l requi re a test dri ve as part
of the repai r veri fi cati on procedure. The purpose of
the test dri ve i s to try to dupl i cate the di agnosti c
code or symptom condi ti on.
NOTE: After the repair of pump or speed
signal DTC’s, the vehicle must be driven at 25
km/h (15 mph) to clear the DTC from the CAB.
WARNING: BEFORE ROAD TESTING A
VEHICLE, BE SURE THAT ALL
COMPONENTS ARE REASSEMBLED.
DURING THE TEST DRIVE, DO NOT TRY TO
READ THE DRBIIIா SCREEN WHILE IN
MOTION. DO NOT HANG THE DRB FROM
THE REAR VIEW MIRROR OR OPERATE IT
YOURSELF. HAVE AN ASSISTANT
AVAILABLE TO OPERATE THE DRBIIIா.
4. 4 DIAGNOSIS
1. Your di agnosti c test procedure must begi n wi th a
thorough vi sual i nspecti on of the ABS for dam-
aged components or di sconnected connectors.
The brake l amps must be operati onal pri or to
conti nui ng.
2. Connect the DRBI I I ௡ to the data l i nk connector
l ocated under the dash. I f the DRBI I I ௡ does not
power up, check the power and ground suppl i es
to the connector.
3. Sel ect ‘‘Anti l ock Brakes’’. Turn the i gni ti on on. I f
the DRBI I I ௡ di spl ays ‘‘No Response’’, perform
the proper test.
4. Read and record al l ABS di agnosti c troubl e
codes. I f the ‘‘CAB Power Feed Ci rcui t’’ troubl e
code i s present, i t must be repai red pri or to
addressi ng any other DTC’s. I f any addi ti onal
codes are present, proceed to the appropri ate
test.
5. I f there are no di agnosti c troubl e codes present,
sel ect ‘‘I nputs/Outputs’’ and read the brake
swi tch i nput as you press and rel ease the brake
pedal . I f the di spl ay does not match the state of
the pedal , perform the appropri ate test. Read the
‘‘G-Swi tch’’ status, wi th the vehi cl e on a l evel
surface, both swi tches shoul d read ‘‘CLOSED’’. I f
the status i s not correct, perform the appropri ate
test. I f a probl em wi th the ABS warni ng i ndi ca-
tor exi sts, refer to the appropri ate test.
6. I f no other probl em are found, i t wi l l be neces-
sary to road test the vehi cl e. THE DRBIII௡
MUST NOT BE CONNECTED TO THE
DATA LINK CONNECTOR WHEN ROAD
TESTING FOR PROPER ANTILOCK OP-
ERATION. THE SYSTEM IS DISABLED
WHILE IN DIAGNOSTIC MODE. Perform
several anti l ock stops from above 50 Km/h (30
mph) and then repeat steps 2, 3, and 4. I f any
di agnosti c troubl e codes are present, proceed to
the appropri ate test.
7. The fol l owi ng condi ti ons shoul d be consi dered
‘‘NORMAL’’ operati on, and no repai rs shoul d be
attempted to correct them.
– Brake pedal feedback duri ng an ABS stop
(cl i cki ng, vi brati ng)
– Cl i cki ng, groani ng or buzzi ng at 10 Km/h (6
mph) (dri ve off sel f test)
– Groani ng noi se duri ng an ABS stop
– Sl i ght brake pedal drop and pop noi se when
i gni ti on i s i ni ti al l y turned on
– Brake pedal ratcheti ng down at the end of an
ABS stop
8. I f the compl ai nt i s “ABS cycl i ng” at the end of a
stop at l ow speeds, i t may be caused by a
margi nal wheel speed sensor si gnal . The sensor
ai r gap, tone wheel condi ti on, and/or brakes
hangi ng up are possi bl e causes of thi s condi ti on.
9. After a road test i n whi ch no probl ems were
found, refer to any Techni cal Servi ce Bul l eti ns
that may appl y.
5.0 REQUIRED TOOLS AND
EQUIPMENT
DRBI I I ௡ (di agnosti c read-out box)
jumper wi res
ohmmeter
vol tmeter
test l amp
7
GENERAL INFORMATION
6.0 GLOSSARY OF TERMS
ABS anti l ock brake system
AC al ternati ng current
BCM Body Control Modul e
CAB control l er anti l ock brake
CCD Chrysl er Col l i si on Detecti on
DC di rect current
DLC data l i nk connector
DRBIII௡ di agnosti c read-out box
DTC di agnosti c troubl e code
HCU hydraul i c control uni t
HZ Hertz
J BLK juncti on bl ock
J TEC Jeep and Truck Engi ne Control l er
LF l eft front
LR l eft rear
PCM Powertrai n Control Modul e
PDC power di stri buti on center
P/M pump motor
RF ri ght front
RR ri ght rear
SCI Seri al Communi cati on I nterface
SOL Sol enoi d
WSS wheel speed sensor
8
GENERAL INFORMATION
7.0
DIAGNOSTIC INFORMATION AND
PROCEDURES
9
Symptom:
CAB POWER FEED CIRCUIT
When Monitored and Set Condition:
CAB POWER FEED CIRCUIT
When Moni tored: I gni ti on on. The CAB moni tors the Fused B(+) ci rcui t at al l ti mes for
proper system vol tage.
Set Condi ti on: I f the Fused B(+) vol tage i s mi ssi ng when the CAB detects that an i nternal
mai n dri ver i s not ЉonЉ, the Di agnosti c Troubl e Code (DTC) i s set.
POSSIBLE CAUSES
I NTERMI TTENT DTC
B(+) CI RCUI T SHORTED TO GROUND
BLOWN FUSE - FUSED B(+) CI RCUI T
CAB - FUSED B(+) CI RCUI T SHORTED TO GROUND
FUSED B(+) CI RCUI T OPEN
NO B+ SUPPLY TO FUSE
CAB - FUSED B(+) CI RCUI T OPEN
TEST ACTION APPLICABILITY
1 Turn the i gni ti on on.
Wi th the DRBI I I ௡, erase DTC’s.
Turn the i gni ti on off.
Turn the i gni ti on on.
Dri ve the vehi cl e above 25 km/h (15 mph) for at l east 10 seconds.
Stop the vehi cl e.
Wi th the DRBI I I ௡, read DTC’s.
Does the DRBI I I ௡ di spl ay CAB Power Feed Ci rcui t DTC present ri ght now?
Al l
Yes → Go To 2
No → Go To 9
2 Turn the i gni ti on off.
Remove and I nspect Fuse 12 i n the PDC.
I s the Fuse bl own?
Al l
Yes → Go To 3
No → Go To 6
10
BRAKES (CAB)
TEST ACTION APPLICABILITY
3 Turn the i gni ti on off.
Remove Fuse 12 from the PDC.
Di sconnect the CAB harness connector.
Note: Check connector - Clean/repair as necessary.
Usi ng a test l i ght connected to 12 vol ts, probe the Fused B(+) Ci rcui t.
Does the test l i ght i l l umi nate bri ghtl y?
Al l
Yes → Repai r the Fused B(+) Ci rcui t Shorted to Ground.
Perform ABS VERI FI CATI ON TEST - VER 1.
No → Go To 4
4 Turn the i gni ti on off.
Remove Fuse 12 from the PDC.
The CAB must be connected for the resul ts of thi s test to be val i d.
Usi ng a test l i ght connected to 12 vol ts, probe the Fused B+ ci rcui t at the PDC fuse
termi nal .
Does the test l i ght i l l umi nate bri ghtl y?
Al l
Yes → Repl ace the Control l er Anti l ock Brake i n accordance wi th the
Servi ce I nformati on.
Perform ABS VERI FI CATI ON TEST - VER 1.
No → Go To 5
5 Turn the i gni ti on off.
I f there are no potenti al causes remai ni ng, vi ew repai r.
Al l
Conti nue
Repl ace the Fuse.
Perform ABS VERI FI CATI ON TEST - VER 1.
6 Turn the i gni ti on off.
Remove Fuse 12 from the PDC.
Di sconnect the CAB harness connector.
Note: Check connector - Clean/repair as necessary.
Measure the resi stance of the Fused B+ ci rcui t between the PDC fuse termi nal and
the CAB connector.
I s the resi stance bel ow 5 ohms?
Al l
Yes → Go To 7
No → Repai r the Fused B+ ci rcui t for an open.
Perform ABS VERI FI CATI ON TEST - VER 1.
7 Remove Fuse 12 from the PDC.
Turn the i gni ti on on.
Measure the vol tage of the Fused B+ suppl y to Fuse 12 i n the PDC.
I s the vol tage above 10 vol ts?
Al l
Yes → Go To 8
No → Repai r the B+ Suppl y ci rcui t for an open.
Perform ABS VERI FI CATI ON TEST - VER 1.
8 I f there are no potenti al causes remai ni ng, vi ew repai r. Al l
Repai r
Repl ace the Control l er Anti l ock Brake i n accordance wi th the
Servi ce I nformati on.
Perform ABS VERI FI CATI ON TEST - VER 1.
11
BRAKES (CAB)
CAB POWER FEED CIRCUIT — Continued
TEST ACTION APPLICABILITY
9 Turn the i gni ti on off.
Vi sual l y i nspect the rel ated wi ri ng harness. Look for any chafed, pi erced, pi nched, or
parti al l y broken wi res.
Vi sual l y i nspect the rel ated wi re harness connectors. Look for broken, bent, pushed
out, or corroded termi nal s.
Refer to any Hotl i ne l etters or Techni cal Servi ce Bul l eti ns that may appl y.
Were any probl ems found?
Al l
Yes → Repai r as necessary.
Perform ABS VERI FI CATI ON TEST - VER 1.
No → Test Compl ete.
12
BRAKES (CAB)
CAB POWER FEED CIRCUIT — Continued
Symptom:
CONTROLLER FAILURE
When Monitored and Set Condition:
CONTROLLER FAILURE
When Moni tored: I gni ti on on. The CAB moni tors i ts i nternal mi croprocessors for correct
operati on.
Set Condi ti on: I f the CAB detects an i nternal faul t, the DTC i s set.
POSSIBLE CAUSES
GROUND AND POWER CONNECTI ONS
GROUND CI RCUI T HI GH RESI STANCE
GROUND CI RCUI T I NTERFERENCE
CAB - I NTERNAL FAI LURE
TEST ACTION APPLICABILITY
1 I nspect for non-factory wi ri ng that may i nterfere wi th CAB power or ground ci rcui ts.
Di sconnect the CAB harness connector.
I nspect the CAB wi ri ng harness for i ncorrect routi ng and damage.
I nspect the CAB harness and component connectors for corrosi on and damage.
Were any concerns found?
Al l
Yes → Repai r as necessary.
Perform ABS VERI FI CATI ON TEST - VER 1.
No → Go To 2
2 Turn the i gni ti on off.
Di sconnect the CAB harness connector.
Note: Check connector - Clean/repair as necessary.
Measure the resi stance of the CAB ground ci rcui ts to body ground.
I s the resi stance bel ow 1.0 ohm?
Al l
Yes → Go To 3
No → Repai r the Ground ci rcui t hi gh resi stance.
Perform ABS VERI FI CATI ON TEST - VER 1.
3 Turn the i gni ti on off.
Di sconnect the CAB harness connector.
Note: Check connector - Clean/repair as necessary.
Turn the i gni ti on on.
Turn on al l accessori es.
Measure the vol tage of the Ground ci rcui t.
I s the vol tage bel ow 1.0 vol ts?
Al l
Yes → Go To 4
No → Repai r as necessary. Unspl i ce any accessori es connected to the
CAB ground ci rcui t. Reroute and shi el d any hi gh vol tage cabl es
away from the CAB ground ci rcui t.
Perform ABS VERI FI CATI ON TEST - VER 1.
13
BRAKES (CAB)
TEST ACTION APPLICABILITY
4 I f there are no possi bl e causes remai ni ng, vi ew repai r. Al l
Repai r
Repl ace the CAB.
Perform ABS VERI FI CATI ON TEST - VER 1.
14
BRAKES (CAB)
CONTROLLER FAILURE — Continued
Symptom:
G-SWITCH NOT PROCESSABLE
When Monitored and Set Condition:
G-SWITCH NOT PROCESSABLE
When Moni tored: I gni ti on on. The CAB sends a test si gnal out to the G-swi tch and
moni tors the sense ci rcui ts #1 and #2.
Set Condi ti on: I f the sense ci rcui ts are open for 2 mi nutes whi l e dri vi ng or an otherwi se
i mproper si gnal i s detected at any ti me, the Di agnosti c Troubl e Code (DTC) i s set.
POSSIBLE CAUSES
G-SWI TCH TEST SI GNAL CI RCUI T OPEN
I NTERMI TTENT DTC
G-SWI TCH TEST SI GNAL OR SENSE CI RCUI T SHORT TO VOLTAGE OR GROUND
G-SWI TCH SI GNAL CI RCUI T I NTERNAL OPEN
CAB - TEST SI GNAL CI RCUI T OPEN
G-SWI TCH #1 SENSE CI RCUI T OPEN
G-SWI TCH #1 SENSE SWI TCH OPEN
CAB - #1 SENSE CI RCUI T OPEN
G-SWI TCH #2 SENSE CI RCUI T OPEN
G-SWI TCH #2 SENSE SWI TCH OPEN
CAB - #2 SENSE CI RCUI T OPEN
TEST ACTION APPLICABILITY
1 Turn the i gni ti on on.
Wi th the DRBI I I ௡, read the status of the G-Swi tch i nternal swi tches.
What i s the status of both of the G-Swi tches?
Al l
Both G-Swi tches are cl osed.
Go To 2
Both G-Swi tches are open.
Go To 3
Onl y the #1 G-Swi tch i s open.
Go To 7
Onl y the #2 G-Swi tch i s open.
Go To 10
15
BRAKES (CAB)
TEST ACTION APPLICABILITY
2 Turn the i gni ti on off.
Vi sual l y i nspect the rel ated wi ri ng harness. Look for any chafed, pi erced, pi nched, or
parti al l y broken wi res.
Vi sual l y i nspect the rel ated wi re harness connectors. Look for broken, bent, pushed
out, or corroded termi nal s.
Refer to any Hotl i ne l etters or Techni cal Servi ce Bul l eti ns that may appl y.
Were any probl ems found?
Al l
Yes → Repai r as necessary.
Perform ABS VERI FI CATI ON TEST - VER 1.
No → Test Compl ete.
3 Turn the i gni ti on off.
Di sconnect the CAB connector.
Check connector - Clean/repair as necessary.
Di sconnect the G-Swi tch Sensor Connector.
NOTE: Check connector - Clean/repair as necessary.
Measure the resi stance of the G-Swi tch Test Si gnal ci rcui t.
I s the resi stance bel ow 5 ohms?
Al l
Yes → Go To 4
No → Repai r the G-Swi tch Test Si gnal Ci rcui t Open.
Perform ABS VERI FI CATI ON TEST - VER 1.
4 Turn the i gni ti on off.
Di sconnect the CAB Connector.
Check connector - Clean/repair as necessary.
Di sconnect the G-Swi tch Sensor Connector.
Check connector - Clean/repair as necessary.
Turn the i gni ti on on.
Usi ng a 12-vol t test l i ght connected to ground, check the Test Si gnal and both Sense
ci rcui ts.
Usi ng a 12-vol t test l i ght connected to 12-vol ts, check the Test Si gnal and both Sense
ci rcui ts.
CAUTION: The test light should not light at any test point.
Does the test l i ght i l l umi nate at any test poi nt?
Al l
Yes → Repai r the G-Swi tch Test Si gnal or Sense ci rcui t for a short to
vol tage or ground.
Perform ABS VERI FI CATI ON TEST - VER 1.
No → Go To 5
5 Turn the i gni ti on off.
Di sconnect the G-Swi tch Connector.
Check connector - Clean/repair as necessary.
Remove G-Swi tch from vehi cl e.
Whi l e hol di ng the G-Swi tch l evel , measure the resi stance of the G-Swi tch Test Si gnal
ci rcui t and the G-Swi tch #1 Sense ci rcui t i n the G-Swi tch connector.
I s the resi stance bel ow 5 ohms?
Al l
Yes → Go To 6
No → Repl ace G-Swi tch.
Perform ABS VERI FI CATI ON TEST - VER 1.
16
BRAKES (CAB)
G-SWITCH NOT PROCESSABLE — Continued
TEST ACTION APPLICABILITY
6 I f there are no potenti al causes remai ni ng, vi ew repai r. Al l
Repai r
Repl ace the CAB.
Perform ABS VERI FI CATI ON TEST - VER 1.
7 Turn the i gni ti on off.
Di sconnect the CAB Connector.
Note: Check connector - Clean/repair as necessary.
Di sconnect the G-Swi tch Sensor Connector.
Measure the resi stance of the G-Swi tch #1 Sense Ci rcui t.
I s the resi stance bel ow 5 ohms?
Al l
Yes → Go To 8
No → Repai r the G-Swi tch #1 Sense ci rcui t open.
Perform ABS VERI FI CATI ON TEST - VER 1.
8 Turn the i gni ti on off.
Check connector - Clean/repair as necessary.
Remove G-Swi tch from vehi cl e.
Whi l e hol di ng the G-Swi tch l evel , measure the resi stance of the G-Swi tch Test Si gnal
ci rcui t and the G-Swi tch #1 Sense ci rcui t i n the G-Swi tch connector.
I s the resi stance bel ow 5 ohms?
Al l
Yes → Go To 9
No → Repl ace G-Swi tch Assembl y.
Perform ABS VERI FI CATI ON TEST - VER 1.
9 I f there are no potenti al causes remai ni ng, vi ew repai r. Al l
Repai r
Repl ace the CAB.
Perform ABS VERI FI CATI ON TEST - VER 1.
10 Turn the i gni ti on off.
Di sconnect the CAB Connector.
Note: Check connector - Clean/repair as necessary.
Di sconnect the G-Swi tch Connector.
Note: Check connector - Clean/repair as necessary.
Measure the resi stance of the G-Swi tch #2 Sense Ci rcui t.
I s the resi stance bel ow 5 ohms?
Al l
Yes → Go To 11
No → Repai r the G-Swi tch #2 Sense Ci rcui t Open.
Perform ABS VERI FI CATI ON TEST - VER 1.
11 Turn the i gni ti on off.
Di sconnect the G-Swi tch connector.
Note: Check connector - Clean/repair as necessary.
Remove the G-Swi tch from vehi cl e.
Whi l e hol di ng the G-Swi tch l evel , measure the resi stance of the G-Swi tch Test Si gnal
ci rcui t and the G-Swi tch #2 Sense ci rcui t i n the G-Swi tch connector.
I s the resi stance bel ow 5 ohms?
Al l
Yes → Go To 12
No → Repl ace the G-Swi tch Assembl y.
Perform ABS VERI FI CATI ON TEST - VER 1.
17
BRAKES (CAB)
G-SWITCH NOT PROCESSABLE — Continued
TEST ACTION APPLICABILITY
12 I f there are no potenti al causes remai ni ng, vi ew repai r. Al l
Repai r
Repl ace the CAB.
Perform ABS VERI FI CATI ON TEST - VER 1.
18
BRAKES (CAB)
G-SWITCH NOT PROCESSABLE — Continued
SymptomList:
LEFT FRONT SENSOR CIRCUIT FAILURE
LEFT REAR SENSOR CIRCUIT FAILURE
RIGHT FRONT SENSOR CIRCUIT FAILURE
RIGHT REAR SENSOR CIRCUIT FAILURE
Test Note: All symptomslistedabovearediagnosedusingthesametests.
Thetitlefor thetestswill beLEFT FRONT SENSOR CIRCUIT
FAILURE.
When Monitored and Set Condition:
LEFT FRONT SENSOR CIRCUIT FAILURE
When Moni tored: I gni ti on on. The CAB moni tors the Wheel Speed Sensor ci rcui ts
conti nuousl y.
Set Condi ti on: I f the CAB detects an open or shorted wheel speed sensor ci rcui t, the
Di agnosti c Troubl e Code (DTC) wi l l set.
LEFT REAR SENSOR CIRCUIT FAILURE
When Moni tored: I gni ti on on. The CAB moni tors the Wheel Speed Sensor ci rcui ts
conti nuousl y.
Set Condi ti on: I f the CAB detects an open or shorted wheel speed sensor ci rcui t, the
Di agnosti c Troubl e Code (DTC) wi l l set.
RIGHT FRONT SENSOR CIRCUIT FAILURE
When Moni tored: I gni ti on on. The CAB moni tors the Wheel Speed Sensor ci rcui ts
conti nuousl y.
Set Condi ti on: I f the CAB detects an open or shorted wheel speed sensor ci rcui t, the
Di agnosti c Troubl e Code (DTC) wi l l set.
RIGHT REAR SENSOR CIRCUIT FAILURE
When Moni tored: I gni ti on on. The CAB moni tors the Wheel Speed Sensor ci rcui ts
conti nuousl y.
Set Condi ti on: I f the CAB detects an open or shorted Wheel speed sensor ci rcui t, the
Di agnosti c Troubl e Code (DTC) wi l l set.
POSSIBLE CAUSES
SENSOR OR CONNECTOR DAMAGE
I NTERMI TTENT DTC
WHEEL SPEED SENSOR OPEN OR SHORTED TO GROUND
WHEEL SPEED SENSOR (+) OR (-) CI RCUI T SHORTED TO VOLTAGE
19
BRAKES (CAB)
POSSIBLE CAUSES
WHEEL SPEED SENSOR (+) OR (-) CI RCUI T SHORTED TO GROUND
WHEEL SPEED SENSOR CI RCUI TS SHORTED TOGETHER
SPEED SENSOR (+) OR (-) CI RCUI T OPEN
CAB - I NTERNAL SHORT OR OPEN
TEST ACTION APPLICABILITY
1 Turn the i gni ti on on.
Wi th the DRBI I I ௡, read DTC’s.
Wi th the DRBI I I ௡, erase DTC’s.
Turn the i gni ti on off.
Turn the i gni ti on on.
Wi th the DRBI I I ௡, read DTC’s.
Does the DRBI I I ௡ di spl ay a Wheel Speed Sensor Ci rcui t Fai l ure DTC?
Al l
Yes → Go To 2
No → Go To 9
2 Turn the i gni ti on off.
I nspect the affected Wheel Speed Sensor and Connector.
I s the Sensor or Connector Damaged?
Al l
Yes → Repai r as necessary.
Perform ABS VERI FI CATI ON TEST - VER 1.
No → Go To 3
3 Turn the i gni ti on off.
Di sconnect the affected Wheel Speed Sensor connector.
Note: Check connector - Clean/repair as necessary.
Measure the resi stance across the Wheel Speed Sensor (+) and (-) ci rcui ts at the
Sensor si de of the connector.
Measure the resi stance between ground and the (+) and (-) ci rcui ts on the Sensor si de
of the connector.
I s the Sensor resi stance 900 to 1300 ohms and resi stance to ground more than 15k
ohms?
Al l
Yes → Go To 4
No → Repai r the short or repl ace the Wheel Speed Sensor, as necessary.
Perform ABS VERI FI CATI ON TEST - VER 1.
4 Turn the i gni ti on off.
Di sconnect the affected Wheel Speed Sensor connector.
Note: Check connector - Clean/repair as necessary.
Di sconnect the CAB connector.
Note: Check connector - Clean/repair as necessary.
Turn the i gni ti on on.
Measure the vol tage of the Wheel Speed Sensor (+) and (-) ci rcui ts.
I s the vol tage above 1 vol t at ei ther ci rcui t?
Al l
Yes → Repai r the Wheel Speed Sensor ci rcui t for a short to vol tage.
Perform ABS VERI FI CATI ON TEST - VER 1.
No → Go To 5
20
BRAKES (CAB)
LEFT FRONT SENSOR CIRCUIT FAILURE — Continued
TEST ACTION APPLICABILITY
5 Turn the i gni ti on off.
Di sconnect the affected Wheel Speed Sensor Connector.
Di sconnect the CAB Connector.
Measure the resi stance between the Wheel Speed Sensor (+) and (-) ci rcui ts and
ground.
I s the resi stance bel ow 15,000 ohms for ei ther ci rcui t?
Al l
Yes → Repai r the Wheel Speed Sensor ci rcui t short to ground.
Perform ABS VERI FI CATI ON TEST - VER 1.
No → Go To 6
6 Turn the i gni ti on off.
Di sconnect the CAB Connector.
Di sconnect the affected Wheel Speed Sensor harness connector.
Measure the resi stance through the Wheel Speed Sensor (+) and (-) ci rcui ts at the
CAB harness connector.
I s the resi stance bel ow 200 ohms?
Al l
Yes → Repai r the Wheel Speed Sensor ci rcui ts shorted together.
Perform ABS VERI FI CATI ON TEST - VER 1.
No → Go To 7
7 Turn the i gni ti on off.
Di sconnect the affected Wheel Speed Sensor Connector.
Note: Check connector - Clean/repair as necessary.
Di sconnect the CAB Connector.
Note: Check connector - Clean/repair as necessary.
Measure the resi stance of the Wheel Speed Sensor (+) and (-) ci rcui ts.
I s the resi stance bel ow 5 ohms for both ci rcui ts?
Al l
Yes → Go To 8
No → Repai r the Wheel Speed Sensor (+) or (-) ci rcui t for an open.
Perform ABS VERI FI CATI ON TEST - VER 1.
8 I f there are no possi bl e causes remai ni ng, vi ew repai r. Al l
Repai r
Repl ace the Control l er Anti l ock Brake i n accordance wi th the
Servi ce I nformati on.
Perform ABS VERI FI CATI ON TEST - VER 1.
9 Turn the i gni ti on off.
Vi sual l y i nspect the rel ated wi ri ng harness. Look for any chafed, pi erced, pi nched, or
parti al l y broken wi res.
Vi sual l y i nspect the rel ated wi re harness component and i n-l i ne connectors. Look for
broken, bent, pushed out, or corroded termi nal s.
Refer to any Hotl i ne l etters or Techni cal Servi ce Bul l eti ns that may appl y.
Were any probl ems found?
Al l
Yes → Repai r as necessary.
Perform ABS VERI FI CATI ON TEST - VER 1.
No → Test Compl ete.
21
BRAKES (CAB)
LEFT FRONT SENSOR CIRCUIT FAILURE — Continued
SymptomList:
LEFT FRONT SENSOR SIGNAL FAILURE
LEFT REAR SENSOR SIGNAL FAILURE
RIGHT FRONT SENSOR SIGNAL FAILURE
RIGHT REAR SENSOR SIGNAL FAILURE
Test Note: All symptomslistedabovearediagnosedusingthesametests.
Thetitlefor thetests will beLEFT FRONT SENSOR SIGNAL
FAILURE.
When Monitored and Set Condition:
LEFT FRONT SENSOR SIGNAL FAILURE
When Moni tored: Wheel speed compari son i s checked at dri ve off and conti nuousl y
thereafter.
Set Condi ti on: I f, duri ng an ABS stop, the CAB commands any val ve sol enoi d on for an
extended l ength of ti me, and does not see a correspondi ng wheel speed change, the
Di agnosti c Troubl e Code (DTC) i s set. The DTC can al so set i f the si gnal i s mi ssi ng or
errati c.
LEFT REAR SENSOR SIGNAL FAILURE
When Moni tored: Wheel speed compari son i s checked at dri ve off and conti nuousl y
thereafter.
Set Condi ti on: I f, duri ng an ABS stop, the CAB commands any val ve sol enoi d on for an
extended l ength of ti me, and does not see a correspondi ng wheel speed change, the
Di agnosti c Troubl e Code (DTC) i s set. The DTC can al so set i f the si gnal i s mi ssi ng or
errati c.
RIGHT FRONT SENSOR SIGNAL FAILURE
When Moni tored: Wheel speed compari son i s checked at dri ve off and conti nuousl y
thereafter.
Set Condi ti on: I f, duri ng an ABS stop, the CAB commands any val ve sol enoi d on for an
extended l ength of ti me, and does not see a correspondi ng wheel speed change, the
Di agnosti c Troubl e Code (DTC) i s set. The DTC can al so set i f the si gnal i s mi ssi ng or
errati c.
RIGHT REAR SENSOR SIGNAL FAILURE
When Moni tored: Wheel speed compari son i s checked at dri ve off and conti nuousl y
thereafter.
Set Condi ti on: I f, duri ng an ABS stop, the CAB commands any val ve sol enoi d on for an
extended l ength of ti me, and does not see a correspondi ng wheel speed change, the
Di agnosti c Troubl e Code (DTC) i s set. The DTC can al so set i f the si gnal i s mi ssi ng or
errati c.
22
BRAKES (CAB)
POSSIBLE CAUSES
SPEED SENSOR OR CONNECTOR DAMAGED
TONE WHEEL DAMAGED
WHEEL SPEED SENSOR AI R GAP OUT OF SPECI FI CATI ON
WHEEL BEARI NG EXCESS RUNOUT
WHEEL SPEED SENSOR I NOPERATI VE
CAB - CAN’T READ WHEEL SPEED SENSOR SI GNAL
I NTERMI TTENT SI GNAL DTC
TEST ACTION APPLICABILITY
1 Turn the i gni ti on on.
Usi ng the DRBI I I ௡, moni tor al l Wheel Speed Sensors whi l e an assi stant dri ves the
vehi cl e.
Sl owl y accel erate as strai ght as possi bl e from a stop to 24 km/h (15 mph).
Note the DRBI I I ௡ Wheel Speed Sensor readi ngs.
I s one wheel speed si gnal zero or di fferi ng from others by more than 5 km/h (3 mph)?
Al l
Yes → Go To 2
No → Go To 7
2 Turn the i gni ti on off.
I nspect the Wheel Speed Sensor and Connector at the affected wheel .
I s the Sensor or Connector Damaged?
Al l
Yes → Repai r as necessary. The CAB must sense al l four wheel s at 25
km/h (15 mph) before i t wi l l exti ngui sh the ABS I ndi cator.
Perform ABS VERI FI CATI ON TEST - VER 1.
No → Go To 3
3 Turn the i gni ti on off.
At the affected wheel , i nspect the Tone Wheel for damaged or mi ssi ng teeth, cracks,
or l ooseness.
Note: TheToneWheel Teeth should beperfectly square, not bent or nicked.
I s the Tone Wheel OK?
Al l
Yes → Go To 4
No → Repl ace the Tone Wheel . The CAB must sense al l four wheel s at
25 km/h (15 mph) before i t wi l l exti ngui sh the ABS I ndi cator.
Perform ABS VERI FI CATI ON TEST - VER 1.
4 Turn the i gni ti on off.
Usi ng a Feel er Gauge, measure the Wheel Speed Sensor Ai r Gap.
NOTE: The Air Gap should be checked in at least four places on the Tone
Wheel.
I s the Ai r Gap between 0.42 mm - 1.71 mm (0.017Љ - 0.068Љ) ?
Al l
Yes → Go To 5
No → Repai r as necessary. The CAB must sense al l four wheel s at 25
km/h (15 mph) before i t wi l l exti ngui sh the ABS I ndi cator.
Perform ABS VERI FI CATI ON TEST - VER 1.
23
BRAKES (CAB)
LEFT FRONT SENSOR SIGNAL FAILURE — Continued
TEST ACTION APPLICABILITY
5 Turn the i gni ti on off.
I nspect the wheel beari ng for excessi ve runout or cl earance.
Note: Refer to the appropriate service information, if necessary, for proce-
dures or specifications.
I s the beari ng runout OK ?
Al l
Yes → Go To 6
No → Repai r as necessary. The CAB must sense al l four wheel s at 25
km/h (15 mph) before i t wi l l exti ngui sh the ABS I ndi cator.
Perform ABS VERI FI CATI ON TEST - VER 1.
6 Turn the i gni ti on off.
Rai se the affected wheel off the ground.
Di sconnect the Wheel Speed Sensor connector at the affected wheel .
Set up an AC vol tmeter to read the output of the Wheel Speed Sensor.
Qui ckl y rotate the wheel by spi nni ng the ti re by hand.
Measure the Wheel Speed Sensor AC vol tage output.
Does the vol tage go above 650 mi l l i vol ts as the wheel i s rotated?
Al l
Yes → Repl ace the Control l er Anti l ock Brake i n accordance wi th the
Servi ce I nformati on.
Perform ABS VERI FI CATI ON TEST - VER 1.
No → Repl ace the Wheel Speed Sensor i n accordance wi th the Servi ce
I nformati on. The CAB must sense al l four wheel s at 25 km/h (15
mph) before i t wi l l exti ngui sh the ABS I ndi cator.
Perform ABS VERI FI CATI ON TEST - VER 1.
7 Turn the i gni ti on off.
Vi sual l y i nspect the affected Wheel Speed Sensor for correct i nstal l ati on.
Vi sual l y i nspect the Tone Wheel for l ooseness and correct i nstal l ati on.
Vi sual l y i nspect the wi ri ng harness for l oose or i ntermi ttent connecti ons.
Vi sual l y i nspect mechani cal brake components.
I nspect for condi ti ons that may cause l ockup or drag.
I nspect for sei zed cal i per or wheel cyl i nder pi ston.
I nspect al l components for a condi ti on whi ch may cause a Wheel Speed Si gnal DTC
to set.
I s any Component Damaged?
Al l
Yes → Repai r as necessary. The CAB must sense al l four wheel s at 25
km/h (15 mph) before i t wi l l exti ngui sh the ABS I ndi cator.
Perform ABS VERI FI CATI ON TEST - VER 1.
No → Test Compl ete.
24
BRAKES (CAB)
LEFT FRONT SENSOR SIGNAL FAILURE — Continued
Symptom:
PUMP MOTOR NOT WORKING PROPERLY
When Monitored and Set Condition:
PUMP MOTOR NOT WORKING PROPERLY
When Moni tored: I gni ti on on. The CAB commands the pump on at 20 km/h (12 mph) to
check i ts operati on, i f the brake swi tch i s not appl i ed. I f the dri ver has thei r foot on the
brake, the test wi l l run at 40 km/h (25 mph). The CAB moni tors pump vol tage
conti nuousl y.
Set Condi ti on: The DTC i s stored when the CAB detects: 1) I mproper vol tage decay after
the pump was turned off. 2) Pump not energi zed by the CAB, but vol tage i s present for 3.5
seconds. 3) Pump i s turned on by the CAB, but thei r i s i nsuffi ci ent vol tage to operate i t.
POSSIBLE CAUSES
ABS PUMP MOTOR I NTERMI TTENT DTC
FUSED B(+) CI RCUI T I NTERMI TTENTLY SHORTED TO GROUND
FUSED B(+) CI RCUI T SHORTED TO GROUND
CAB - FUSED B(+) CI RCUI T SHORTED TO GROUND
FUSE BLOWN - PUMP MOTOR CI RCUI T
NO B+ SUPPLY TO FUSE
ABS PUMP MOTOR I NOPERATI VE
FUSED B(+) CI RCUI T OPEN
GROUND CI RCUI T OPEN
GROUND CI RCUI T HI GH RESI STANCE
CAB - I NTERNAL FAULT
TEST ACTION APPLICABILITY
1 Turn the i gni ti on on.
Wi th the DRBI I I ௡, read DTC’s.
Wi th the DRBI I I ௡, erase DTC’s.
Turn the i gni ti on off.
Turn the i gni ti on on.
Wi th the DRBI I I ௡, actuate the ABS pump motor.
Di d the Pump Motor operate when actuated?
Al l
No → Go To 2
Yes → Go To 13
2 Turn the i gni ti on off.
Remove and i nspect the ABS Pump fuse i n the PDC.
I s the Fuse bl own?
Al l
Yes → Go To 3
No → Go To 7
25
BRAKES (CAB)
TEST ACTION APPLICABILITY
3 Turn the i gni ti on off.
Make sure the Pump Motor connector i s secure.
Vi sual l y i nspect the Fused B(+) Ci rcui t i n the wi ri ng harness from the PDC to the
CAB. Look for any si gn of an I ntermi ttent Short to Ground.
I s the wi ri ng harness OK?
Al l
Yes → Go To 4
No → Repai r the Fused B(+) Ci rcui t shorted to ground. The CAB must
sense al l four wheel s at 25 km/h (15 mph) before i t wi l l exti ngui sh
the ABS I ndi cator.
Perform ABS VERI FI CATI ON TEST - VER 1.
4 Turn the i gni ti on off.
Remove ABS PUMP Fuse 8 from the Power Di stri buti on Center (PDC).
Di sconnect the CAB connector.
Make sure the Pump Motor connector i s secure.
Note: Check connector - Clean/repair as necessary.
Usi ng a test l i ght connected to 12 vol ts, probe the Fused B (+) Ci rcui t.
I s the test l i ght on?
Al l
Yes → Repai r the Fused B(+) ci rcui t short to ground. The CAB must
sense al l four wheel s at 25 km/h (15 mph) before i t wi l l exti ngui sh
the ABS I ndi cator.
Perform ABS VERI FI CATI ON TEST - VER 1.
No → Go To 5
5 Turn the i gni ti on off.
Remove ABS PUMP Fuse 12 from the PDC.
The CAB must be connected for the resul ts of thi s test to be val i d.
Usi ng a test l i ght connected to 12 vol ts, probe the Fused B (+) ci rcui t i n the PDC.
I s the test l i ght on?
Al l
Yes → Repl ace the Control l er Anti l ock Brake i n accordance wi th the
Servi ce I nformati on.
Perform ABS VERI FI CATI ON TEST - VER 1.
No → Go To 6
6 Turn the i gni ti on off.
Make sure the Pump Motor connector i s secure
I f there are no potenti al causes remai ni ng, repl ace the Fuse.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace the ABS Pump Motor Fuse. The CAB must sense al l four
wheel s at 25 km/h (15 mph) before i t wi l l exti ngui sh the ABS
I ndi cator.
Perform ABS VERI FI CATI ON TEST - VER 1.
26
BRAKES (CAB)
PUMP MOTOR NOT WORKING PROPERLY — Continued
TEST ACTION APPLICABILITY
7 Turn the i gni ti on off.
Remove ABS PUMP Fuse #12 from the Power Di stri buti on Center (PDC).
Di sconnect the CAB connector.
Note: Check connector - Clean/repair as necessary.
Measure the resi stance of the Fused B (+) ci rcui t between the PDC Fuse Termi nal
and the CAB connector.
I s the resi stance bel ow 10 ohms?
Al l
Yes → Go To 8
No → Repai r the Fused B(+) ci rcui t for an open. The CAB must sense al l
four wheel s at 25 km/h (15 mph) before i t wi l l exti ngui sh the ABS
I ndi cator.
Perform ABS VERI FI CATI ON TEST - VER 1.
8 Turn the i gni ti on on.
Usi ng a 12-vol t test l i ght connected to ground, check the B+ suppl y to Fuse 12 i n the
PDC.
I s the B+ suppl y OK?
Al l
Yes → Go To 9
No → Repai r the B+ suppl y for an open. The CAB must sense al l four
wheel s at 25 km/h (15 mph) before i t wi l l exti ngui sh the ABS
I ndi cator.
Perform ABS VERI FI CATI ON TEST - VER 1.
9 Turn the i gni ti on off.
Di sconnect Pump Motor Connector.
Connect a 10 gauge jumper wi re between pump motor Fused B (+) ci rcui t and a 40
Amp Fused B (+) ci rcui t.
Connect a 10 gauge jumper wi re between pump motor ground ci rcui t and a known
good body ground.
Moni tor Pump Motor operati on.
I s the pump motor runni ng?
Al l
Yes → Go To 10
No → Repl ace the Control l er Anti l ock Brake i n accordance wi th the
Servi ce I nformati on. The CAB must sense al l four wheel s at 25
km/h (15 mph) before i t wi l l exti ngui sh the ABS I ndi cator.
Perform ABS VERI FI CATI ON TEST - VER 1.
10 Turn the i gni ti on off.
Di sconnect CAB Connector.
Note: Check connector - Clean/repair as necessary.
Measure the resi stance of the CAB ground ci rcui ts.
I s the resi stance bel ow 1.0 ohm?
Al l
Yes → Go To 11
No → Repai r the ground ci rcui t for an open. The CAB must sense al l
four wheel s at 25 km/h (15 mph) before i t wi l l exti ngui sh the ABS
I ndi cator.
Perform ABS VERI FI CATI ON TEST - VER 1.
27
BRAKES (CAB)
PUMP MOTOR NOT WORKING PROPERLY — Continued
TEST ACTION APPLICABILITY
11 Make sure the Pump Motor connector i s secure.
Turn the i gni ti on on.
Wi th the DRBI I I ௡, enabl e pump motor actuati on.
NOTE: Pump motor will not operate, but voltage will be applied.
Measure the vol tage drop across the ABS ground ci rcui t connecti on, wi th pump motor
actuati on enabl ed.
I s the vol tage bel ow 0.1 vol t?
Al l
Yes → Go To 12
No → Repai r the Ground ci rcui t for an open. The CAB must sense al l
four wheel s at 25 km/h (15 mph) before i t wi l l exti ngui sh the ABS
I ndi cator.
Perform ABS VERI FI CATI ON TEST - VER 1.
12 I f there are no possi bl e causes remai ni ng, vi ew repai r. Al l
Repai r
Repl ace the Control l er Anti -Lock Brake i n accordance wi th the
Servi ce I nformati on. The CAB must sense al l four wheel s at 25
km/h (15 mph) before i t wi l l exti ngui sh the ABS I ndi cator.
Perform ABS VERI FI CATI ON TEST - VER 1.
13 Turn the i gni ti on off.
Vi sual l y i nspect the rel ated wi ri ng harness. Look for any chafed, pi erced, pi nched, or
parti al l y broken wi res.
Make sure the Pump Motor connecter i s secure.
Vi sual l y i nspect the rel ated wi re harness connectors. Look for broken, bent, pushed
out, or corroded termi nal s.
Refer to any Hotl i ne l etters or Techni cal Servi ce Bul l eti ns that may appl y.
Were any probl ems found?
Al l
Yes → Repai r as necessary. The CAB must sense al l four wheel s at 25
km/h (15 mph) before i t wi l l exti ngui sh the ABS I ndi cator.
Perform ABS VERI FI CATI ON TEST - VER 1.
No → Test Compl ete.
28
BRAKES (CAB)
PUMP MOTOR NOT WORKING PROPERLY — Continued
Symptom:
SYSTEM OVER VOLTAGE
When Monitored and Set Condition:
SYSTEM OVER VOLTAGE
When Moni tored: I gni ti on on. The CAB moni tors the Fused B(+) ci rcui t at al l ti mes for
proper system vol tage.
Set Condi ti on: I f the vol tage i s above 16.5 vol ts, the Di agnosti c Troubl e Code (DTC) i s set.
POSSIBLE CAUSES
BATTERY OVERCHARGED
FUSED I GNI TI ON SWI TCH OUTPUT HI GH
GROUND CI RCUI T OPEN
CAB - I NTERNAL FAULT
I NTERMI TTENT DTC
TEST ACTION APPLICABILITY
1 Turn the i gni ti on on.
Wi th the DRBI I I ௡, erase DTC’s.
Turn the i gni ti on off.
Turn the i gni ti on on.
Start the engi ne.
Wi th the DRBI I I ௡, read DTC’s.
Does the DRBI I I ௡ di spl ay System Overvol tage DTC?
Al l
Yes → Go To 2
No → Go To 6
2 Turn the i gni ti on off.
I nspect for battery charger connected to battery.
I s a battery charger connected to the battery?
Al l
Yes → Charge battery to proper l evel . Di sconnect the battery charger.
Cl ear DTC’s.
Perform ABS VERI FI CATI ON TEST - VER 1.
No → Go To 3
29
BRAKES (CAB)
TEST ACTION APPLICABILITY
3 Turn the i gni ti on off.
Di sconnect the CAB connector.
Note: Check connector - Clean/repair as necessary.
Start the engi ne.
Rai se engi ne RPM’s above 1,800.
Measure the battery vol tage.
I s the vol tage above 16.5 vol ts ?
Al l
Yes → Refer to appropri ate servi ce i nformati on for chargi ng system
testi ng and repai r.
Perform ABS VERI FI CATI ON TEST - VER 1.
No → Go To 4
4 Turn the i gni ti on off.
Di sconnect the CAB connector.
Note: Check connector - Clean/repair as necessary.
Measure the resi stance of the ground ci rcui ts.
I s the resi stance bel ow 1.0 ohm?
Al l
Yes → Go To 5
No → Repai r the Ground ci rcui t for an open.
Perform ABS VERI FI CATI ON TEST - VER 1.
5 I f there are no potenti al causes remai ni ng, vi ew repai r. Al l
Repai r
Repl ace the Control l er Anti l ock Brake.
Perform ABS VERI FI CATI ON TEST - VER 1.
6 Turn the i gni ti on off.
Vi sual l y i nspect the rel ated wi ri ng harness. Look for any chafed, pi erced, pi nched, or
parti al l y broken wi res.
Vi sual l y i nspect the rel ated wi re harness connectors. Look for broken, bent, pushed
out, or corroded termi nal s.
Refer to any Hotl i ne l etters or Techni cal Servi ce Bul l eti ns that may appl y.
Were any probl ems found?
Al l
Yes → Repai r as necessary.
Perform ABS VERI FI CATI ON TEST - VER 1.
No → Test Compl ete.
30
BRAKES (CAB)
SYSTEM OVER VOLTAGE — Continued
Symptom:
SYSTEM UNDER VOLTAGE
When Monitored and Set Condition:
SYSTEM UNDER VOLTAGE
When Moni tored: I gni ti on on. The CAB moni tors the Fused I gni ti on Swi tch Output for
proper system vol tage.
Set Condi ti on: I f the vol tage i s bel ow 9.5 vol ts, the Di agnosti c Troubl e Code (DTC) i s set.
POSSIBLE CAUSES
BATTERY VOLTAGE LOW
I NTERMI TTENT DTC
FUSED I GNI TI ON SWI TCH OUTPUT CI RCUI T HI GH RESI STANCE
GROUND CI RCUI T OPEN
CAB - I NTERNAL FAULT
TEST ACTION APPLICABILITY
1 Turn the i gni ti on on.
Wi th the DRBI I I ௡, erase DTC’s.
Turn the i gni ti on off.
Turn the i gni ti on on.
Start the engi ne.
Dri ve the vehi cl e above 16 km/h (10 mph) for at l east 20 seconds.
Stop the vehi cl e
Wi th the DRBI I I ௡, read DTC’s.
Does the DRBI I I ௡ di spl ay System Undervol tage DTC?
Al l
Yes → Go To 2
No → Go To 6
2 Engi ne Runni ng.
Measure the battery vol tage.
I s the battery vol tage bel ow 10 vol ts?
Al l
Yes → Refer to appropri ate servi ce i nformati on for chargi ng system
testi ng and repai r.
Perform ABS VERI FI CATI ON TEST - VER 1.
No → Go To 3
3 Turn the i gni ti on off.
Di sconnect the CAB connector.
Note: Check connector - Clean/repair as necessary.
Measure the resi stance of the ground ci rcui ts.
I s the resi stance bel ow 1.0 ohm?
Al l
Yes → Go To 4
No → Repai r the Ground ci rcui t for an open.
Perform ABS VERI FI CATI ON TEST - VER 1.
31
BRAKES (CAB)
TEST ACTION APPLICABILITY
4 Di sconnect the CAB harness connector.
Turn the i gni ti on on.
Measure the vol tage of the Fused I gni ti on Swi tch ci rcui t.
I s the vol tage above 10 vol ts?
Al l
Yes → Go To 5
No → Repai r the Fused I gni ti on Swi tch Output Ci rcui t for hi gh resi s-
tance
Perform ABS VERI FI CATI ON TEST - VER 1.
5 I f there are no potenti al causes remai ni ng, vi ew repai r. Al l
Repai r
Repl ace the Control l er Anti l ock Brake.
Perform ABS VERI FI CATI ON TEST - VER 1.
6 Turn the i gni ti on off.
Vi sual l y i nspect the rel ated wi ri ng harness. Look for any chafed, pi erced, pi nched, or
parti al l y broken wi res.
Vi sual l y i nspect the rel ated wi re harness connectors. Look for broken, bent, pushed
out, or corroded termi nal s.
Refer to any Hotl i ne l etters or Techni cal Servi ce Bul l eti ns that may appl y.
Were any probl ems found?
Al l
Yes → Repai r as necessary.
Perform ABS VERI FI CATI ON TEST - VER 1.
No → Test Compl ete.
32
BRAKES (CAB)
SYSTEM UNDER VOLTAGE — Continued
Symptom:
*ABS WARNING INDICATOR ALWAYS ON
POSSIBLE CAUSES
ABS RELAY STUCK
ABS RELAY FUSED B+ CI RCUI T OPEN
ABS RELAY CONTROL CI RCUI T OPEN
CAB I NTERNAL OPEN
ABS I NDI CATOR DRI VER SHORT TO GROUND
I NSTRUMENT CLUSTER CONCERN
TEST ACTION APPLICABILITY
1 Remove the ABS rel ay from PDC.
Perform the key-on bul b test.
Does the ABS I ndi cator l i ght and remai n l i t?
Al l
Yes → Go To 2
No → Go To 3
2 Di sconnect the I nstrument Cl uster C2 harness connector.
Remove the ABS rel ay from the PDC.
Usi ng a 12-vol t test l i ght connected to 12-vol ts, check the ABS Warni ng I ndi cator
Dri ver ci rcui t.
Does the test l i ght i l l umi nate?
Al l
Yes → Repai r the ABS I ndi cator ci rcui t for a short to ground. The CAB
may have to sense al l four wheel s at 25 km/h (15 mph) before i t
wi l l exti ngui sh the ABS I ndi cator.
Perform ABS VERI FI CATI ON TEST - VER 1.
No → Refer to symptom l i st for probl ems rel ated to I nstrument Cl uster.
The CAB may have to sense al l four wheel s at 25 km/h (15 mph)
before i t wi l l exti ngui sh the ABS I ndi cator.
Perform ABS VERI FI CATI ON TEST - VER 1.
3 I nstal l a substi tute rel ay i n pl ace of the ABS rel ay.
Perform the key-on bul b check.
Does the ABS Warni ng I ndi cator operate OK?
Al l
Yes → Repl ace the ABS rel ay. The CAB may have to sense al l four wheel s
at 25 km/h (15 mph) before i t wi l l exti ngui sh the ABS I ndi cator.
Perform ABS VERI FI CATI ON TEST - VER 1.
No → Go To 4
33
BRAKES (CAB)
TEST ACTION APPLICABILITY
4 Remove the ABS rel ay from the PDC.
Turn the i gni ti on on.
Usi ng a 12-vol t test l i ght connected to ground, check the Fused B+ ci rcui t.
Does the test l i ght i l l umi nate?
Al l
Yes → Go To 5
No → Repai r the ABS rel ay Fused B+ ci rcui t for an open. The CAB may
have to sense al l four wheel s at 25 km/h (15 mph) before i t wi l l
exti ngui sh the ABS I ndi cator.
Perform ABS VERI FI CATI ON TEST - VER 1.
5 Remove the ABS rel ay.
Di sconnect the CAB harness connector.
Measure the resi stance of the ABS Rel ay Control ci rcui t.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Repl ace the Control l er Anti l ock Brake.
Perform ABS VERI FI CATI ON TEST - VER 1.
No → Repai r the ABS Rel ay Control ci rcui t for an open. The CAB may
have to sense al l four wheel s at 25 km/h (15 mph) before i t wi l l
exti ngui sh the ABS I ndi cator.
Perform ABS VERI FI CATI ON TEST - VER 1.
34
BRAKES (CAB)
*ABS WARNING INDICATOR ALWAYS ON — Continued
Symptom:
*ABS WARNING INDICATOR INOPERATIVE
POSSIBLE CAUSES
I NSTRUMENT CLUSTER CONCERN
ABS RELAY STUCK
ABS RELAY GROUND CI RCUI T OPEN
ABS RELAY CONTROL CI RCUI T SHORT TO GROUND
CAB I NTERNAL SHORT TO GROUND
ABS I NDI CATOR BULB OPEN
ABS I NDI CATOR DRI VER OPEN
I NSTRUMENT CLUSTER I NTERNAL OPEN
TEST ACTION APPLICABILITY
1 Perform the key-on bul b check.
Do al l bul bs check OK except for the ABS Warni ng I ndi cator?
Al l
Yes → Go To 2
No → Refer to symptom l i st for probl ems rel ated to I nstrument Cl uster.
Perform ABS VERI FI CATI ON TEST - VER 1.
2 I nstal l a substi tute rel ay i n pl ace of the ABS rel ay.
Perform the key-on bul b check.
Does the ABS Warni ng I ndi cator operate OK?
Al l
Yes → Repl ace the ABS rel ay.
Perform ABS VERI FI CATI ON TEST - VER 1.
No → Go To 3
3 Remove the ABS rel ay from PDC.
Connect a jumper wi re between the ABS Warni ng I ndi cator dri ver cavi ty of the ABS
rel ay socket and ground.
Key to RUN
Does the ABS I ndi cator l i ght?
Al l
Yes → Go To 4
No → Go To 6
4 Remove the ABS rel ay from the PDC.
Usi ng a 12-vol t test l i ght connected to 12-vol ts, check the ABS rel ay ground ci rcui t.
Does the test l i ght i l l umi nate?
Al l
Yes → Go To 5
No → Repai r the ABS rel ay Ground ci rcui t for an open.
Perform ABS VERI FI CATI ON TEST - VER 1.
35
BRAKES (CAB)
TEST ACTION APPLICABILITY
5 Remove the ABS rel ay.
Di sconnect the CAB harness connector.
Usi ng a 12-vol t test l i ght connected to 12-vol ts, check the ABS Rel ay Control ci rcui t.
Does the test l i ght i l l umi nate?
Al l
Yes → Repai r the ABS Rel ay Control ci rcui t for a short to ground.
Perform ABS VERI FI CATI ON TEST - VER 1.
No → Repl ace the Control l er Anti l ock Brake.
Perform ABS VERI FI CATI ON TEST - VER 1.
6 I nstal l a substi tute bul b i n pl ace of the ABS I ndi cator bul b.
Perform the key-on bul b check.
Does the ABS bul b i l l umi nate?
Al l
Yes → Repl ace the ABS i ndi cator bul b.
Perform ABS VERI FI CATI ON TEST - VER 1.
No → Go To 7
7 Di sconnect the I nstrument Cl uster C2 harness connector.
Remove the ABS rel ay from the PDC.
Measure the resi stance of the ABS I ndi cator dri ver ci rcui t.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Repl ace the I nstrument Cl uster i n accordance wi th the Servi ce
I nformati on..
Perform ABS VERI FI CATI ON TEST - VER 1.
No → Repai r the ABS I ndi cator Dri ver ci rcui t for an open.
Perform ABS VERI FI CATI ON TEST - VER 1.
36
BRAKES (CAB)
*ABS WARNING INDICATOR INOPERATIVE — Continued
Symptom:
*BRAKE LAMP SWITCH
POSSIBLE CAUSES
CHECK BRAKE LAMP SWI TCH OUTPUT
BRAKE LAMP SWI TCH B+ OPEN
BRAKE LAMP SWI TCH OUTPUT CI RCUI T SHORT OR OPEN
BRAKE LAMP SWI TCH OPEN
CAB -- I NTERNAL OPEN
TEST ACTION APPLICABILITY
1 Wi th the DRBI I I ௡ i n I nputs/Outputs, read the Brake Lamp Swi tch state.
Press and rel ease the brake pedal .
Does the DRBI I I ௡ di spl ay PRESSED and RELEASED?
Al l
Yes → The Brake Lamp Swi tch i s OK.
Perform ABS VERI FI CATI ON TEST - VER 1.
No → Go To 2
2 Di sconnect the Brake Lamp Swi tch harness connector.
Usi ng a 12-vol t test l i ght connected to ground, check the Brake Lamp Swi tch Fused
B+ ci rcui t.
Does the test l i ght i l l umi nate bri ghtl y ?
Al l
Yes → Go To 3
No → Repai r the Brake Lamp Swi tch Fused B+ ci rcui t for an open.
Perform ABS VERI FI CATI ON TEST - VER 1.
3 Di sconnect the Brake Lamp Swi tch harness connector.
Connect a jumper wi re between the Brake Lamp Swi tch B+ and Output ci rcui ts.
Wi th the DRBI I I ௡ i n I nputs/Outputs, read the Brake Lamp Swi tch state.
Does the DRBI I I ௡ di spl ay PRESSED?
Al l
Yes → Repl ace the Brake Lamp Swi tch i n accordance wi th the Servi ce
I nformati on.
Perform ABS VERI FI CATI ON TEST - VER 1.
No → Go To 4
4 Di sconnect the CAB harness connector.
Di sconnect the Brake Lamp Swi tch harness connector.
Check the Brake Lamp Swi tch Output ci rcui t for a short to vol tage and an open.
I s the Brake Lamp Swi tch Output ci rcui t shorted or open?
Al l
Yes → Repai r the Brake Lamp Swi tch Output ci rcui t for a short to
vol tage or an open.
Perform ABS VERI FI CATI ON TEST - VER 1.
No → Repl ace the Control l er Anti -Lock Brake i n accordance wi th the
Servi ce I nformati on.
Perform ABS VERI FI CATI ON TEST - VER 1.
37
BRAKES (CAB)
Symptom:
*FRONT AXLE LOCK INDICATOR REMAINS FLASHING
POSSIBLE CAUSES
CHECKI NG OPERATI ON
I NTERMI TTENT CONDI TI ON
FUSED B(+) CI RCUI T OPEN TO THE FRONT LOCKER RELAY
FRONT LOCKER RELAY
FRONT LOCKER RELAY OUTPUT CI RCUI T OPEN
FRONT LOCKER PUMP GROUND CI RCUI T OPEN
FRONT LOCKER PUMP
FRONT LOCKER I NDI CATOR SWI TCH SENSE CI RCUI T OPEN
FRONT LOCKER I NDCATOR SWI TCH GROUND CI RCUI T OPEN
MECHANI CAL FAULT EXI STS
TEST ACTION APPLICABILITY
1 NOTE: For this test to be valid the Rear Axle must be locked and the Rear
Lock indicator must be illuminated.
Turn the i gni ti on on.
Ensure Transfer Case i s i n 4 ЉLOWЉ range.
Vehi cl e speed i s l ess than 16km/h (10 mph).
Depress the Axl e Lock Swi tch once.
Does the Front Axl e Lock i ndi cator remai n fl ashi ng?
Al l
Yes → Go To 2
No → The condi ti on i s not present at thi s ti me. Moni tor DRBI I I ௡
parameters whi l e wi ggl i ng the rel ated wi ri ng harness. Refer to
any Techni cal Servi ce Bul l eti ns(TSB) that may appl y. Vi sual l y
i nspect the rel ated wi ri ng harness and connector termi nal s.
Perform BODY VERI FI CATI ON TEST - VER 1.
2 Di sconnect the Front Locker Rel ay.
Measure the vol tage of the Fused B(+) ci rcui t i n the Front Locker Rel ay PDC
connector.
I s the vol tage above 10 vol ts?
Al l
Yes → Go To 3
No → Repai r the Fused B(+) ci rcui t for an open.
Perform BODY VERI FI CATI ON TEST - VER 1.
3 Turn the i gni ti on off.
Repl ace the Front Locker Rel ay wi th a known good part.
Turn the i gni ti on on.
Ensure Transfer Case i s i n 4 ЉLOWЉ range.
Depress the Axl e Lock Swi tch once.
Di d the Front Locker Pump turn ON?
Al l
Yes → Repl ace the Front Locker Rel ay.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Go To 4
38
BRAKES (CAB)
TEST ACTION APPLICABILITY
4 Measure the resi stance of the Front Locker Rel ay Output ci rcui t between the PDC
connector and the Front Locker Pump connector.
I s the resi stance above 5.0 ohms?
Al l
Yes → Repai r the Front Locker Rel ay Output ci rcui t for an open.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Go To 5
5 Turn the i gni ti on off.
Di sconnect the Front Locker Pump harness connector.
Measure the resi stance between ground and the Front Locker Pump Ground ci rcui t.
I s the resi stance above 5.0 ohms?
Al l
Yes → Repai r the Front Locker Pump Ground ci rcui t for an open.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Go To 6
6 Turn the i gni ti on on.
Ensure Transfer Case i s i n 4 ЉLOWЉ range.
Depress the Axl e Lock Swi tch once.
Di d the Front Locker Pump operate?
Al l
Yes → Go To 7
No → Refer to Di fferenti al /Dri vel i ne for the rel ated symptom(s).
Perform BODY VERI FI CATI ON TEST - VER 1.
7 Turn the i gni ti on off.
Di sconnect the I nstrument Cl uster C2 harness connector.
Di sconnect the Front Locker I ndi cator Swi tch harness connector.
Measure the resi stance of the Front Locker I ndi cator Swi tch Sense ci rcui t between
the I nstrument Cl uster C2 connector and the Front Locker I ndi cator Swi tch
connector.
I s the resi stance above 5.0 ohms?
Al l
Yes → Repai r the Front Locker I ndi cator Swi tch Sense ci rcui t for an
open.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Go To 8
8 Turn the i gni ti on off.
Di sconnect the Front Locker I ndi cator Swi tch harness connector.
Measure the resi stance between ground and the Front Locker I ndi cator Swi tch
Ground ci rcui t.
I s the resi stance above 5.0 ohms?
Al l
Yes → Repai r the Front Locker I ndi cator Swi tch Ground ci rcui t for an
open.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Refer to Di fferenti al /Dri vel i ne i nformati on for the rel ated symp-
tom(s).
Perform BODY VERI FI CATI ON TEST - VER 1.
39
BRAKES (CAB)
*FRONT AXLE LOCK INDICATOR REMAINS FLASHING — Continued
SymptomList:
*NO RESPONSE FROM CONTROLLER ANTILOCK BRAKE
POSSIBLE CAUSES
ATTEMPT TO COMMUNI CATE WI TH THE PCM
CHECK FUSE #7 I N FUSE BLOCK
OPEN GROUND CI RCUI TS
OPEN FUSED I GNI TI ON SWI TCH OUTPUT CI RCUI T
SCI TRANSMI T CI RCUI T OPEN
CONTROLLER ANTI LOCK BRAKE
TEST ACTION APPLICABILITY
1 Turn the i gni ti on on.
Wi th the DRB attempt to communi cate wi th the PCM.
Was the DRB abl e to communi cate wi th the PCM?
Al l
Yes → Go To 2
No → Refer to symptom l i st for probl ems rel ated to No Response From
PCM.
Perform ABS VERI FI CATI ON TEST - VER 1.
2 Turn the i gni ti on off.
Remove and i nspect fuse #7 i n the Fuse Bl ock.
I s the fuse open?
Al l
Yes → Refer to the wi ri ng di agrams l ocated i n the servi ce i nformati on to
hel p i sol ate a possi bl e short to ground.
Perform ABS VERI FI CATI ON TEST - VER 1.
No → Go To 3
3 Turn the i gni ti on off.
Di sconnect the CAB harness connector.
Usi ng a 12-vol t test l i ght connected to 12-vol ts, probe each ground ci rcui t.
I s the test l i ght i l l umi nated for each ci rcui t?
Al l
Yes → Go To 4
No → Repai r the ground ci rcui t for an open.
Perform ABS VERI FI CATI ON TEST - VER 1.
4 Turn the i gni ti on off.
NOTE: Ensure fuse #7 is installed in the Fuse Block.
Di sconnect the CAB harness connector.
Turn the i gni ti on on.
Usi ng a 12-vol t test l i ght connected to ground, probe the Fused I gni ti on Swi tch
Output ci rcui t.
I s the test l i ght i l l umi nated?
Al l
Yes → Go To 5
No → Repai r the Fused I gni ti on Swi tch Output ci rcui t for an open.
Perform ABS VERI FI CATI ON TEST - VER 1.
40
BRAKES (CAB)
TEST ACTION APPLICABILITY
5 Turn the i gni ti on off.
Di sconnect the CAB harness connector.
Measure the resi stance of the SCI Transmi t ci rcui t between the CAB connector and
the DLC.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 6
No → Repai r the SCI Transmi t ci rcui t for an open.
Perform ABS VERI FI CATI ON TEST - VER 1.
6 I f there are no possi bl e causes remai ni ng, vi ew repai r. Al l
Repai r
Repl ace the Control l er Anti l ock Brake i n accordance wi th the
Servi ce I nformati on.
Perform ABS VERI FI CATI ON TEST - VER 1.
41
BRAKES (CAB)
*NO RESPONSE FROM CONTROLLER ANTILOCK BRAKE — Continued
Symptom:
*REAR AXLE LOCK INDICATOR REMAINS FLASHING
POSSIBLE CAUSES
CHECKI NG OPERATI ON
I NTERMI TTENT CONDI TI ON
OPEN FUSE I N PDC
FUSED B(+) CI RCUI T OPEN TO THE REAR LOCKER RELAY
REAR LOCKER RELAY
REAR LOCKER RELAY OUTPUT CI RCUI T OPEN
REAR LOCKER PUMP GROUND CI RCUI T OPEN
REAR LOCKER PUMP
REAR LOCKER I NDI CATOR SWI TCH SENSE CI RCUI T OPEN
REAR LOCKER I NDCATOR SWI TCH GROUND CI RCUI T OPEN
MECHANI CAL FAULT EXI STS
TEST ACTION APPLICABILITY
1 Turn the i gni ti on on.
Ensure Transfer Case i s i n 4 ЉLOWЉ range.
Vehi cl e speed i s l ess than 16km/h (10 mph).
Depress the Axl e Lock Swi tch once.
Does the Rear Axl e Lock i ndi cator remai n fl ashi ng?
Al l
Yes → Go To 2
No → The condi ti on i s not present at thi s ti me. Moni tor DRBI I I ௡
parameters whi l e wi ggl i ng the rel ated wi ri ng harness. Refer to
any Techni cal Servi ce Bul l eti ns(TSB) that may appl y. Vi sual l y
i nspect the rel ated wi ri ng harness and connector termi nal s.
Perform BODY VERI FI CATI ON TEST - VER 1.
2 I nspect Fuse 24 i n the PDC.
I s the Fuse open, mi ssi ng, or l oose?
Al l
Yes → Repl ace the open or mi ssi ng fuse. I f the fuse i s open make sure to
check for a short to ground i n the Fused B(+) ci rcui t between the
fuse and the rel ay.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Go To 3
3 Di sconnect the Rear Locker Rel ay.
Measure the vol tage of the Fused B(+) ci rcui t i n the Rear Locker Rel ay PDC
connector.
I s the vol tage above 10 vol ts?
Al l
Yes → Go To 4
No → Repai r the Fused B(+)ci rcui t for an open.
Perform BODY VERI FI CATI ON TEST - VER 1.
42
BRAKES (CAB)
TEST ACTION APPLICABILITY
4 Turn the i gni ti on off.
Repl ace the Rear Locker Rel ay wi th a known good part.
Turn the i gni ti on on.
Ensure Transfer Case i s i n 4 ЉLOWЉ range.
Depress the Axl e Lock Swi tch once.
Di d the Rear Locker Pump turn ON?
Al l
Yes → Repl ace the Rear Locker Rel ay.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Go To 5
5 Measure the resi stance of the Rear Locker Rel ay Output ci rcui t between the PDC
connector and the Rear Locker Pump connector.
I s the resi stance above 5.0 ohms?
Al l
Yes → Repai r the Rear Locker Rel ay Output ci rcui t for an open.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Go To 6
6 Turn the i gni ti on off.
Di sconnect the Rear Locker Pump harness connector.
Measure the resi stance between ground and the Rear Locker Pump Ground ci rcui t.
I s the resi stance above 5.0 ohms?
Al l
Yes → Repai r the Rear Locker Pump Ground ci rcui t for an open.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Go To 7
7 Turn the i gni ti on on.
Ensure Transfer Case i s i n 4 ЉLOWЉ range.
Depress the Axl e Lock Swi tch once.
Di d the Rear Locker Pump operate?
Al l
Yes → Go To 8
No → Refer to Di fferenti al /Dri vel i ne for the rel ated symptom(s).
Perform BODY VERI FI CATI ON TEST - VER 1.
8 Turn the i gni ti on off.
Di sconnect the I nstrument Cl uster C1 harness connector.
Di sconnect the Rear Locker I ndi cator Swi tch harness connector.
Measure the resi stance of the Rear Locker I ndi cator Swi tch Sense ci rcui t between
the I nstrument Cl uster C1 connector and the Rear Locker I ndi cator Swi tch connec-
tor.
I s the resi stance above 5.0 ohms?
Al l
Yes → Repai r the Rear Locker I ndi cator Swi tch Sense ci rcui t for an
open.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Go To 9
43
BRAKES (CAB)
*REAR AXLE LOCK INDICATOR REMAINS FLASHING — Continued
TEST ACTION APPLICABILITY
9 Turn the i gni ti on off.
Di sconnect the Rear Locker I ndi cator Swi tch harness connector.
Measure the resi stance between ground and the Rear Locker I ndi cator Swi tch
Ground ci rcui t.
I s the resi stance above 5.0 ohms?
Al l
Yes → Repai r the Rear Locker I ndi cator Swi tch Ground ci rcui t for an
open.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Refer to Di fferenti al /Dri vel i ne i nformati on for the rel ated symp-
tom(s).
Perform BODY VERI FI CATI ON TEST - VER 1.
44
BRAKES (CAB)
*REAR AXLE LOCK INDICATOR REMAINS FLASHING — Continued
Symptom:
*REAR AXLE LOCK INOPERATIVE
POSSIBLE CAUSES
CHECKI NG OPERATI ON
I NSTRUMENT CLUSTER NOT PROPERLY CONFI GURED
VSS, PCM, OR TRANSFER CASE DTC’S PRESENT
OPEN FUSE I N PDC
AXLE LOCK SWI TCH GROUND CI RCUI T OPEN
FUSED B(+) CI RCUI T OPEN TO AXLE LOCK SWI TCH
AXLE LOCK SWI TCH FAI LURE
TEST ACTION APPLICABILITY
1 Turn the i gni ti on on.
Ensure Transfer Case i s i n 4 ЉLOWЉ range.
Vehi cl e speed i s l ess than 16 km/h (10 mph).
Depress the Axl e Lock Swi tch once.
Does the Axl e Lock Swi tch i ndi cator i l l umi nate?
Al l
Yes → The condi ti on i s not present at thi s ti me. Moni tor DRBI I I ௡
parameters whi l e wi ggl i ng the rel ated wi ri ng harness. Refer to
any Techni cal Servi ce Bul l eti ns(TSB) that may appl y. Vi sual l y
i nspect the rel ated wi ri ng harness and connector termi nal s.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Go To 2
2 Turn the i gni ti on on.
Wi th the DRBI I I ௡, ensure the I nstrument Cl uster i s correctl y confi gured for Ti re
si ze, Axl e type, and Transfer Case.
I s the vehi cl e I nstrument Cl uster confi gured correctl y?
Al l
Yes → Go To 3
No → Refer to Body for the rel ated symptom(s).
Perform BODY VERI FI CATI ON TEST - VER 1.
3 Turn the i gni ti on on.
Wi th the DRBI I I ௡, ensure there are no VSS, PCM, or Transfer Case DTC’s present.
NOTE: WhenALL conditionsaremet theInstrument Cluster Enable1State
must indicate - LOW.
Vehi cl e must i ndi cate the transfer case i s i n 4 ЉLOWЉ range, the i gni ti on ON, and
vehi cl e speed i s l ess than 16 km/h (10 mph).
Are any VSS, PCM, or Transfer Case DTC’s present?
Al l
Yes → Refer to the appropri ate servi ce i nformati on for the rel ated
DTC’s.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Go To 4
45
BRAKES (CAB)
TEST ACTION APPLICABILITY
4 I nspect Fuse 26 i n the PDC.
I s the Fuse open, mi ssi ng, or l oose?
Al l
Yes → Repl ace the open or mi ssi ng fuse. I f the fuse i s open make sure to
check for a short to ground i n the Fused B(+) ci rcui t from the fuse
to the swi tch.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Go To 5
5 Turn on the Park l amps.
Observe the Axl e Lock Swi tch.
Does the Axl e Lock Swi tch i l l umi nate?
Al l
Yes → Go To 6
No → Repai r the Axl e Lock Swi tch Ground ci rcui t for an open.
Perform BODY VERI FI CATI ON TEST - VER 1.
6 Di sconnect the Axl e Lock Swi tch connector.
Measure the vol tage of the Fused B(+) ci rcui t i n the Axl e Lock Swi tch connector.
I s the vol tage above 10 vol ts?
Al l
Yes → Repl ace the Axl e Lock Swi tch i n accordance wi th the Servi ce
I nformati on.
Perform BODY VERI FI CATI ON TEST - VER 1.
No → Repai r the Fused B(+) ci rcui t for an open.
Perform BODY VERI FI CATI ON TEST - VER 1.
46
BRAKES (CAB)
*REAR AXLE LOCK INOPERATIVE — Continued
Verification Tests
ABS VERIFICATION TEST - VER 1 APPLICABILITY
1. Turn the i gni ti on off.
2. Connect al l previ ousl y di sconnected components and connectors.
3. Ensure al l accessori es are turned off and the battery i s ful l y charged.
4. Ensure that the I gni ti on i s on, and wi th the DRBI I I , erase al l Di agnosti c Troubl e Codes from
ALL modul es. Start the engi ne and al l ow i t to run for 2 mi nutes and ful l y operate the system
that was mal functi oni ng.
5. Turn the i gni ti on off and wai t 5 seconds. Turn the i gni ti on on and usi ng the DRBI I I , read
DTC’s from ALL modul es.
6. I f any Di agnosti c Troubl e Codes are present, return to Symptom l i st and troubl eshoot new
or recurri ng symptom.
7. NOTE: For Sensor Signal and Pump Motor faults, theCAB must senseall 4wheels
at 25 km/h (15 mph) before it will extinguish theABS Indicator.
8. I f there are no DTC’s present after turni ng i gni ti on on, road test the vehi cl e for at l east 5
mi nutes. Perform several anti l ock braki ng stops.
9. Caution: Ensure braking capability is available before road testing.
10. Agai n, wi th the DRBI I I ௡ read DTC’s. I f any DTC’s are present, return to Symptom l i st.
11. I f there are no Di agnosti c Troubl e Codes (DTC’s) present, and the customer’s concern can no
l onger be dupl i cated, the repai r i s compl ete.
Are any DTC’s present or i s the ori gi nal concern sti l l present?
Al l
Yes → Repai r i s not compl ete, refer to appropri ate symptom.
No → Repai r i s compl ete.
BODY VERIFICATION TEST - VER 1 APPLICABILITY
1. Di sconnect al l jumper wi res and reconnect al l previ ousl y di sconnected components and
connectors.
2. NOTE: If the SKIM or PCM was replaced, refer to the service information for
proper programming procedures.
3. NOTE: If theMIC was replaced, configurenewcluster with TireSize, Axle, T-Case
Type, and EQ Setting.
4. Ensure al l accessori es are turned off and the battery i s ful l y charged.
5. Wi th the DRBI I I ௡, record and erase al l DTC’s from ALL modul es. Start and run the engi ne
for 2 mi nutes. Operate al l functi ons of the system that caused the ori gi nal concern.
6. Turn the i gni ti on off and wai t 5 seconds. Turn the i gni ti on on and usi ng the DRBI I I ௡, read
DTC’s from ALL modul es.
Are any DTCs present or i s the ori gi nal condi ti on sti l l present?
Al l
Yes → Repai r i s not compl ete, refer to the appropri ate symptom.
No → Repai r i s compl ete.
47
VERIFICATION TESTS
NOTES
48
8.0 COMPONENT LOCATIONS
8. 1 CONTROLLER ANTILOCK BRAKE
8. 2 DATA LINK CONNECTOR
8. 3 G-SWITCH
C
O
M
P
O
N
E
N
T
L
O
C
A
T
I
O
N
S
49
COMPONENT LOCATIONS
8. 4 FUSES & RELAYS
8. 5 WHEEL SPEED SENSORS
FRONT REAR DRUM BRAKES
8. 6 WHEEL SPEED SENSOR CONNECTORS
LEFT FRONT RIGHT FRONT
C
O
M
P
O
N
E
N
T
L
O
C
A
T
I
O
N
S
50
COMPONENT LOCATIONS
REAR
8. 7 BRAKE SWITCHES
8. 7. 1 PARKING BRAKE 8. 7. 2 BRAKE SWITCH
C
O
M
P
O
N
E
N
T
L
O
C
A
T
I
O
N
S
51
COMPONENT LOCATIONS
NOTES
52
9.0 CONNECTOR PINOUTS
AXLE LOCK SWITCH (OFF-ROAD PACKAGE) - 8 WAY
CAV CIRCUIT FUNCTION
1 Z1 20BK GROUND
2 E2 20OR PANEL LAMPS FEED
3 M1 20PK/WT FUSED B(+)
4 G302 20RD/WT LOCKER ENABLE SIGNAL 1
5 G303 20VT/DG LOCKER ENABLE SIGNAL 2
6 G305 20VT/LG REAR LOCKER REQUEST
7 G304 20VT/DB FRONT LOCKER REQUEST
8 - -
BRAKE LAMP SWITCH - GRAY 6 WAY
CAV CIRCUIT FUNCTION
1 K29 20WT/PK BRAKE LAMP SWITCH SENSE
1 K29 20WT/PK BRAKE LAMP SWITCH SENSE
2 Z1 20BK/WT GROUND
3 V32 20YL/RD SPEED CONTROL ON/OFF SWITCH SENSE
4 V30 20DB/RD SPEED CONTROL BRAKE LAMP SWITCH OUTPUT
5 F32 18PK/DB FUSED B(+)
6 L50 18WT/TN BRAKE LAMP SWITCH OUTPUT
BRAKE WARNING INDICATOR SWITCH - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 G9 20GY/BK BRAKE WARNING INDICATOR DRIVER
2 G99 20GY/WT BRAKE WARNING INDICATOR DRIVER
C115 (OFF-ROAD PACKAGE) - BLACK (ENGINE SIDE)
CAV CIRCUIT
1 Z1 20BK
2 G300 20VT/WT
C
O
N
N
E
C
T
O
R
P
I
N
O
U
T
S
53
CONNECTOR PINOUTS
C115 (OFF-ROAD PACKAGE) - BLACK (FRONT FEEDBACK OVERLAY SIDE)
CAV CIRCUIT
1 Z1 16BK
2 G300 16VT/WT
C116 (OFF-ROAD PACKAGE) - LT GRAY (ENGINE SIDE)
CAV CIRCUIT
1 Z1 20BK
2 G301 20VT/LB
C116 (OFF-ROAD PACKAGE) - LT GRAY (REAR FEEDBACK OVERLAY SIDE)
CAV CIRCUIT
1 Z1 16BK
2 G301 16VT/LB
CLUTCH PEDAL POSITION SWITCH (M/T) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 T141 18YL/RD FUSED IGNITION SWITCH OUTPUT (START)
2 A41 18YL FUSED IGNITION SWITCH OUTPUT (START)
C
O
N
N
E
C
T
O
R
P
I
N
O
U
T
S
54
CONNECTOR PINOUTS
CONTROLLER ANTILOCK BRAKE - 25 WAY
CAV CIRCUIT FUNCTION
1 B1 18YL/DB RIGHT REAR WHEEL SPEED SENSOR (-)
2 B3 18LG/DB LEFT REAR WHEEL SPEED SENSOR (-)
3 B7 18WT RIGHT FRONT WHEEL SPEED SENSOR (+)
4 B9 18RD LEFT FRONT WHEEL SPEED SENSOR (+)
5 - -
6 B41 18YL/VT G-SWITCH NO. 1 SENSE
7 B42 18TN/WT G-SWITCH NO. 2 SENSE
8 Z22 12BK/PK GROUND
9 A20 12RD/DB FUSED B(+)
10 B4 18LG LEFT REAR WHEEL SPEED SENSOR (+)
11 B8 18RD/DB LEFT FRONT WHEEL SPEED SENSOR (-)
12 L50 18WT/TN BRAKE LAMP SWITCH OUTPUT
13 B43 18PK/OR G-SWITCH TEST SIGNAL
14 - -
15 - -
16 G83 18GY/BK ABS RELAY CONTROL
17 B2 18YL RIGHT REAR WHEEL SPEED SENSOR (+)
18 B6 18WT/DB RIGHT FRONT WHEEL SPEED SENSOR (-)
19 - -
20 D21 18PK SCI TRANSMIT
21 - -
22 - -
23 F20 18VT/WT FUSED IGNITION SWITCH OUTPUT (RUN)
24 Z22 12BK/PK GROUND
25 A10 12RD/DG FUSED B(+)
DATA LINK CONNECTOR - BLACK 16 WAY
CAV CIRCUIT FUNCTION
1 - -
2 D25 20VT/YL PCI BUS
3 - -
4 Z2 20BK/LG GROUND
5 Z12 20BK/TN GROUND
6 D32 20LG/WT SCI RECEIVE
7 D21 20PK SCI TRANSMIT
8 - -
9 D23 20WT/BR FLASH PROGRAM ENABLE
10 - -
11 - -
12 - -
13 - -
14 D20 20LG/PK SCI RECEIVE
15 - -
16 M1 20PK/WT FUSED B(+)
C
O
N
N
E
C
T
O
R
P
I
N
O
U
T
S
55
CONNECTOR PINOUTS
FRONT LOCKER INDICATOR SWITCH (OFF-ROAD PACKAGE) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 Z1 16BK GROUND
2 G300 16VT/WT FRONT LOCKER INDICATOR SWITCH SENSE
FRONT LOCKER PUMP (OFF-ROAD PACKAGE) - LT GRAY 3 WAY
CAV CIRCUIT FUNCTION
1 Z1 18BK GROUND
2 - -
3 A750 18TN/RD FRONT LOCKER RELAY OUTPUT
G-SWITCH (LHD) - 3 WAY
CAV CIRCUIT FUNCTION
1 B42 20TN/WT G-SWITCH NO. 2 SENSE
2 B41 20YL/VT G-SWITCH NO. 1 SENSE
3 B43 20PK/OR G-SWITCH TEST SIGNAL
INSTRUMENT CLUSTER C1 - 12 WAY
CAV CIRCUIT FUNCTION
1 L61 18GY LEFT TURN SIGNAL
2 L60 18TN RIGHT TURN SIGNAL
3 G34 16RD/GY (LHD) HIGH BEAM INDICATOR DRIVER
3 L3 16RD/OR (RHD) HIGH BEAM INDICATOR DRIVER
4 L39 16LB (EXCEPT EX-
PORT)
FOG LAMP FEED
4 L38 16BR/WT (EXPORT) REAR FOG LAMP FEED
5 L7 18BK/YL HEADLAMP SWITCH OUTPUT
6 G305 20VT/LG (OFF-ROAD
PACKAGE)
REAR LOCKER REQUEST
7 G301 20VT/LB (OFF-ROAD
PACKAGE)
REAR LOCKER INDICATOR SWITCH SENSE
8 Z2 18BK/LG GROUND
9 G303 20VT/DG (OFF-ROAD
PACKAGE)
LOCKER ENABLE SIGNAL 2
10 D23 20WT/BR -
11 G5 20DB/WT FUSED IGNITION SWITCH OUTPUT (RUN-START)
12 M1 20PK/WT FUSED B(+)
C
O
N
N
E
C
T
O
R
P
I
N
O
U
T
S
56
CONNECTOR PINOUTS
INSTRUMENT CLUSTER C2 - 16 WAY
CAV CIRCUIT FUNCTION
1 C80 20DB/WT (HARD TOP) REAR WINDOW DEFOGGER SWITCH SENSE
2 G10 20LG/RD SEAT BELT SWITCH SENSE
3 G76 20TN/YL PASSENGER DOOR AJ AR SWITCH SENSE
4 G75 20TN DRIVER DOOR AJ AR SWITCH SENSE
5 M2 20YL COURTESY LAMP FEED
6 E2 20OR PANEL LAMPS FEED
7 C81 20LB/WT (HARD TOP) REAR WINDOW DEFOGGER RELAY CONTROL
8 G19 20LG/OR (ABS) ABS WARNING INDICATOR DRIVER
9 G99 20GY/WT BRAKE WARNING INDICATOR DRIVER
10 G304 20VT/DB (OFF-ROAD
PACKAGE)
FRONT LOCKER REQUEST
11 G107 20BK/RD (4X4) 4WD INDICATOR
12 D25 20VT/YL PCI BUS
13 G26 20LB KEY-IN IGNITION SWITCH SENSE
14 G302 20RD/WT (OFF-
ROAD PACKAGE)
LOCKER ENABLE SIGNAL 1
15 E19 20RD PANEL LAMPS DIMMER SIGNAL
16 G300 20VT/WT (OFF-ROAD
PACKAGE)
FRONT LOCKER INDICATOR SWITCH SENSE
LEFT FRONT WHEEL SPEED SENSOR - 2 WAY
CAV CIRCUIT FUNCTION
1 B8 18RD/DB LEFT FRONT WHEEL SPEED SENSOR (-)
2 B9 18RD LEFT FRONT WHEEL SPEED SENSOR (+)
LEFT FRONT WHEEL SPEED SENSOR (SENSOR SIDE) - 2 WAY
CAV CIRCUIT FUNCTION
1 RD/DB LEFT FRONT WHEEL SPEED SENSOR (-)
2 RD LEFT FRONT WHEEL SPEED SENSOR (+)
C
O
N
N
E
C
T
O
R
P
I
N
O
U
T
S
57
CONNECTOR PINOUTS
LEFT REAR WHEEL SPEED SENSOR - 2 WAY
CAV CIRCUIT FUNCTION
1 B3 18LG/DB LEFT REAR WHEEL SPEED SENSOR (-)
2 B4 18LG LEFT REAR WHEEL SPEED SENSOR (+)
LEFT REAR WHEEL SPEED SENSOR (SENSOR SIDE) - 2 WAY
CAV CIRCUIT FUNCTION
1 LG/DB LEFT REAR WHEEL SPEED SENSOR (-)
2 LG LEFT REAR WHEEL SPEED SENSOR (+)
C
O
N
N
E
C
T
O
R
P
I
N
O
U
T
S
58
CONNECTOR PINOUTS
C
O
N
N
E
C
T
O
R
P
I
N
O
U
T
S
59
CONNECTOR PINOUTS
FUSES (PDC)
FUSE
NO.
AMPS FUSED CIRCUIT FUNCTION
1 40A A111 12RD/LB FUSED B(+)
2 40A A4 12BK/PK FUSED B(+)
3 40A A6 12RD/BK FUSED B(+)
4 40A A16 12GY (2.4L) FUSED B(+)
5 20A A30 16RD/WT (A/T) FUSED B(+)
6 30A A2 14PK/BK FUSED B(+)
7 - - -
8 40A A10 12RD/DG (ABS) FUSED B(+)
9 30A A14 14RD/WT FUSED B(+)
9 30A A14 14RD/WT FUSED B(+)
10 40A A3 12RD/WT FUSED B(+)
11 - - -
12 30A A20 12RD/DB (ABS) FUSED B(+)
13 40A F30 12RD/PK FUSED B(+)
14 - - -
15 50A M1 16PK/WT FUSED B(+)
15 50A M1 20PK/WT (ABS) FUSED B(+)
16 15A A142 14DG/PK AUTOMATIC SHUT DOWN RELAY OUTPUT
16 15A F142 18OR/DG AUTOMATIC SHUT DOWN RELAY OUTPUT
17 20A F70 16PK/BK FUSED B(+)
18 20A F31 18VT FUSED B(+)
18 20A F31 18VT FUSED B(+)
19 20A F39 16PK/LG (FRONT FOG LAMPS) FUSED B(+)
20 15A F60 16RD/WT FUSED B(+)
21 10A A17 20RD/GY FUSED B(+)
22 20A A1 18RD FUSED B(+)
23 20A A61 18DG/BK FUSED B(+)
24 20A A88 18RD/DB (OFF-ROAD PACKAGE) FUSED B(+)
25 - - -
26 10A M1 20PK/WT FUSED B(+)
27 20A L9 18BK/WT FUSED B(+)
28 20A F42 18DG/LG AUTOMATIC SHUT DOWN RELAY OUTPUT
28 20A A142 14DG/PK AUTOMATIC SHUT DOWN RELAY OUTPUT
FRONT LOCKER RELAY (IN PDC/OFF-ROAD PACKAGE)
CAV CIRCUIT FUNCTION
D10 A88 18RD/DB FUSED B(+)
D11 G304 20VT/DB FRONT LOCKER REQUEST
D12 - -
D13 A88 18RD/DB FUSED B(+)
D14 A750 18TN/RD FRONT LOCKER RELAY OUTPUT
REAR LOCKER RELAY (IN PDC/OFF-ROAD PACKAGE)
CAV CIRCUIT FUNCTION
D2 A88 18RD/DB FUSED B(+)
D4 A88 18RD/DB FUSED B(+)
D5 - -
D6 G305 20VT/LG REAR LOCKER REQUEST
D8 A850 18RD/WT REAR LOCKER RELAY OUTPUT
C
O
N
N
E
C
T
O
R
P
I
N
O
U
T
S
60
CONNECTOR PINOUTS
REAR LOCKER INDICATOR SWITCH (OFF-ROAD PACKAGE) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 Z1 16BK GROUND
2 G301 16VT/LB REAR LOCKER INDICATOR SWITCH SENSE
REAR LOCKER PUMP (OFF-ROAD PACKAGE) - LT GRAY 3 WAY
CAV CIRCUIT FUNCTION
1 Z1 18BK GROUND
2 - -
3 A850 18RD/WT REAR LOCKER RELAY OUTPUT
RIGHT FRONT WHEEL SPEED SENSOR - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 B6 18WT/DB RIGHT FRONT WHEEL SPEED SENSOR (-)
2 B7 18WT RIGHT FRONT WHEEL SPEED SENSOR (+)
C
O
N
N
E
C
T
O
R
P
I
N
O
U
T
S
61
CONNECTOR PINOUTS
RIGHT FRONT WHEEL SPEED SENSOR (SENSOR SIDE) - 2 WAY
CAV CIRCUIT FUNCTION
1 WT/DB RIGHT FRONT WHEEL SPEED SENSOR (-)
2 WT RIGHT FRONT WHEEL SPEED SENSOR (+)
RIGHT REAR WHEEL SPEED SENSOR - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 B1 18YL/DB RIGHT REAR WHEEL SPEED SENSOR (-)
2 B2 18YL RIGHT REAR WHEEL SPEED SENSOR (+)
RIGHT REAR WHEEL SPEED SENSOR (SENSOR SIDE) - 2 WAY
CAV CIRCUIT FUNCTION
1 YL/DB RIGHT REAR WHEEL SPEED SENSOR (-)
2 YL RIGHT REAR WHEEL SPEED SENSOR (+)
C
O
N
N
E
C
T
O
R
P
I
N
O
U
T
S
62
CONNECTOR PINOUTS
VEHICLE SPEED SENSOR - BLACK 3 WAY
CAV CIRCUIT FUNCTION
1 K6 18VT/WT 5V SUPPLY
2 K4 20BK/LB SENSOR GROUND 1
3 G7 18WT/OR VEHICLE SPEED SENSOR SIGNAL
C
O
N
N
E
C
T
O
R
P
I
N
O
U
T
S
63
CONNECTOR PINOUTS
NOTES
64
10.0 SCHEMATIC DIAGRAMS
10. 1 TEVES MARK 20I CONTROLLER ANTILOCK BRAKE - ABS
S
C
H
E
M
A
T
I
C
D
I
A
G
R
A
M
S
65
SCHEMATIC DIAGRAMS
10. 2 AXLE LOCK
S
C
H
E
M
A
T
I
C
D
I
A
G
R
A
M
S
66
SCHEMATIC DIAGRAMS
TABLE OF CONTENTS
1.0 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.1 SYSTEM COVERAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.2 SIX-STEP TROUBLESHOOTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . .1
2.0 IDENTIFICATION OF SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
3.0 SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION . . . . . . . . . . . . . . . . . . . . . .1
3.1 GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
3.2 FUNCTIONAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
3.2.1 AUTOSTICK FEATURE (IF APPLICABLE) . . . . . . . . . . . . . . . . . . . . . . .1
3.2.2 TRANSMISSION OPERATION AND SHIFT SCHEDULING AT
VARIOUS OIL TEMPERATURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
3.3 DIAGNOSTIC TROUBLE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
3.3.1 HARD CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
3.3.2 ONE TRIP FAILURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
3.3.3 INTERMITTENT CODE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
3.3.4 STARTS SINCE SET COUNTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
3.3.5 TROUBLE CODE ERASURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
3.3.6 EATX DTC EVENT DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
3.3.7 LIST OF DIAGNOSTIC TROUBLE CODES (DETAILED
DESCRIPTIONS FOLLOW LIST) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
3.3.8 DTC DESCRIPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
3.3.9 QUICK LEARN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
3.3.10 CLUTCH VOLUMES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
3.3.11 ELECTRONIC PINION FACTOR (IF APPLICABLE) . . . . . . . . . . . . . . .19
3.4 USING THE DRBIIIா . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
3.5 DRBIIIா ERROR MESSAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
3.5.1 DRBIIIா DOES NOT POWER UP (BLANK SCREEN). . . . . . . . . . . . . .19
3.5.2 DISPLAY IS NOT VISIBLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
3.6 TRANSMISSION SIMULATOR (MILLER TOOL # 8333) AND ELECTRONIC
TRANSMISSION ADAPTER KIT (MILLER TOOL #8333-1A) . . . . . . . . . . . . . . 19
4.0 DISCLAIMERS, SAFETY, AND WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
4.1 DISCLAIMERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
4.2 SAFETY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
4.2.1 TECHNICIAN SAFETY INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . .20
4.2.2 VEHICLE PREPARATION FOR TESTING. . . . . . . . . . . . . . . . . . . . . . .20
4.2.3 SERVICING SUB-ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
4.2.4 DRBIIIா SAFETY INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
4.3 WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
4.3.1 VEHICLE DAMAGE WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
4.3.2 ROAD TESTING A COMPLAINT VEHICLE. . . . . . . . . . . . . . . . . . . . . .21
4.3.3 ELECTRONIC PINION FACTOR WARNINGS (IF APPLICABLE) . . . .22
4.3.4 BULLETINS AND RECALLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
5.0 REQUIRED TOOLS AND EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
6.0 GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
6.1 ACRONYMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
6.2 DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
i
TABLE OF CONTENTS - Continued
7.0 DIAGNOSTIC INFORMATION AND PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . .23
COMMUNICATION
*NO RESPONSE FROM TRANSMISSION CONTROL MODULE . . . . . . . . . . . . . . . . .24
TRANSMISSION - 42RLE
P0122-THROTTLE POSITION SENSOR/APPS LOW . . . . . . . . . . . . . . . . . . . . . . . . . .27
P0123-THROTTLE POSITION SENSOR/APPS HIGH . . . . . . . . . . . . . . . . . . . . . . . . . .29
P0124- THROTTLE POSITION SENSOR/APPS INTERMITTENT. . . . . . . . . . . . . . . . .31
P0218-HIGH TEMPERATURE OPERATION ACTIVATED . . . . . . . . . . . . . . . . . . . . . . .33
P0562-LOW BATTERY VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
P0604-INTERNAL TCM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
P0605-INTERNAL TCM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
P0613-INTERNAL TCM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
P0706-CHECK SHIFTER SIGNAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
P0711-TRANSMISSION TEMPERATURE SENSOR PERFORMANCE. . . . . . . . . . . . .47
P0712-TRANSMISSION TEMPERATURE SENSOR LOW. . . . . . . . . . . . . . . . . . . . . . .50
P0713-TRANSMISSION TEMPERATURE SENSOR HIGH . . . . . . . . . . . . . . . . . . . . . .53
P0714-TRANSMISSION TEMPERATURE SENSOR INTERMITTENT . . . . . . . . . . . . .56
P0715-INPUT SPEED SENSOR ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
P0720-OUTPUT SPEED SENSOR ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
P0725-ENGINE SPEED SENSOR CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
P0731-GEAR RATIO ERROR IN 1ST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
P0732-GEAR RATIO ERROR IN 2ND. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
P0733-GEAR RATIO ERROR IN 3RD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
P0734-GEAR RATIO ERROR IN 4TH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
P0736-GEAR RATIO ERROR IN REVERSE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
P0740-TORQUE CONVERTER CLUTCH CONTROL CIRCUIT. . . . . . . . . . . . . . . . . . .82
P0750-LR SOLENOID CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
P0755-2/4 SOLENOID CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
P0760-OD SOLENOID CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
P0765-UD SOLENOID CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
P0841-LR PRESSURE SWITCH SENSE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . .100
P0845-2/4 HYDRAULIC PRESSURE TEST FAILURE . . . . . . . . . . . . . . . . . . . . . . . . .104
P0846-2/4 PRESSURE SWITCH SENSE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . .108
P0870-OD HYDRAULIC PRESSURE TEST FAILURE . . . . . . . . . . . . . . . . . . . . . . . . .112
P0871-OD PRESSURE SWITCH SENSE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . .116
P0884-POWER UP AT SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120
P0888-RELAY OUTPUT ALWAYS OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121
P0890-SWITCHED BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
P0891-TRANSMISSION RELAY ALWAYS ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125
P0897-WORN OUT/BURNT TRANSAXLE FLUID. . . . . . . . . . . . . . . . . . . . . . . . . . . . .128
P0944-LOSS OF PRIME. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130
P0992- 2-4/OD HYDRAULIC PRESSURE TEST FAILURE . . . . . . . . . . . . . . . . . . . . .133
P1652-SERIAL COMMUNICATION LINK MALFUNCTION. . . . . . . . . . . . . . . . . . . . . .135
P1684-BATTERY WAS DISCONNECTED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137
P1687-NO COMMUNICATION WITH THE MIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140
P1694-BUS COMMUNICATION WITH ENGINE MODULE. . . . . . . . . . . . . . . . . . . . . .142
P1775-SOLENOID SWITCH VALVE LATCHED IN TCC POSITION . . . . . . . . . . . . . .144
P1776-SOLENOID SWITCH VALVE LATCHED IN LR POSITION. . . . . . . . . . . . . . . .148
P1790-FAULT IMMEDIATELY AFTER SHIFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152
P1793-TRD LINK COMMUNICATION ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153
P1794-SPEED SENSOR GROUND ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .156
ii
TABLE OF CONTENTS - Continued
P1797-MANUAL SHIFT OVERHEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158
*BACKUP LAMPS COME ON WHILE SHIFTER IS NOT IN REVERSE POSITION. .160
*BACKUP LAMPS INOPERATIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .162
*CHECKING PARK/NEUTRAL SWITCH OPERATION . . . . . . . . . . . . . . . . . . . . . . . . .165
*INCORRECT TRANSMISSION FLUID LEVEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .167
*NO SPEEDOMETER OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .168
*TRANSMISSION NOISY WITH NO DTC’S PRESENT . . . . . . . . . . . . . . . . . . . . . . . .169
*TRANSMISSION SHIFTS EARLY WITH NO DTC’S . . . . . . . . . . . . . . . . . . . . . . . . . .170
*TRANSMISSION SIMULATOR 8333 WILL NOT POWER UP . . . . . . . . . . . . . . . . . .171
VERIFICATION TESTS
VERIFICATION TESTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .172
8.0 COMPONENT LOCATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .175
8.1 POWERTRAIN CONTROL MODULE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .175
8.2 INPUT/OUTPUT SPEED SENSORS/TRS COMPONENT LOCATIONS . . . . . .175
8.3 TRANSMISSION CONTROL MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .175
8.4 TRANSMISSION SOLENOID/PRESSURE SWITCH ASSEMBLY . . . . . . . . . . .176
9.0 CONNECTOR PINOUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .177
CRANKSHAFT POSITION SENSOR (2.4L/4.0L A/T) - BLACK 3 WAY . . . . . . . . . . . .177
DATA LINK CONNECTOR - BLACK 16 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .177
INPUT SPEED SENSOR - 2 WAY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .177
OUTPUT SPEED SENSOR - 2 WAY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .177
OVERDRIVE OFF SWITCH - 4 WAY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .178
TRANSMISSION CONTROL RELAY (IN PDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .180
POWERTRAIN CONTROL MODULE C1 - BLACK 32 WAY. . . . . . . . . . . . . . . . . . . . .180
POWERTRAIN CONTROL MODULE C2 - WHITE 32 WAY. . . . . . . . . . . . . . . . . . . . .181
POWERTRAIN CONTROL MODULE C3 - GRAY 32 WAY. . . . . . . . . . . . . . . . . . . . . .182
THROTTLE POSITION SENSOR (2.4L) - WHITE/BLUE 3 WAY . . . . . . . . . . . . . . . . .182
THROTTLE POSITION SENSOR (4.0L) - 3 WAY. . . . . . . . . . . . . . . . . . . . . . . . . . . . .183
TRANSFER CASE SWITCH (EXCEPT OFF-ROAD PACKAGE) - BLACK 2 WAY . . .183
TRANSFER CASE SWITCH (OFF-ROAD PACKAGE) - BLACK 2 WAY. . . . . . . . . . .183
TRANSMISSION CONTROL MODULE - 60 WAY. . . . . . . . . . . . . . . . . . . . . . . . . . . . .184
TRANSMISSION RANGE SENSOR - 10 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .185
TRANSMISSION SOLENOID/PRESSURE SWITCH ASSEMBLY - 10 WAY. . . . . . . .185
10.0 SCHEMATIC DIAGRAMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .187
11.0 CHARTS AND GRAPHS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .189
11.1 PRESSURE SWITCH STATES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .189
11.2 SOLENOID APPLICATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .189
11.3 SHIFT LEVER ERROR CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .189
11.4 TRANSMISSION TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . .190
iii
NOTES
iv
1.0 INTRODUCTION
The procedures contai ned i n thi s manual i ncl ude
al l of the speci fi cati ons, i nstructi ons, and graphi cs
needed to di agnose 42RLE El ectroni c Automati c
Transmi ssi on (EATX) probl ems. The di agnosti cs i n
thi s manual are based on the fai l ure condi ti on or
symptom bei ng present at the ti me of di agnosi s.
When repai rs are requi red, refer to the appropri -
ate vol ume of the servi ce manual for the proper
removal and repai r procedure.
Di agnosti c procedures change every year. New
di agnosti c systems may be added and/or carryover
systems may be enhanced. READ THI S MANUAL
BEFORE TRYI NG TO DI AGNOSE A VEHI CLE
TROUBLE CODE. I t i s recommended that you
revi ew the enti re manual to become fami l i ar wi th
al l new and changed di agnosti c procedures.
Thi s book refl ects many suggested changes from
readers of past i ssues. After usi ng thi s book, i f you
have any comments or recommendati ons, pl ease fi l l
out the form at the back of the book and mai l i t back
to us.
1. 1 SYSTEM COVERAGE
Thi s di agnosti c procedures manual covers al l TJ
equi pped wi th a 42RLE Transmi ssi on.
1. 2 SIX-STEP TROUBLESHOOTING
PROCEDURE
Di agnosi s of the 42RLE el ectroni c Transmi ssi on
i s done i n si x basi c steps:
• veri fi cati on of compl ai nt
• veri fi cati on of any rel ated symptoms
• symptom anal ysi s
• probl em i sol ati on
• repai r of i sol ated probl em
• veri fi cati on of proper operati on
2.0 IDENTIFICATION OF
SYSTEM
Vi sual i denti fi cati on of vehi cl es equi pped wi th a 4
speed transmi ssi on, the Sol enoi d/Pressure Swi tch
Assembl y i s l ocated on the passenger si de, The
Transmi ssi on Range Sensor, I nput Speed Sensor
and Output Speed Sensor are l ocated on the dri vers
si de of the transmi ssi on. Refer to the Servi ce I nfor-
mati on for transmi ssi on I D tag descri pti ons.
3.0 SYSTEM DESCRIPTION AND
FUNCTIONAL OPERATION
3. 1 GENERAL DESCRIPTION
The 42RLE el ectroni c Transmi ssi on i s a conven-
ti onal Transmi ssi on i n that i t uses hydraul i cal l y
appl i ed cl utches to shi ft a pl anetary gear trai n.
However, the el ectroni c control system repl aces
many of the mechani cal and hydraul i c components
used i n conventi onal transmi ssi on val ve bodi es.
3. 2 FUNCTIONAL OPERATION
The 42RLE/AE el ectroni c Transmi ssi on has a
ful l y adapti ve control system. The system performs
i t’s functi ons based on conti nuous real -ti me sensor
feedback i nformati on. The control system automat-
i cal l y adapts to changes i n engi ne performance and
fri cti on el ement vari ati ons to provi de consi stent
shi ft qual i ty. The control system ensures that cl utch
operati on duri ng upshi fti ng and downshi fti ng i s
more responsi ve wi thout i ncreased harshness.
The Transmi ssi on Control Modul e (TCM) conti n-
uousl y checks for el ectri cal probl ems, mechani cal
probl ems, and some hydraul i c probl ems. When a
probl em i s sensed, the TCM stores a di agnosti c
troubl e code. Some of these codes cause the Trans-
mi ssi on to go i nto Li mp-i n or defaul t mode. Whi l e i n
thi s mode, el ectri cal power i s taken away from the
Transmi ssi on vi a the TCM, de-energi zi ng the trans-
mi ssi on control rel ay, and taki ng power from the
sol enoi d pack. When thi s happens, the onl y Trans-
mi ssi on mechani cal functi ons are:
Park and Neutral
Reverse
Second Gear
No upshi fts or downshi fts are possi bl e. The posi -
ti on of the manual val ve al one al l ows the three
ranges that are avai l abl e. Al though vehi cl e perfor-
mance i s seri ousl y degraded whi l e i n thi s mode, i t
al l ows the owner to dri ve the vehi cl e i n for servi ce.
Once the DRBI I I ௡ i s i n the EATX porti on of the
di agnosti c program, i t constantl y moni tors the
TCM to see i f the system i s i n Li mp-i n mode. I f the
Transmi ssi on i s i n Li mp-i n mode, the DRBI I I ௡ wi l l
fl ash the red LED.
3. 2. 1 AUTOSTICK FEATURE (IF
APPLICABLE)
Thi s feature al l ows the dri ver to manual l y shi ft the
Transmi ssi on when the shi ft l ever i s pul l ed i nto the
AutoSti ck posi ti on. When i n AutoSti ck mode, the
i nstrument cl uster di spl ays the current gear.
1
GENERAL INFORMATION
3. 2. 2 TRANSMISSION OPERATION AND
SHIFT SCHEDULING AT VARIOUS
OIL TEMPERATURES
The transmi ssi on covered i n thi s manual has
uni que shi ft schedul es dependi ng on the tempera-
ture of the transmi ssi on oi l . The shi ft schedul e i s
modi fi ed to extend the l i fe of the transmi ssi on whi l e
operati ng under extreme condi ti ons.
The oi l temperature i s measured wi th a Temper-
ature Sensor on the 42RLE/AE transmi ssi on. The
Temperature Sensor i s an i ntegral component of the
Transmi ssi on Range Sensor (TRS). I f the Tempera-
ture Sensor i s faul ty, the transmi ssi on wi l l defaul t
to a cal cul ated oi l temperature. Oi l temperature
wi l l then be cal cul ated through a compl ex heat
transfer equati on usi ng engi ne cool ant tempera-
ture, battery/ambi ent temperature, and engi ne off
ti me from the Body Control Modul e (BCM). These
i nputs are recei ved from the PCI bus peri odi cal l y
and used to i ni ti al i ze the oi l temperature at start
up. Once the engi ne i s started, the TCM updates
the transmi ssi on oi l temperature based on torque
converter sl i p speed, vehi cl e speed, gear, and engi ne
cool ant temperature to determi ne an esti mated oi l
temperature duri ng vehi cl e operati on. Vehi cl es us-
i ng cal cul ated oi l temperature track oi l tempera-
ture reasonabl y accurate duri ng normal operati on.
However, i f a transmi ssi on i s overfi l l ed, a transmi s-
si on oi l cool er becomes restri cted, or i f a customer
dri ves aggressi vel y i n l ow gear, the cal cul ated oi l
temperature wi l l be i naccurate. Consequentl y the
shi ft schedul e sel ected may be i nappropri ate for the
current condi ti ons. The key hi ghl i ghts of the vari -
ous shi ft schedul es are as fol l ows:
Extreme Cold: Oi l temperature at start up bel ow
26.6°C (-16°F)
> Goes to Col d schedul e above -24°C (-12°F) oi l
temperature
> Park, Reverse, Neutral and 2nd gear onl y (pre-
vents shi fti ng whi ch may fai l a cl utch wi th fre-
quent shi fts)
Cold: Oi l temperature at start up above -24°C
(-12°F) and bel ow 2.2°C (36°F)
> Goes to Warm schedul e above 4.4°C (40°F) oi l
temperature
> Del ayed 2-3 upshi ft approxi matel y 35-50 Km/h
(22 - 31 MPH)
> Del ayed 3-4 upshi ft 72-85 Km/h (45-53 MPH)
> Earl y 4-3 coastdown shi ft approxi matel y 48
Km/h (30 MPH)
> Earl y 3-2 coastdown shi ft approxi matel y 27
Km/h (17 MPH)
> Hi gh speed 4-2, 3-2, 2-1 ki ckdown shi fts are
prevented
> No EMCC
Warm: Oi l temperature at start up above 2.2°C
(36°F) and bel ow 27°C (80°F)
> Goes to a Hot schedul e above 27°C (80°F) oi l
temperature
> Normal operati on (upshi fts, ki ckdowns, and
coastdowns)
> No EMCC
Hot: Oi l temperature at start up above 27°C (80°F)
> Goes to a Overheat schedul e above 115°C (240°F)
oi l temperature
> Normal operati on (upshi fts, ki ckdowns, and
coastdowns)
> Ful l EMCC, No PEMCC except to engage
FEMCC, except at cl osed throttl e at speeds above
113-133 Km/h (70 - 83 MPH)
Overheat: Oi l temperature above 115°C (240°F) or
engi ne cool ant temperature above 118°C (244°F)
> Goes to a Hot bel ow 110°C (230°F) oi l tempera-
ture or a Super Overheat above 115°C (240°F) oi l
temperature
> Del ayed 2-3 upshi ft 40-51 Km/h (25-32 MPH)
> Del ayed 3-4 upshi ft 66-77 Km/h (41-48 MPH)
> 3rd gear FEMCC from 48-77 Km/h (30-48 MPH)
> 3rd gear PEMCC from 43-50 Km/h (27-31 MPH)
Super Overheat: Oi l temperature above 127°C
(260°F)
> Goes back to a Overheat bel ow 115°C (240°F) oi l
temperature
> Al l a Overheat shi ft schedul es features appl y
> 2nd gear PEMCC above 35 Km/h (22 MPH)
> Above 35 Km/h (22 MPH) the torque converter
wi l l not unl ock unl ess the throttl e i s cl osed (i .e. at
80 Km/h (50 MPH) a 4th FEMCC to 3rd FEMCC
shi ft wi l l be made duri ng a part throttl e ki ck-
down or a 4th FEMCC to 2nd PEMCC shi ft wi l l
be made at wi de open throttl e) or i f a wi de open
throttl e 2nd PEMCC to 1 ki ckdown i s made.
Causes for operation in the wrong tempera-
ture shift schedule:
Extreme Col d or Col d shi ft schedul e at start up:
> Temperature Sensor ci rcui t.
> Overheat or Super Overheat shi ft schedul e
after extended operati on:
> Operati on i n ci ty traffi c or stop and go traffi c
> Engi ne i dl e speed too hi gh
> Aggressi ve dri vi ng i n l ow gear
> Trai l er towi ng i n OD gear posi ti on (use 3
posi ti on (or A/S 3rd) i f frequent shi fti ng oc-
curs)
> Cool i ng system fai l ure causi ng engi ne to op-
erate over 110°C (230°F)
2
GENERAL INFORMATION
> Engi ne cool ant temperature stays l ow too l ong
- I f engi ne cool ant temperature drops bel ow
65°C (150°F), the transmi ssi on wi l l di sengage
EMCC. Extended operati on wi th the EMCC
di sengaged wi l l cause the transmi ssi on to
overheat.
> Brake swi tch i ssue wi l l cause the EMCC to
di sengage. Extended operati on wi th the
EMCC di sengaged wi l l cause the transmi s-
si on to overheat.
> Transmi ssi on fl ui d overfi l l ed
> Transmi ssi on cool er or cool er l i nes restri cted
> Transmi ssi on Temperature Sensor ci rcui t
3. 3 DIAGNOSTIC TROUBLE CODES
Di agnosti c troubl e codes (DTC’s) are codes stored
by the Transmi ssi on Control Modul e (TCM) that
hel p us di agnose Transmi ssi on probl ems. They are
vi ewed usi ng the DRBI I I ௡ scan tool .
Al ways begi n by performi ng a vi sual i nspecti on of
the wi ri ng, connectors, cool er l i nes and the trans-
mi ssi on. Any obvi ous wi ri ng probl ems or l eaks
shoul d be repai red pri or to performi ng any di agnos-
ti c test procedures. Some engi ne dri veabi l i ty prob-
l ems can be mi si nterpreted as a transmi ssi on prob-
l em. Ensure that the engi ne i s runni ng properl y
and that no PCM DTC’s are present that coul d
cause a transmi ssi on compl ai nt.
I f there i s a communi cati on bus probl em, troubl e
codes wi l l not be accessi bl e unti l the probl em i s
fi xed. The DRBI I I ௡ wi l l di spl ay an appropri ate
message. The fol l owi ng i s a possi bl e l i st of causes
for a bus probl em:
– open or short to ground/battery i n PCI bus
ci rcui t.
– i nternal fai l ure of any modul e or component on
the bus
Each di agnosti c troubl e code i s di agnosed by
fol l owi ng a speci fi c testi ng sequence. The di agnosti c
test procedures contai n step-by-step i nstructi ons
for determi ni ng the cause of a transmi ssi on di ag-
nosti c troubl e code. Possi bl e sources of the code are
checked and el i mi nated one by one. I t i s not neces-
sary to perform al l of the tests i n thi s book to
di agnose an i ndi vi dual code. These tests are based
on the probl em bei ng present at the ti me that the
test i s run.
All testingshouldbedonewithafullycharged
battery.
I f the TCM records a DTC that wi l l adversel y
affect vehi cl e emi ssi ons, i t wi l l request (vi a the
communi cati on bus) that the PCM i l l umi nate the
Mal functi on I ndi cator Lamp (MI L). Al though these
DTC’s wi l l be stored i n the TCM i mmedi atel y as a 1
tri p fai l ure, i t may take up to fi ve mi nutes of
accumul ated troubl e confi rmati on to set the DTC
and i l l umi nate the MI L. Three consecuti ve success-
ful OBDI I (EURO STAGE I I I OBD) tri ps or cl eari ng
the DTC’s wi th a di agnosti c tool (DRBI I I ௡ or equi v-
al ent) i s requi red to exti ngui sh the MI L. When the
TCM requests that the PCM i l l umi nate the MI L,
the PCM sets a DTC P0700 ($89) to al ert the
techni ci an that there are DTC’s i n the TCM. Thi s
must al so be erased i n the PCM i n order to exti n-
gui sh the MI L.
3. 3. 1 HARD CODE
Any Di agnosti c Troubl e Code (DTC) that i s set
whenever the system or component i s moni tored i s
a HARD code. Thi s means that the probl em i s there
every ti me the TCM checks that system or compo-
nent. Some codes wi l l set i mmedi atel y at start up
and others wi l l requi re a road test under speci fi c
condi ti ons. I t must be determi ned i f a code i s
repeatabl e (Hard) or i ntermi ttent before attempt-
i ng di agnosi s.
3. 3. 2 ONE TRIP FAILURES
A One Tri p Fai l ure, when read from the TCM, i s
a hard OBDI I (EURO STAGE I I I OBD) code that
has not matured for the ful l 5 mi nutes. Thi s appl i es
to codes that wi l l onl y set after 5 mi nutes of
substi tuted gear operati on.
3. 3. 3 INTERMITTENT CODE
A di agnosti c troubl e code that i s not there every
ti me the TCM checks the ci rcui t or functi on i s an a
i ntermi ttent code. Some i ntermi ttent codes, such as
codes P1684(12), P0891(14), P0888(15), P0725(18),
P1694(19), P0871(21), P0846(22), P1724(24),
P0706(28), P0120(29), P0750(41), P0755(42),
P0760(43), P0765(44), P1793(48), P0715(56),
P0720(57), P1794(58), P0951(70), P1799(74),
P0884(76), P1687(77), and P1652(78) are caused by
wi ri ng or connector probl ems. However i ntermi t-
tent codes 50 - 54 are usual l y caused by i ntermi t-
tent hydraul i c seal l eakage i n the cl utch and/or
accumul ator ci rcui ts. Probl ems that come and go
l i ke thi s are the most di ffi cul t to di agnose, they
must be l ooked for under the speci fi c condi ti ons
that cause them.
3. 3. 4 STARTS SINCE SET COUNTER
For the most recent code, the Starts Si nce Set
counter counts the number of ti mes the vehi cl e has
started si nce i t was l ast set. The counter wi l l count
up to 255 starts. Note that thi s code onl y appl i es to
the l ast or most recent code set.
When there are no di agnosti c troubl e codes stored
i n memory, the DRBI I I ௡ wi l l di spl ay NO DTC’s
PRESENT and the reset counter wi l l show
“STARTS SI NCE CLEAR = XXX
3
GENERAL INFORMATION
The number of starts hel ps determi ne i f the
di agnosti c troubl e code i s hard or i ntermi ttent.
– I f the count i s l ess than 3, the code i s usual l y a
hard code.
– I f the count i s greater than 3, i t i s consi dered
an i ntermi ttent code. Thi s means that the
engi ne has been started most of the ti me
wi thout the code recurri ng.
3. 3. 5 TROUBLE CODE ERASURE
A Di agnosti c troubl e code wi l l be cl eared from
TCM memory i f i t has not reset for 40 warm-up
cycl es.
A warm-up cycl e i s defi ned as suffi ci ent vehi cl e
operati on such that the cool ant temperature has
ri sen by at l east 22°C (40°F) from engi ne starti ng
and reaches a mi ni mum temperature of 71°C
(160°F).
The Mal functi on I ndi cator Lamp (MI L) wi l l turn
off after 3 good tri ps or when the DTC’s are cl eared
from the TCM.
3. 3. 6 EATX DTC EVENT DATA
EATX DTC EVENT DATA can be used as a
di agnosti c ai d when experi enci ng El ectroni c Trans-
mi ssi ons wi th i ntermi ttent probl ems. When a Di ag-
nosti c Troubl e Code (DTC) i s set, the vehi cl es EATX
i nputs are stored i n the control l er memory and are
retri evabl e wi th the DRBI I I ௡. Thi s i nformati on can
be hel pful when a DTC can not be dupl i cated.
The EATX DTC EVENT DATA i s l ocated i n the
DRBI I I ௡, under the Transmi ssi on system menu, i n
the sub-screen Mi scel l aneous. I t i s a good practi ce
to document the EATX DTC EVENT DATA before
begi nni ng any di agnosti c or servi ce procedure.
A thorough understandi ng of how the transmi s-
si on works i s benefi ci al i n order to i nterpret the
data correctl y. These ski l l s are necessary i n order to
avoi d an i ncorrect di agnosi s.
A MASTERTECH vi deo and reference book was
produced i n January 2002 that expl ai ns many of
the features of the EATX DTC EVENT DATA wi th
several exampl es on how to i nterpret the i nforma-
ti on and suggested trai ni ng materi al to hel p under-
stand al l the speci fi cs.
EATX DTC EVENT DATA can onl y be erased by:
1. Di sconnecti ng the battery.
2. Performi ng a DRBI I I ௡ QUI CK LEARN proce-
dure.
3. Reprogrammi ng the EATX control l er.
Erasi ng Transmi ssi on DTCs does not cl ear the
EATX DTC EVENT DATA.
3. 3. 7 LIST OF DIAGNOSTIC TROUBLE
CODES (DETAILED DESCRIPTIONS
FOLLOW LIST)
The TCM may report any of the fol l owi ng DTC’s.
DTC P-Code Name of Code Limp-in MIL
11 P0613 I nternal TCM Yes Yes
12 P1684 Battery was di sconnected No No
13 P0613 I nternal TCM Yes Yes
14 P0891 Transmi ssi on Rel ay al ways on Yes Yes
15 P0888 Rel ay output al ways off Yes Yes
16 P0605 I nternal TCM Yes Yes
17 P0604 I nternal TCM Yes Yes
18 P0725 Engi ne speed sensor ci rcui t Yes Yes
19 P1694 Bus communi cati on wi th engi ne modul e No No
20 P0890 Swi tched battery Yes Yes
21 P0871 OD pressure swi tch sense ci rcui t Yes Yes-1
22 P0846 2/4 pressure swi tch sense ci rcui t Yes Yes
24 P0841 LR pressure swi tch sense ci rcui t Yes Yes
28 P0706 Check shi fter si gnal No No
29 P0124 Throttl e Posi ti on Sensor/APPS i ntermi ttent No Yes-3
2A P0122 Throttl e Posi ti on Sensor /APPS l ow No Yes-3
2B P0123 Throttl e Posi ti on Sensor /APPS hi gh No Yes-3
31 P0870 OD hydraul i c pressure test fai l ure Yes Yes
32 P0845 2/4 hydraul i c pressure test fai l ure Yes Yes
33 P0992 2-4/OD hydraul i c pressure test fai l ure Yes Yes
35 P0944 Loss of pri me No No
4
GENERAL INFORMATION
The TCM may report any of the fol l owi ng DTC’s.
DTC P-Code Name of Code Limp-in MIL
36 P1790 Faul t i mmedi atel y after shi ft No No
37 P1775 Sol enoi d swi tch val ve l atched i n TCC posi ti on No Yes
38 P0740 Torque converter cl utch control ci rcui t No Yes
41 P0750 LR Sol enoi d ci rcui t Yes Yes
42 P0755 2/4 Sol enoi d ci rcui t Yes Yes
43 P0760 OD Sol enoi d ci rcui t Yes Yes
44 P0765 UD Sol enoi d ci rcui t Yes Yes
45 P0613 I nternal TCM No No
47 P1776 Sol enoi d swi tch val ve l atched i n LR posi ti on Yes Yes
48 P1793 TRD l i nk communi cati on error No Yes-4
50 P0736 Gear rati o error i n reverse Yes Yes
51 P0731 Gear rati o error i n 1st Yes Yes
52 P0732 Gear rati o error i n 2nd Yes Yes
53 P0733 Gear rati o error i n 3rd Yes Yes
54 P0734 Gear rati o error i n 4th Yes Yes
56 P0715 I nput speed sensor error Yes Yes
57 P0720 Output speed sensor error Yes Yes
58 P1794 Speed sensor ground error Yes Yes
71 P1797 Manual shi ft overheat No No
73 P0897 Worn out/burnt Transmi ssi on fl ui d No No
75 P0218 Hi gh temperature operati on acti vated No No
7A P0711 Transmi ssi on temperature sensor performance No No
7B P0712 Transmi ssi on temperature sensor l ow No No
7C P0713 Transmi ssi on temperature sensor hi gh No No
7D P0714 Transmi ssi on temperature sensor i ntermi ttent No No
76 P0884 Power up at speed No No
77 P1687 No communi cati on wi th the MI C No No
78 P1652 Seri al communi cati on l i nk mal functi on No No-2
79 P0562 Low battery vol tage Yes Yes
Notes:
P1xxx DTC’s wi l l set the MI L onl y after 10 seconds of vehi cl e operati on.
1 - The Mi l wi l l be l i t onl y i f DTC P0706 i s al so present
2 - The MI L wi l l be l i t by the engi ne control l er
3 - The MI L wi l l be l i t onl y i f the engi ne control l er i s not cal i brated for throttl e substi tuti on.
4 - The MI L wi l l be l i t for engi nes that l i mi t throttl e after a TRD probl em.
Yes (underl i ned) i ndi cates that thi s DTC can take up to fi ve mi nutes of probl em i denti fi cati on before
i l l umi nati ng the MI L.
3. 3. 8 DTC DESCRIPTIONS
Name of code: P0613 (11, 13, or 45) - I nternal
Control l er
Whenmonitored:Whenever the key i s i n the Run
or Run/Start posi ti on.
Set condition: Thi s code i s set whenever Trans-
mi ssi on Control Modul e (TCM) senses an i nternal
error.
Theory of operation: The TCM i s constantl y
moni tori ng i t’s i nternal processor. I f an i nternal
probl em i s detected, thi s DTC wi l l be set. Thi s DTC
can al so be set by a bad ground to the TCM and/or
Trans Control Rel ay.
Transmission Effects: The MI L wi l l i l l umi nate
(thi s DTC can take up to fi ve mi nutes of probl em
i denti fi cati on before i l l umi nati ng the MI L) and the
transmi ssi on system wi l l defaul t to the I mmedi ate
Shutdown routi ne.
Possible causes:
> TCM ground ci rcui t.
> Rel ay ground ci rcui t.
> TCM
Name of code: P1684(12) - Battery was Di scon-
nected (I nformati onal code Onl y)
When monitored: Whenever the key i s i n the
Run/Start posi ti on.
5
GENERAL INFORMATION
Set condition: Thi s code i s set whenever the
Transmi ssi on Control Modul e (TCM) i s di scon-
nected from battery power (B+) or ground. I t wi l l
al so be set duri ng the DRBI I I ௡ Battery Di sconnect
procedure.
Theory of operation: A battery backed RAM
(Random Access Memory) i s used to mai ntai n some
l earned val ues. When the battery B(+) i s di scon-
nected, the memory i s l ost. When the B(+) i s
restored, thi s memory l oss i s detected by the TCM.
The code i s set and the l earned val ues are i ni ti al -
i zed to known constants or previ ousl y l earned
val ues from EEPROM (El ectroni c Erasabl e Pro-
grammabl e Read Onl y Memory). Thi s resul ts i n
the i ni ti al i zati on of some parameters.
Transmission Effects: Loss of troubl e code data.
I mmedi ate Li mp-i n mode i f power i s l ost whi l e
operati ng the vehi cl e. Normal operati on i s re-
sumed i f the power i s restored duri ng the same key
start.
Possible causes:
> Battery vol tage removed from TCM
> TCM di sconnected
> Dead Battery
> Low battery vol tage duri ng cranki ng
> Battery Di sconnect by DRBI I I ௡ or MDS
> Bad TCM ground ci rcui t.
Name of code: P0891(14) - Transmi ssi on Rel ay
Al ways On
When monitored: I gni ti on key i s turned from off
posi ti on to run posi ti on and/or i gni ti on key i s
turned from crank posi ti on to run posi ti on.
Set condition:Thi s code i s set i f the Transmi ssi on
Control Modul e (TCM) senses greater than 3 vol ts
at the Trans Rel ay Output (swi tched battery) ter-
mi nal of the TCM pri or to the TCM energi zi ng the
rel ay.
Theory of operation: The transmi ssi on control
rel ay i s used to suppl y power to the sol enoi d pack
when the transmi ssi on i s i n normal operati ng
mode. When the rel ay i s off, no power i s suppl i ed to
the sol enoi d pack and the transmi ssi on i s i n
Li mp-i n mode. The rel ay output i s fed back to the
TCM through pi ns 16 and 17. I t i s referred to as the
Trans Rel ay Output ci rcui t or swi tched battery.
Transmission Effects: The MI L wi l l i l l umi nate
and the transmi ssi on system defaul ts to Logi cal
Li mp-i n mode. Logi cal Li mp-i n mode resul ts i n the
same modes of operati on as Li mp-i n. Si nce the
rel ay i s stuck “on”, the TCM can not open the rel ay,
and the TCM shi fts to 2nd gear.
Possible causes:
> Rel ay (wel ded contacts)
> Short to battery i n 12-vol t suppl y and/or
Transmi ssi on Control Rel ay Output ci rcui t(s)
> Short to vol tage
> TCM connector probl ems
> TCM
Name of code: P0888(15) - Rel ay Output Al ways
Off
When monitored: Conti nuousl y
Set condition: Thi s code i s set when l ess than 3
vol ts are present at the Trans Rel ay Output
(swi tched battery) termi nal s at the Transmi ssi on
Control Modul e (TCM) when the TCM i s energi z-
i ng the rel ay.
Theory of operation: The transmi ssi on control
rel ay i s used to suppl y power to the sol enoi d pack
when the transmi ssi on i s i n normal operati ng
mode. When the rel ay i s off, no power i s suppl i ed to
the sol enoi d pack and the transmi ssi on i s i n
Li mp-i n mode. The rel ay output i s fed back to the
TCM through pi ns 16 and 17. I t i s referred to as the
Trans Rel ay Output ci rcui t or swi tched battery.
After a control l er reset (i gni ti on key turned to
the run posi ti on or after cranki ng engi ne), the
control l er energi zes the rel ay. Pri or to thi s the
TCM veri fi es that the contacts are open by check-
i ng for no vol tage at the swi tched battery termi -
nal s. After the rel ay i s energi zed, the TCM moni -
tors the termi nal s to veri fy that the vol tage i s
greater than 3 vol ts.
Transmission Effects: The MI L i l l umi nates and
the transmi ssi on system defaul ts to Li mp-i n mode.
Possible causes:
> Rel ay fai l ure (i ntermi ttent rel ay functi on
caused by oxi di zed or contami nated rel ay
contacts)
> Short to ground or open ci rcui t i n the Trans-
mi ssi on Control Rel ay ci rcui t(s)
> TCM connector probl em
> TCM
Name of code: P0725(18) - Engi ne Speed Sensor
Ci rcui t
NOTE: This code is not a Transmission Input
Speed Sensor DTC
When monitored: Whenever the engi ne i s run-
ni ng.
Set condition: Thi s code i s set when the engi ne
speed sensed by the Transmi ssi on Control Modul e
(TCM) i s l ess than 390 RPM or greater than 8000
RPM for more that 2.0 seconds.
Theory of operation: The TCM uses ei ther a
EATX RPM si gnal (si mul ated Crank Sensor si gnal )
or the TCM uses the Crank Posi ti on Sensor si gnal
to cal cul ate engi ne RPM dependi ng on the engi ne
appl i cati on. The si gnal suppl i ed by the PCM and
uses a dedi cated ci rcui t i s cal l ed the EATX RPM
Si gnal ci rcui t. The Crank Posi ti on Sensor si gnal i s
a spl i ced ci rcui t from the engi ne Crank Posi ti on
Sensor. Check the wi ri ng schemati cs to determi ne
6
GENERAL INFORMATION
whi ch (engi ne speed sensor ci rcui t) i s used i n the
vehi cl e. I f the TCM i nterprets thi s si gnal to be out
of range when the engi ne i s runni ng (as reported
by the PCM over the bus) the code i s set.
Transmission Effects: The MI L i l l umi nates and
the transmi ssi on system defaul ts to Li mp-i n mode.
Possible causes:
> Open or short i n EATX RPM Si gnal ci rcui t.
> Open or short i n Crank Posi ti on Sensor Si g-
nal ci rcui t.
> Open or short i n Crank Posi ti on Sensor
ground ci rcui t.
> TCM and/or PCM connector probl ems
> TCM
> PCM
Name of code: P1694(19) - Bus Communi cati on
wi th Engi ne Modul e
When monitored: Conti nuousl y wi th key on.
Set condition: I f no PCI bus messages are re-
cei ved from the Powertrai n Control Modul e (PCM)
for 10 seconds. Theory of operati on: The TCM
communi cates wi th the PCM usi ng the PCI bus. I t
rel i es on certai n i nformati on to functi on properl y.
The TCM conti nuousl y moni tors the PCI bus to
check for messages broadcast from the PCM.
Transmission Effects: Del ayed 3-4 shi fts. No
EMCC and earl y 3-4 shi fts for a few mi nutes after
engi ne i s started.
Possible causes:
> Open or shorted PCI bus ci rcui t
> TCM
> PCM
Name of code: P0890(20) - Swi tched Battery
When monitored: I gni ti on key i s turned from off
posi ti on to run posi ti on and/or i gni ti on key i s
turned from crank posi ti on to run posi ti on.
Set condition:Thi s code i s set i f the Transmi ssi on
Control Modul e (TCM) senses vol tage on any of the
pressure swi tch i nputs pri or to the TCM energi zi ng
the rel ay.
Theory of operation: The transmi ssi on control
rel ay i s used to suppl y power to the sol enoi d pack
when the transmi ssi on i s i n normal operati ng
mode. When the rel ay i s off, no power i s suppl i ed to
the sol enoi d pack and the transmi ssi on i s i n
Li mp-i n mode. The rel ay output i s fed back to the
TCM through pi ns 16 and 17. I t i s referred to as the
Trans Rel ay Output ci rcui t or a swi tched battery.
I mmedi atel y after a control l er reset (i gni ti on key
turned to the run posi ti on or after cranki ng en-
gi ne), the TCM veri fi es that the rel ay contacts are
open by checki ng for no vol tage at the swi tched
battery termi nal s. After thi s i s veri fi ed, the vol tage
at the Sol enoi d Pack pressure swi tches i s checked.
There shoul d be no vol tage on the pressure
swi tches at thi s ti me. The TCM wi l l then acti vate
the rel ay.
Transmission Effects: The MI L i l l umi nates and
the transmi ssi on system defaul ts to Li mp-i n mode.
Possible causes:
> Short to battery on one or more pressure
swi tch sense ci rcui ts
> TCM connector probl ems
> TCM
Name of code: P0871(21) - OD Pressure Swi tch
Sense Ci rcui t
When monitored: Whenever the engi ne i s run-
ni ng.
Set condition: Thi s code i s set i f the OD pressure
swi tch i s open or cl osed at the wrong ti me i n a
gi ven gear (see chart bel ow).
Theory of operation: The Transmi ssi on system
uses three pressure swi tches to moni tor the fl ui d
pressure i n the LR, 2/4, and OD cl utch ci rcui ts. The
pressure swi tches are conti nuousl y moni tored for
the correct states i n each gear as shown bel ow.
Transmission Effects: Normal operati on wi l l be
experi enced i f no other codes are present. TCM wi l l
i gnore the code. Li mp-i n condi ti on wi l l onl y occur i f
code P0871(21) i s present wi th a code P0706(28).
Possible causes:
> I f code P0944(35) i s present, i gnore code
P0871(21) and perform code P0944 di agnosti c
procedures
> OD pressure swi tch sense ci rcui t open or
shorted to ground between TCM and sol enoi d
pack
> OD pressure swi tch sense ci rcui t shorted to
battery
> Sol enoi d pack
> Loose val ve body bol ts
> Pl ugged fi l ter - i nternal transmi ssi on or
torque converter fai l ure
> TCM
7
GENERAL INFORMATION
Name of code: P0846(22) - 2/4 Pressure Swi tch
Sense Ci rcui t
When monitored: Whenever the engi ne i s run-
ni ng.
Set condition: Thi s code i s set i f the 2/4 pressure
swi tch i s open or cl osed at the wrong ti me i n a
gi ven gear (see chart bel ow).
Theory of operation: The Transmi ssi on system
uses three pressure swi tches to moni tor the fl ui d
pressure i n the LR, 2/4, and OD el ements. The
pressure swi tches are conti nuousl y moni tored for
the correct states i n each gear as shown bel ow.
Transmission Effects: I f the 2/4 pressure swi tch
i s i denti fi ed as cl osed i n P or N, the code wi l l
i mmedi atel y be set and normal operati on wi l l be
al l owed for that gi ven key start. I f the probl em i s
i denti fi ed for 3 successi ve key starts, the transmi s-
si on wi l l go i nto Li mp-i n mode.
I f the 2/4 pressure swi tch i s i denti fi ed as bei ng
cl osed i n 1st or 3rd gear and was not i denti fi ed as
bei ng cl osed i n P or N, then 2nd gear or 4th gear
wi l l be substi tuted for 1st or 3rd gear dependi ng on
throttl e angl e and vehi cl e speed. A short peri od of
ti me after the gear substi tuti on, the transmi ssi on
wi l l return to normal operati ng mode. I f the trans-
mi ssi on i s shi fted back i nto 1st or 3rd gear through
normal operati on, and the 2/4 pressure swi tch
remai ns cl osed, 2nd or 4th gear wi l l be substi tuted
bri efl y and then resume normal operati on. I f four
gear substi tuti ons occur i n a gi ven key start, the
transmi ssi on wi l l go i nto Li mp-i n mode.
I f the 2/4 pressure swi tch i s open (i ndi cati ng no
2/4 cl utch pressure) i n 2nd or 4th gear, the TCM
sets code P0846(22) and conti nues wi th normal
operati on. The transmi ssi on wi l l onl y go i nto
Li mp-i n mode i f a code P0706(28) i s al so present. I f
no 2/4 cl utch pressure i s present a gear rati o code
P0732(52) or P0734(54) wi l l be set and cause the
l i mp-i n condi ti on.
Possible causes:
> I f code P0944(35) i s present, i gnore code
P0846(22) and perform code P0944 di agnosti c
procedures
> 2/4 pressure swi tch sense ci rcui t open or
shorted to ground between TCM and sol enoi d
pack
> 2/4 pressure swi tch sense ci rcui t shorted to
battery
> Sol enoi d pack
> Transmi ssi on overheated - Excessi ve regul a-
tor val ve l eakage i n val ve body causi ng hi gh
l i ne pressure whi ch resul ts i n 2/4 sol enoi d
bl ow-off i n 1st or 3rd gear. May requi re new
val ve body i f i t happens onl y when hot.
> Loose val ve body bol ts
> Pl ugged fi l ter - i nternal transmi ssi on or
torque converter fai l ure
> TCM
Name of code: P0841(24) - LR Pressure Swi tch
Sense Ci rcui t
When monitored: Whenever the engi ne i s run-
ni ng.
Set condition: Thi s code i s set i f the LR pressure
swi tch i s ei ther open or cl osed at the wrong ti me i n
a gi ven gear.
Theory of operation: The Transmi ssi on system
uses three pressure swi tches to moni tor the fl ui d
pressure i n the LR, 2/4, and OD el ements. The
pressure swi tches are conti nuousl y moni tored for
the correct states i n each gear as shown bel ow.
Transmission Effects: I f a set condi ti on i s i den-
ti fi ed, 1st gear and torque converter l ock-up
(EMCC) wi l l be i nhi bi ted. The vehi cl e wi l l l aunch
i n 2nd gear and shi ft normal l y through the gears
wi thout al l owi ng EMCC. I f duri ng the same key
start, the set condi ti on i s no l onger val i d, the
transmi ssi on wi l l return to normal operati on (1st
and EMCC avai l abl e). Li mp-i n wi l l not occur un-
l ess code P0841(24) i s accompani ed by a code
P0706(28) and the MI L wi l l i l l umi nate after 5
mi nutes of substi tuted operati on.
Possible causes:
> I f code P0944(35) i s present, i gnore code
P0841(24) and perform code P0944(35) di ag-
nosti c procedures
> LR pressure swi tch sense ci rcui t open or
shorted to ground between TCM and sol enoi d
pack
> LR pressure swi tch sense ci rcui t shorted to
battery
8
GENERAL INFORMATION
> Sol enoi d pack
> Val ve body - sol enoi d swi tch val ve stuck i n
LU posi ti on. May be accompani ed by a code
P1775(37)
> Loose val ve body bol ts
> Pl ugged fi l ter - i nternal transmi ssi on or
torque converter fai l ure
> TCM
Name of code: P0706(28) - Check Shi fter Si gnal
When Monitored: Conti nuousl y wi th the key on.
Set Condition: 3 occurrences i n one key start of
an i nval i d PRNDL code whi ch l asts for more than
0.1 second.
Theory of Operation: The C1 through C4 (T1,
T3, T41, and T42) sense ci rcui ts communi cate the
shi ft l ever posi ti on to the TCM. Each ci rcui t i s
termi nated at the transmi ssi on wi th a swi tch.
Each swi tch can be ei ther open or cl osed, depend-
i ng on the shi ft l ever posi ti on. The TCM can decode
thi s i nformati on and determi ne the shi ft l ever
posi ti on. Each shi ft l ever posi ti on has a certai n
combi nati on of swi tches whi ch wi l l be open and
cl osed, thi s i s cal l ed a PRNDL code. There are 4
swi tches, therefore: there are many possi bl e com-
bi nati ons of open and cl osed swi tches (codes). How-
ever, there are onl y 9 val i d codes (8 for AutoSti ck),
one for each gear posi ti on and three recogni zed
between gear codes. The remai nder of the codes
shoul d never occur, these are cal l ed i nval i d codes.
The fol l owi ng chart shows the normal swi tch states
for each shi ft l ever posi ti on.
TRS Park T1 Rev T2 N T2 OD T3 3/AS T3 L
T1 (C4) OP OP OP CL CL CL CL CL OP CL CL
T3 (C3) CL CL OP OP OP OP OP CL CL CL CL
T41 (C1) CL OP OP OP CL OP OP OP OP OP OP
T42 (C2) CL CL CL CL CL CL OP OP OP OP CL
ThefollowingareDRBIII௡ reported Shift Le-
ver Error Codes (chart)
Transmission Effects and possible causes:
Scenario 1) - Al l PRNDL l i ghts stay i l l umi nated
i ndefi ni tel y i n Park fol l owi ng a Key start.
> Wrong Part Number TCM for appl i cati on
> TRS connector not pl ugged i n
> C1 through C4 (T1, T3, T41, or T42) ci rcui ts are
open, shorted to ground, or shorted to 12 vol ts.
> PCI bus fai l ure (Open or shorted resul ti ng i n no
communi cati on to BCM or Cl uster)
> TRS
> TCM
> BCM
Scenario2) - “P” i s i ndi cated fol l owi ng a key start
but al l PRNDL l i ghts i l l umi nate i n “N” fol l owi ng a
shi ft from “R” to “N”. I f PRNDL l i ghts i l l umi nate i n
“N” and shi fter i s moved di rectl y i nto “3” or “L”
posi ti on wi thout pausi ng i n “OD”, then the “OD”
posi ti on shi ft schedul e and el ectroni c di spl ay wi l l
i ndi cate “OD” unti l the shi fter i s shi fted i nto the
“OD” posi ti on and hel d for at l east 3 seconds.
> Worn Manual Lever (Rooster Comb). Check for
heavy weari ng by TRS swi tch contacts
> I ntermi ttent C1 through C4 (T1, T3, T41 or T42)
ci rcui ts. Check for corrosi on, termi nal push-outs
or spread termi nal s at 60-way and/or TRS
swi tch 10-way connector
> TRS
> TCM
> BCM
Scenario 3) - I f an i nval i d code happens whi l e
operati ng i n the “3” or “L” posi ti on, the “3” or “L”
shi ft schedul e and el ectroni c di spl ay wi l l be frozen
(regardl ess of whether “OD”, “3” or “L” i s sel ected).
The di spl ay wi l l be frozen unti l the shi fter i s moved
to the “N” posi ti on (al l PRNDL l i ghts wi l l i l l umi -
nate) and then back to the “OD” posi ti on. The “N”
and “OD” posi ti on must be hel d for at l east 3
seconds i n each posi ti on to resume the normal
“OD” shi ft schedul e and el ectroni c di spl ay.
> I ntermi ttent C1 through C4 (T1, T3, T41 or T42)
ci rcui ts. Check for corrosi on, termi nal push-outs
or spread termi nal s at 60-way and/or TRS con-
nector
> TRS
> TCM
> BCM
These same symptoms may occur wi thout the code
P0706(28) getti ng set. I t i s possi bl e that the i nval i d
code that was sensed by the TCM onl y occurred
once or twi ce duri ng the gi ven i gni ti on key start
and/or di d not l ast for l onger than 0.1 second.
9
GENERAL INFORMATION
Name of code: P0124(29) - Throttl e Posi ti on
Sensor/APPS I ntermi ttent
Nameof code: P0122(2A) - Throttl e Posi ti on Sen-
sor /APPS Low
Nameof code: P0123(2B) - Throttl e Posi ti on Sen-
sor /APPS Hi gh
When monitored: Whenever the key i s on or the
engi ne i s runni ng. Engi ne speed > 500 rpm
Set condition:
P0124 - Throttl e angl e change > 5° i n 7 mi l l i sec-
onds the Faul t set ti me mi l l i seconds 0.448
seconds
P0122 - Throttl e angl e < 6° the Faul t Set Ti me:
0.448 seconds
P0123 - Throttl e angl e > 120.6° the Faul t Set Ti me:
0.448 seconds
Theory of operation: The transmi ssi on control -
l er recei ves the throttl e posi ti on si gnal and i ts
ground from the Throttl e Posi ti on Sensor (TPS).
The TPS has a 5 vol t pul l up suppl i ed by the engi ne
control l er. The throttl e si gnal i s checked for out-of-
range as wel l as i ntermi ttent operati on (excessi ve
si gnal changes). The engi ne control l er transmi ts
the throttl e val ue vi a the Bus. Most engi ne control -
l ers can synthesi ze the throttl e val ue i f the throttl e
posi ti on sensor si gnal i s l ost. I f a throttl e error i s
detected by the transmi ssi on control l er and the
throttl e val ue i s avai l abl e vi a the Bus, the Bus
throttl e val ue wi l l be used and normal operati on
wi l l conti nue, however a throttl e faul t code wi l l be
set. I f a throttl e error i s detected and the throttl e
val ue i s not avai l abl e vi a the Bus, normal opera-
ti on wi l l be di sconti nued, a throttl e faul t code wi l l
be set, and the MI L wi l l be turned on after 5 mi n.
of substi tuted operati on.
Transmission Effects:
¼ I f throttl e val ue i s avai l abl e vi a the Bus -No
effect.
¼ I f throttl e val ue i s not avai l abl e vi a the Bus
A defaul t throttl e val ue i s used.
Torque converter l ock-up i nhi bi ted.
4th gear i nhi bi ted.
Li mi ted shi ft schedul e.
MI L on after 5 mi n. of substi tuted operati on.
Possible causes:
> Open or shorted TPS si gnal and/or ground ci r-
cui ts
> TCM connector probl ems
> TPS or TPS connector (Check PCM DTC’s)
> PCM
> TCM
Name of code: P0870(31) - OD Hydraul i c Pres-
sure Test Fai l ure
P0845(32) - 2/4 Hydraul i c Pressure Test Fai l ure
P0992(33) - 2-4/OD Hydraul i c Pressure Test Fai l ure
When monitored: I n 1st, 2nd, or 3rd gear wi th
engi ne speed above 1000 RPM shortl y after a shi ft
and every mi nute thereafter.
Set condition: I mmedi atel y after a shi ft i nto 1st,
2nd, or 3rd gear, wi th engi ne speed above 1000
RPM, the TCM momentari l y turns on el ement
pressure to the 2/4 and/or OD cl utch ci rcui ts to
i denti fy that the appropri ate pressure swi tch
cl oses. I f the pressure swi tch does not cl ose i t i s
tested agai n. I f the swi tch does not cl ose the second
ti me, the appropri ate code i s set.
Theory of operation: The Transmi ssi on Control
Modul e (TCM) tests the OD and 2/4 pressure
swi tches when they are off (OD and 2/4 are tested
i n 1st gear, OD i n 2nd gear, and 2/4 i n 3rd gear).
The test veri fi es that the swi tches are operati onal .
The TCM veri fi es that the swi tch cl oses when the
correspondi ng el ement i s appl i ed. I f a swi tch fai l s
to cl ose, i t i s retested, I f i t fai l s the second test, the
code i s set.
Transmission Effects: The MI L i l l umi nates and
the transmi ssi on system defaul ts to Li mp-i n mode.
Possible causes:
> Pressure swi tch sense ci rcui t shorted to battery
between TCM and sol enoi d pack.
> Low l i ne pressure
> Sol enoi d Pack
Nameof code: Name of code: P0944(35) - Loss Of
Pri me
When monitored: I f the transmi ssi on i s sl i ppi ng
i n any forward gear and the pressure swi tches are
not i ndi cati ng pressure, a l oss of pri me test i s run.
Set condition:I f the transmi ssi on begi ns to sl i p i n
any forward gear, and the pressure swi tch or
swi tches that shoul d be cl osed for a gi ven gear are
open, a l oss of pri me test begi ns. Al l avai l abl e
el ements (i n 1st gear LR, 2/4 and OD, i n 2nd, 3rd,
and 4th gear 2/4 and OD) are turned on by the
Transmi ssi on Control Modul e (TCM) to see i f pump
pri me exi sts. The code i s set i f none of the pressure
swi tches respond. The TCM wi l l conti nue to run
the l oss of pri me test unti l pump pressure returns.
10
GENERAL INFORMATION
Theory of operation: The l oss of pri me test i s
used to prevent transmi ssi on faul ts, whi ch can be
caused by a l ack of pump pri me.
Transmission Effects: Vehi cl e wi l l not move or
transmi ssi on sl i ps. Normal operati on wi l l conti nue
i f pump pri me returns.
Possible causes:
> Low transmi ssi on fl ui d l evel
> PRNDL i ndi cates a val i d OD code i n the hydrau-
l i c reverse posi ti on
> Transmi ssi on fl ui d fi l ter cl ogged or damaged
> Transmi ssi on fl ui d fi l ter i mproperl y i nstal l ed
(Bol ts l oose or O-ri ng mi ssi ng)
> Oi l pump - I f a customer has a probl em when the
transmi ssi on i s col d. Where someone shi fts to
reverse, reverse i s engaged, and then shi fts to
OD and does not get OD (gets a neutral condi -
ti on), and then can not get reverse or OD for 3-20
seconds, repl ace the oi l pump. Hi gh si de cl ear-
ance i n the oi l pump wi l l set a code 35. The pump
wi l l pri me upon start-up, but as the torque
converter purges ai r (drai n down) the ai r wi l l
l eak across the i nner rotor i nto the pump sucti on
port and cause a l oss of pri me ri ght after the
shi ft i nto OD. After 3 - 20 seconds, pump pri me
wi l l return and normal operati on wi l l conti nue.
The pump shoul d be repl aced onl y after al l other
possi bl e causes above have been checked and
veri fi ed.
Name of code: P1790(36) - Faul t I mmedi atel y
After Shi ft
When monitored: After a gear rati o error i s
stored.
Set condition: Thi s code i s set i f the associ ated
gear rati o code i s stored wi thi n 1.3 seconds after a
shi ft.
Theory of operation: Thi s code wi l l onl y be
stored al ong wi th a 50 seri es code. I f thi s code i s
set, i t i ndi cates the probl em i s mechani cal i n na-
ture. When thi s code exi sts, di agnosi ng the trans-
mi ssi on shoul d be based on the associ ated gear
rati o code and pri mari l y mechani cal causes shoul d
be consi dered.
Transmission Effects: None
Possible causes:
> Mechani cal causes as l i sted under associ ated
gear rati o code.
Nameof code: P1775(37) - Sol enoi d Swi tch Val ve
Latched i n TCC Posi ti on
When monitored: Duri ng an attempted shi ft i nto
1st gear.
Set condition: Thi s code i s set i f three unsuccess-
ful attempts are made to get i nto 1st gear i n one
gi ven key start.
Theory of operation: The sol enoi d swi tch val ve
(SSV) control s the di recti on of the transmi ssi on
fl ui d when the LR/TCC sol enoi d i s energi zed. The
SSV wi l l be i n the downshi fted posi ti on i n 1st gear,
thus di recti ng the fl ui d to the LR cl utch ci rcui t. I n
2nd, 3rd, and 4th, i t wi l l be i n the upshi fted
posi ti on and di rects the fl ui d i nto the torque con-
verter cl utch (TCC).
When shi fti ng i nto 1st gear, a speci al hydraul i c
sequence i s performed to ensure SSV movement
i nto the downshi fted posi ti on. The LR pressure
swi tch i s moni tored to confi rm SSV movement. I f
movement i s not confi rmed (the LR pressure
swi tch does not cl ose), 2nd gear i s substi tuted for
1st.
Transmission Effects: Transmi ssi on wi l l have no
1st gear (2nd gear wi l l be substi tuted), and no
EMCC operati on and the MI L wi l l i l l umi nate after
5 mi nutes of substi tuted operati on
Possible causes:
> PRNDL i ndi cates a val i d OD code i n the hydrau-
l i c reverse posi ti on
> Val ve body - Sol enoi d val ve stuck i n TCC posi -
ti on
> Hi gh i dl e speed
> Sol enoi d mal functi on - LR pressure swi tch wi l l
not cl ose
> LR Pressure Swi tch Sense ci rcui t shorted to
battery
Name of code: P0740(38) - Torque Converter
Cl utch Control Ci rcui t
When monitored: Duri ng El ectroni cal l y Modu-
l ated Converter Cl utch (EMCC)
Set condition:
a) The transmi ssi on must be i n EMCC, wi th the
i nput speed greater than 1750 RPM. The TCC/LR
sol enoi d must achi eve i t’s maxi mum duty cycl e and
sti l l not be abl e to pul l the engi ne speed wi thi n 60
RPM of i nput speed.
b) I f the transmi ssi on i s i n FEMCC and the engi ne
can sl i p the TCC by more than 100 RPM (Engi ne
speed - I nput speed) for 10 seconds.
The code wi l l be set i f one of these event happens
three ti mes at a throttl e angl e l ess than 30 degrees.
Theory of operation: When i n 2nd, 3rd, or 4th
gear, the torque converter cl utch (TCC) can be
l ocked when certai n condi ti ons are met. The TCC
pi ston i s el ectroni cal l y modul ated by i ncreasi ng
the duty cycl e of the LR/TCC sol enoi d unti l the
torque converter sl i p di fference (di fference be-
tween engi ne and turbi ne speed) i s wi thi n 60 RPM.
Then the LR/TCC sol enoi d i s ful l y energi zed
(FEMCC /100% duty cycl e). Torque converter sl i p
i s moni tored i n FEMCC to ensure adequate cl utch
capaci ty.
11
GENERAL INFORMATION
Transmission Effects: EMCC wi l l sti l l be avai l -
abl e after code i s set. MI L wi l l i l l umi nate after 5
mi nutes of accumul ated sl i p i n FEMCC. The trans-
mi ssi on wi l l attempt normal operati on (not i n
Li mp-i n) even after the MI L i s i l l umi nated.
Possible causes:
> Worn pump bushi ng and/or fai l ed torque con-
verter - both shoul d be repl aced duri ng a rebui l d
wi th code P0740(38) present
> Sol enoi d pack.
Name of code: P0750(41) - LR Sol enoi d Ci rcui t
P0755(42) - 2/4 Sol enoi d Ci rcui t
P0760(43) - OD Sol enoi d Ci rcui t
P0765(44) - UD Sol enoi d Ci rcui t
When monitored: I gni ti on key i s turned from off
posi ti on to run posi ti on and/or i gni ti on key i s
turned from crank posi ti on to run posi ti on, then
every 10 seconds thereafter, or when a gear rati o or
pressure swi tch error DTC i s detected.
Set condition: Al l four sol enoi ds are tested for
conti nui ty conti nuousl y i mmedi atel y upon start up
and duri ng vehi cl e operati on. For sol enoi ds that
are currentl y energi zed, power i s momentari l y i n-
terrupted, then reenergi zed. For sol enoi ds that are
not currentl y energi zed, the sol enoi d i s momen-
tari l y energi zed, then deenergi zed. Under both
si tuati ons, i f an i nducti ve spi ke i s not sensed by the
Transmi ssi on Control Modul e (TCM) duri ng the
conti nui ty check, i t i s retested twi ce. I f i t fai l s the
test the thi rd ti me, the appropri ate code i s set.
Theory of operation: Four sol enoi ds are used to
control the fri cti on el ements (cl utches). The conti -
nui ty of the sol enoi ds ci rcui ts are peri odi cal l y
tested. Each sol enoi d i s turned on or off dependi ng
on i t’s current state. An i nducti ve spi ke shoul d be
detected by the TCM duri ng thi s test. I f no spi ke i s
detected, the ci rcui t i s tested agai n to veri fy the
fai l ure. I n addi ti on to the peri odi c testi ng, the
sol enoi d ci rcui ts are tested i f a gear rati o or pres-
sure swi tch error occurs. I n thi s case, one fai l ure
wi l l resul t i n the appropri ate code bei ng set.
Transmission Effects: The MI L wi l l i l l umi nate
and the transmi ssi on goes i nto neutral i f code i s set
above 35 Km/h (22 MPH), Li mp-i n mode when
vehi cl e speed i s bel ow 35 Km/h (22 MPH).
Possible causes:
> Open or shorted sol enoi d ci rcui t(s) between TCM
and sol enoi d pack.
> Open ground ci rcui t.
> TCM connector probl ems.
> Sol enoi d pack connector probl em.
> Sol enoi d Pack.
> TCM
Nameof code: P1776(47) - Sol enoi d Swi tch Val ve
Latched i n LR Posi ti on
When monitored: Conti nuousl y when doi ng par-
ti al or ful l EMCC (PEMCC or FEMCC)
Set condition: I f the transmi ssi on senses the LR
pressure swi tch cl osi ng whi l e performi ng PEMCC
or FEMCC. Thi s code wi l l be set after two unsuc-
cessful attempts to perform PEMCC or FEMCC.
Theory of operation: The sol enoi d swi tch val ve
(SSV) control s the di recti on of the transmi ssi on
fl ui d when the LR/TCC sol enoi d i s energi zed. SSV
wi l l be i n the downshi fted posi ti on i n 1st gear, thus
di recti ng the fl ui d to the LR cl utch ci rcui ts. I n 2nd,
3rd, and 4th, the SSV wi l l be i n the upshi fted
posi ti on and di rects the fl ui d i nto the torque con-
verter cl utch (TCC).
When doi ng PEMCC or FEMCC, the LR pres-
sure swi tch shoul d i ndi cate no pressure i f the SSV
i s i n the TCC posi ti on. I f the LR pressure swi tch
i ndi cates pressure whi l e i n PEMCC or FEMCC,
EMCC operati on i s aborted and i nhi bi ted to avoi d
i nadvertent appl i cati on of the LR cl utch. Parti al
EMCC wi l l be attempted i f the LR pressure swi tch
does not i ndi cate pressure. A second detecti on of
LR pressure resul ts i n setti ng the code.
Transmission Effects: At speeds above 72 Km/h
(45 MPH), EMCC i s i nhi bi ted. Once speed fal l s
bel ow 72 Km/h (45 MPH), the transmi ssi on wi l l go
i nto Li mp-i n mode and the MI L wi l l i l l umi nate
after 5 mi nutes of substi tuted operati on.
Possible causes:
> Val ve body - Sol enoi d val ve stuck i n LR posi ti on
> I ntermi ttent short to ground or open ci rcui t i n
LR Pressure Swi tch Sense ci rcui t (wi th code 24
onl y)
> Sol enoi d pack (wi th code P0841(24) onl y)
> TCM (wi th code P0841(24) onl y)
12
GENERAL INFORMATION
Name of code: P1793(48) - TRD Li nk Communi -
cati on Error
NOTE: The MIL will be lit for some engines
that limit throttle after a TRD failure
When monitored: Whenever the engi ne i s run-
ni ng
Set condition: Thi s code i s set when the TCM
sends mul ti pl e torque reducti on messages to the
PCM and the TCM does not recei ve a response
from the PCM.
Theory of operation: Duri ng hi gh torque shi fts
the TCM wi l l send a message requesti ng that the
PCM reduce engi ne power unti l the shi ft i s com-
pl eted. Thi s message i s sent from the TCM to the
Powertrai n Control Modul e across the Torque
Management Request Sense Ci rcui t. The PCM wi l l
acknowl edge the TCM request by sendi ng a mes-
sage across the PCI bus wi thi n a speci fi c amount of
ti me. The TRD Li nk communi cati on i s al so tested
peri odi cal l y for operati on whenever the engi ne i s
runni ng and the vehi cl e i s not movi ng wi th zero
degrees throttl e.
Transmission Effects: Maxi mum throttl e angl e
used by TCM wi l l be 54 degrees. As a resul t a
customer my compl ai n about l oss of performance or
of short shi fti ng when dri vi ng aggressi vel y.
Possible causes:
> Sti cky Throttl e Posi ti on Sensor (TPS)
> Wi ri ng or Connector probl ems i n the Torque
Management Request Sense Ci rcui t
> PCM
> TCM
Name of code: P0736(50) - Gear Rati o Error i n
Reverse
P0731(51) - Gear Rati o Error i n 1st
P0732(52) - Gear Rati o Error i n 2nd
P0733(53) - Gear Rati o Error i n 3rd
P0734(54) - Gear Rati o Error i n 4th
P0715(56) - I nput Speed Sensor Error
P0720(57) - Output Speed Sensor Error
P1794(58) - Speed Sensor Ground Error
When monitored: The transmi ssi on gear rati o i s
moni tored conti nuousl y whi l e the transmi ssi on i s
i n gear.
Set condition:Thi s code i s set i f the gear rati o i s
not correct for a peri od of ti me.
– Codes 50 through 54 sets i f the rati o of the
i nput RPM (Nt) to the output RPM (No) does
not match the gi ven gear rati o.
– Code 56 sets i f there i s an excessi ve change i n
i nput RPM i n any gear
– Code 57 sets i f there i s an excessi ve change i n
output RPM i n any gear
– Code 58 sets after a TCM reset i n neutral and
Nt/No equal s a rati o of i nput to output of 2.50
A hard code sets wi thi n 3 seconds, an i ntermi t-
tent code sets wi thi n 15 seconds.
Theory of operation: The transmi ssi on system
uses two speed sensors, one to measure i nput RPM
and one to measure output RPM. These i nputs are
essenti al for proper transmi ssi on operati on. There-
fore, the i ntegri ty of thi s data i s veri fi ed through
the fol l owi ng checks:
1) When i n gear, i f the gear rati o does not compare
to a known gear rati o, the correspondi ng i n-gear
troubl e code i s set (codes 50 through 54).
2) An excessi ve change i n i nput or output speeds
i ndi cati ng si gnal i ntermi ttent wi l l resul t i n codes
56 and/or 57 bei ng set.
3) After a TCM reset i n neutral , observi ng errati c
output and i nput speed sensor si gnal s i ndi cates a
l oss of the common speed sensors ground. Thi s sets
a code 58.
Transmission Effects: The transmi ssi on wi l l not
go i nto Li mp-i n mode unti l three gear rati o error
events occur i n a gi ven key start al so the MI L wi l l
i l l umi nate after 5 mi nutes of substi tuted opera-
ti on. Thi s al l ows for i ntermi ttent probl ems to cor-
rect themsel ves wi thout openi ng the rel ay. How-
ever, i f a gear rati o error devel ops, a code i s al ways
set, but i f the condi ti on corrects i tsel f the transmi s-
si on wi l l conti nue wi thout requi ri ng the i gni ti on
key to be cycl ed on and off. Many di fferent events
coul d occur gi ven the range of fai l ures possi bl e for
codes 50 through 58. The fol l owi ng are a few
exampl es:
– Codes 51, 52, 53, 54, 56, and 57 at speeds
above 72 Km/h (45 MPH) - The appropri ate
code i s set, EMCC i s aborted and current gear
i s mai ntai ned. I f whi l e sti l l travel i ng above 72
Km/h (45 MPH), the gear rati o becomes val i d
agai n, EMCC wi l l reengage and normal oper-
ati on wi l l resume. I f the gear rati o becomes
i ntermi ttent and recovers three ti mes i n a
gi ven key start, the current gear wi l l be mai n-
tai ned and EMCC i nhi bi ted, then the trans-
mi ssi on wi l l go i nto Li mp-i n mode i f throttl e i s
appl i ed bel ow 72 Km/h (45 MPH) or at 35
Km/h (22 MPH) wi th cl osed throttl e.
– Codes 51, 52, 53, 54, 56, and 57 at speeds
between 35 and 72 Km/h (22 and 45 MPH) - I f
one of these codes i s set between 35 and 72
Km/h (22 and 45 MPH), the current gear wi l l
be mai ntai ned unti l the gear rati o probl em
corrects i tsel f. I f throttl e i s appl i ed, the trans
wi l l go to 2nd gear. I f thi s happens and the
gear rati o probl em goes away, normal opera-
ti on wi l l resume. I f three gear rati o probl ems
are i denti fi ed i n a gi ven key start, the current
gear wi l l be frozen unti l throttl e i s appl i ed.
13
GENERAL INFORMATION
The transmi ssi on wi l l then go i nto Li mp-i n
mode wi th throttl e appl i ed at speeds between
35 and 72 Km/h (22 and 45 MPH)
– Codes 51, 52, 53, 54, 56, and 57 at speeds
bel ow 35 Km/h (22 MPH) - I f a gear rati o
probl em i s i denti fi ed bel ow 35 Km/h (22
MPH), the transmi ssi on wi l l i mmedi atel y
substi tute second gear for the current gear. I f
the gear rati o probl em goes away, normal
operati on wi l l resume. I f three gear rati o
probl ems are i denti fi ed i n a gi ven key start,
the transmi ssi on wi l l go i nto Li mp-i n mode.
Possible causes:
Code P0736(50) - Excl udes geartrai n fai l ures
whi ch shoul d be obvi ous upon di sassembl y
> I f code P0944(35) i s al so set, fol l ow di agnosti c
procedure for code P0944(35) fi rst
> Val ve body - #1 bal l check or LR swi tch val ve
sti cki ng - may al so set code P0731(51)
> Speed sensor or associ ated wi ri ng - may al so set
codes P0731(51), P0715(56), or P0720(57)
> Fai l ed or sl i ppi ng LR cl utch - may al so set code
P0731(51)
– LR seal l eakage (I ntermi ttent no dri ve or
reverse)
– Sti cky LR accumul ator seal s (I ntermi ttent no
dri ve or reverse)
> Fai l ed reverse cl utch (hard code)
– OD/Rev l i p seal l eakage
– Worn reacti on shaft support seal ri ngs
– Snap ri ng out of posi ti on
Code P0731(51) - Excl udes geartrai n fai l ures
whi ch shoul d be obvi ous upon di sassembl y
> I f code P0944(35) i s al so set, fol l ow di agnosti c
procedure for code P0944(35) fi rst
> Val ve body - #1 bal l check or LR swi tch val ve
sti cki ng - may al so set code P0736(56) or have no
Reverse
> Speed sensor or associ ated wi ri ng - may al so set
codes P0736(50), P0715(56), or P0720(57)
> Fai l ed or i ntermi ttent sl i ppi ng UD cl utch - may
al so set P0732(52), or P0733(53)
– UD seal l eakage (i ntermi ttent)
– Worn i nput cl utch hub bushi ng (hard code at
heavy throttl e)
– Sti cky UD accumul ator seal s (i ntermi ttent)
– Worn reacti on shaft support seal ri ngs (hard
code at heavy throttl e)
– Sol enoi d pack (UD pressure i n 4th gear)
> Fai l ed or sl i ppi ng LR cl utch - may al so set code
P0736(56) or have no Reverse
– LR seal l eakage (I ntermi ttent)
– Sti cky LR accumul ator seal s (I ntermi ttent)
Code P0732(52) - Excl udes geartrai n fai l ures
whi ch shoul d be obvi ous upon di sassembl y
> I f code P0944(35) i s al so set, fol l ow di agnosti c
procedure for code P0944(35) fi rst
> Fai l ed or sl i ppi ng 2/4 cl utch - may al so set code
P0734(54)
– 2/4 seal l eakage (i ntermi ttent)
– Sti cky accumul ator seal s (i ntermi ttent)
> Fai l ed or i ntermi ttent sl i ppi ng UD cl utch - may
al so set code P0731(51) and/or P0733(53)
– UD seal l eakage (i ntermi ttent)
– Worn i nput cl utch hub bushi ng (hard code at
heavy throttl e)
– Sti cky UD accumul ator seal s (i ntermi ttent)
– Worn reacti on shaft support seal ri ngs (hard
code at heavy throttl e)
– Sol enoi d pack (UD pressure i n 4th gear)
Code P0733(53) - Excl udes geartrai n fai l ures
whi ch shoul d be obvi ous upon di sassembl y
> I f code P0944(35) i s al so set, fol l ow di agnosti c
procedure for code P0944(35) fi rst
> Fai l ed or sl i ppi ng OD cl utch - may al so set code
P0734(54)
– OD and Reverse i nner and outer l i p seal
l eakage (usual l y hard code)
– Sti cky OD accumul ator seal s (i ntermi ttent)
– Worn reacti on shaft support seal ri ngs (hard
code at heavy throttl e)
– Broken OD/UD tapered snap ri ng - (hard code
at heavy throttl e)
> Fai l ed or i ntermi ttent sl i ppi ng UD cl utch - may
al so set code P0731(51) and/or P0732(52)
– UD seal l eakage (i ntermi ttent)
– Worn i nput cl utch hub bushi ng (hard code at
heavy throttl e)
– Sti cky UD accumul ator seal s (i ntermi ttent)
– Worn reacti on shaft support seal ri ngs (hard
code at heavy throttl e)
– Sol enoi d pack (UD pressure i n 4th gear)
Code P0734(54) - Excl udes geartrai n fai l ures
whi ch shoul d be obvi ous upon di sassembl y
> I f code P0944(35) i s al so set, fol l ow di agnosti c
procedure for code P0944(35) fi rst
> Fai l ed or sl i ppi ng OD cl utch - may al so set code
P0733(53)
– OD and Reverse i nner and outer l i p seal
l eakage (usual l y hard code)
– Sti cky OD accumul ator seal s (i ntermi ttent)
– Worn reacti on shaft support seal ri ngs (hard
code at heavy throttl e)
14
GENERAL INFORMATION
– Broken OD/UD tapered snap ri ng - (hard code
at heavy throttl e)
> Fai l ed or sl i ppi ng 2/4 cl utch - may al so set code
P0732(52)
– 2/4 seal l eakage (i ntermi ttent)
– Sti cky accumul ator seal s (i ntermi ttent)
Codes P0715(56) and P0720(57)
> Fai l ed i nput or output speed sensor (i ntermi t-
tent or hard code)
> Shorted or open wi ri ng between TCM and speed
sensor(s) (i ntermi ttent)
> Connector probl ems at 60 TCM connector and/or
speed sensor connector
Code P1794(58)
> Open or shorted speed sensor ground (speed
sensor ground i s di fferent from chassi s ground)
> Open or shorted Temperature Sensor wi ri ng to
TRS
> TRS - Wi l l al so set code P1799(74)
> TCM
Nameof code: P1797(71)- Manual Shi ft Overheat
When monitored: Whenever the engi ne i s run-
ni ng.
Set condition:
1) I f the engi ne temperature exceeds 124 C (255°F)
whi l e operati ng i n AutoSti ck mode.
2) I f the transmi ssi on temperature exceeds 135°C
(275°F) whi l e i n AutoSti ck mode
Theory of operation: Transmi ssi on and engi ne
temperatures are moni tored duri ng vehi cl e opera-
ti on. I f condi ti ons occur causi ng the engi ne or
transmi ssi on to overheat, the AutoSti ck mode wi l l
be cancel ed, and a code wi l l be set.
Transmission Effects: The 3 posi ti on shi ft sched-
ul e that i s used i n non-AutoSti ck appl i cati ons i s
substi tuted whi l e operati ng i n the AutoSti ck gear
sel ector posi ti on. No Li mp-i n mode occurs.
Possible causes:
> Engi ne overheat - refer to servi ce i nformati on
for di agnosi s and repai r
> Transmi ssi on Overheat
– Restri cted transmi ssi on cool i ng system
– Transmi ssi on fl ui d overfi l l ed
– Radi ator fan not functi oni ng properl y
– Extended dri vi ng i n l ow gear
NOTE: Strenuous driving conditions may
cause the vehicle to overheat. If the driver
operates in or initiates AutoStick with an
overheated vehicle, the code will be set.
Name of code: P0897(73) - Worn Out/Burnt
Transmi ssi on Fl ui d
When monitored: At every Ful l y El ectroni cal l y
Modul ated Converter Cl utch (FEMCC) to Parti al
El ectroni cal l y Modul ated Converter Cl utch
(PEMCC) transi ti on mi l es when A/C compressor
cl utch i s bei ng cycl ed.
Set condition: The code wi l l be set i f vehi cl e
shudder i s detected 20 ti mes when the A/C cl utch i s
cycl ed.
Theory of operation: Whi l e i n 3rd or 4th gear
FEMCC and just before the A/C cl utch engages, the
Powertrai n Control Modul e (PCM) requests the
Transmi ssi on Control Modul e (TCM) to momen-
tari l y establ i sh PEMCC operati on. I f vehi cl e shud-
der i s detected duri ng the FEMCC to PEMCC
transi ti on, a counter i s i ncremented. I f the count
reaches 20, the troubl e code i s set. The dri ver may
then noti ce harsh bumps when the A/C cl utch i s
bei ng cycl ed, but vehi cl e shudder wi l l be el i mi -
nated. After 35 OBDI I (EURO STAGE I I I OBD)
warm-up starts or i f the code i s cl eared, PEMCC
wi l l be reacti vated to see i f shudder i s sti l l present.
I f one shudder event occurs, the code wi l l be reset.
Cl eari ng the code and runni ng battery di sconnect
wi th the DRBI I I ௡ i s the onl y way to reset the
shudder counter from 20 back to zero.
Transmission Effects: Thi s code does not cause
the transmi ssi on to go i nto Li mp-i n mode. How-
ever, once the code i s set, FEMCC to PEMCC
operati on before the A/C cl utch engagement wi l l be
di sabl ed for 35 OBDI I (EURO STAGE I I I OBD)
warm up starts.
Possible causes:
> Degraded transmi ssi on fl ui d
> Wheel s severel y out of al i gnment
> I nternal torque converter probl em
Name of code: P0218(75) - Hi gh Temperature
Operati on Acti vated.
When monitored: Whenever the engi ne i s run-
ni ng.
Set condition: I mmedi atel y once the Overheat
Shi ft Schedul e i s acti vated.
Theory of operation: I f the transmi ssi on oi l
temperature ri ses above 115°C (240°F), the over-
heat shi ft schedul e i s acti vated refer to Transmi s-
si on Operati on as a functi on of Transmi ssi on Oi l
Temperature and the code i s set. The DTC i s an
i nformati on code onl y and i s bei ng set to ai d the
techni ci an i n determi ni ng root cause of a customer
dri veabi l i ty i ssue. The code i s al so i ntended to al ert
the techni ci an to determi ne i f a cool i ng system
mal functi on has occurred or i f an addi ti onal trans-
mi ssi on ai r to oi l cool er shoul d be added to the
vehi cl e i f the customer regul arl y dri ves i n a man-
ner that overheats the transmi ssi on. Extended
operati on above 115°C (240°F) wi l l reduce the
durabi l i ty of the transmi ssi on and shoul d be
avoi ded. Correcti ng the cool i ng system mal functi on
15
GENERAL INFORMATION
or i nstal l i ng an addi ti onal transmi ssi on oi l cool er
wi l l i mprove transmi ssi on durabi l i ty especi al l y for
customers who operate i n ci ty/constructi on stop
and go traffi c, tow trai l ers regul arl y, dri ve aggres-
si vel y i n l ow gear or dri ve regul arl y i n mountai n-
ous areas.
Transmission effects: I nformati on onl y code. -
Overheat shi ft schedul e was acti vated, no Li mp-i n
condi ti on occurs. 2nd gear parti al EMCC above 40
Km/h (25 MPH), 3rd gear EMCC from 45-69 Km/h
(28-43 MPH), del ayed 3-4 upshi ft at 69 Km/h (43
MPH), earl y 4-3 coastdown at 66 Km/h (41 MPH),
EMCC operati on under al l condi ti ons above 40
Km/h (25 MPH) except at cl osed throttl e or 1st
gear.
Possible causes:
– Transmi ssi on Overfi l l ed wi th Oi l
– Engi ne cool i ng fan fai l ure
– Engi ne thermostat stuck cl osed
– Radi ator corroded or packed wi th di rt
– Transmi ssi on Oi l Cool er Pl ugged
– Customer dri vi ng pattern requi res addi ti onal
transmi ssi on cool i ng
Name of code: P0884(76) - Power Up at Speed
When monitored: When TCM (transmi ssi on con-
trol modul e) i ni ti al l y powers-up.
Set condition: I f the TCM powers up whi l e i n the
‘‘Dri ve’’ posi ti on and the vehi cl e i s goi ng above 32
Km/h (20 MPH), the code i s set.
Theory of Operation: I f a vehi cl e l oses power to
the TCM, the vehi cl e wi l l go to the 2nd gear mode
si nce there i s no power avai l abl e to control the
transmi ssi on sol enoi ds. However i f power i s re-
stored, the TCM wi l l power-up and normal opera-
ti on wi l l be restored. Thi s DTC i denti fi es that
power to the TCM was restored when the gear
sel ector was i n a ‘‘Dri ve’’ posi ti on whi l e the vehi cl e
was movi ng at speeds above 32 Km/h (20 MPH). I f
someone shi fts to Neutral and cycl es the i gni ti on
key and qui ckl y shi fts to “Dri ve” whi l e movi ng
before the TCM comes out of i ts STARTROUTI NE,
the DTC can be set. Therefore i t i s cri ti cal that thi s
DTC di agnosi s repai r procedure shoul d onl y be
used i f the vehi cl e i s experi enci ng i ntermi ttent 2nd
gear operati on and subsequentl y a return to nor-
mal operati on duri ng normal dri vi ng.
Transmission Effects: No Li mp-i n condi ti on. The
DTC i s for i nformati on onl y when tryi ng to di ag-
nosi s i ntermi ttent 2nd gear operati on and subse-
quentl y a return to normal operati on.
Possible causes:
– No Probl em i f vehi cl e i s started i n ‘‘neutral ’’ at
speeds above 32 Km/h (20 MPH) and shi fted
qui ckl y to ‘‘Dri ve’’ before TCM comes out of
the START ROUTI NE.
FOR INTERMITTENT 2ND GEAR OPERA-
TION AND THEN A SUBSEQUENT RETURN
TO NORMAL OPERATION WITHOUT CY-
CLING THE IGNITION KEY
– I ntermi ttent Di rect Battery connecti on be-
tween TCM (60-way pi n 56) and battery.
– I ntermi ttent Fused I gni ti on Swi tch Output
between TCM (60-way pi n 11) and i gni ti on
swi tch.
– I ntermi ttent Ground to TCM (60 way pi ns 53
and 57).
Name of code: P1687(77) - No Communi cati on
wi th the MI C
When monitored: Conti nuousl y wi th key on.
Set condition: I f no PCI bus messages are re-
cei ved from the Mechani cal I nstrument Cl uster
(MI C) for 25 seconds.
Theory of operation: The TCM communi cates
wi th the MI C usi ng the PCI bus. I t rel i es on certai n
i nformati on to functi on properl y. The TCM conti n-
uousl y moni tors the PCI bus to check for messages
broadcast from the PCM.
Transmission effects: Possi bl e i mproper TCM
AutoSti ck confi gurati on.
Possible causes:
> Open or shorted PCI bus ci rcui t from MI C
> MI C
> TCM (I f other communi cati ons codes are stored
i n the TCM onl y)
Nameof code: P1652(78) - Seri al Communi cati on
Li nk Mal functi on
When monitored: Conti nuousl y wi th key on.
Set condition: I f no PCI bus messages are re-
cei ved by the Transmi ssi on Control Modul e (TCM)
for 10 seconds.
Theory of operation: The TCM communi cates
wi th the other modul es i n the vehi cl e usi ng the PCI
bus. I t rel i es on certai n i nformati on to functi on
properl y. The TCM conti nuousl y moni tors the PCI
bus to check for messages broadcast from the
certai n modul es.
Transmission Effects: Possi bl e i mproper TCM
AutoSti ck confi gurati on and del ayed 3-4 shi fts. No
EMCC and earl y 3-4 shi fts for a few mi nutes after
engi ne i s started.
Possible causes:
> Open or shorted PCI bus ci rcui t from BCM
> TCM
Name of code: P0562(79) Low Battery Vol tage
When monitored: Conti nuousl y wi th engi ne run-
ni ng and Transmi ssi on Rel ay energi zed.
Set condition: I f the vol tage sensed at the Trans-
mi ssi on Control Rel ay Output ci rcui t (pi ns 16 and
17 at TCM) for 15 seconds.
16
GENERAL INFORMATION
Theory of operation: The Transmi ssi on system
requi res suffi ci ent battery vol tage i n order to ener-
gi ze the transmi ssi on sol enoi ds. The TCM conti n-
uousl y moni tors the vol tage avai l abl e to the sol e-
noi ds.
Transmission effects: At speeds above 72 Km/h
(45 MPH) the transmi ssi on system wi l l defaul t to
neutral . Bel ow 72 Km/h (45 MPH) the transmi s-
si on system wi l l defaul t to Li mp-i n mode and the
MI L wi l l i l l umi nate after 5 mi nutes of substi tuted
operati on. Manual gear sel ecti on of Park, Reverse,
Neutral and Second wi l l be avai l abl e.
Possible causes:
> Chargi ng system probl em
> Poor/Hi gh resi stance connecti on between TCM
and Battery/Al ternator
> TCM pi n 16 and 17 hi gh resi stance or poor
connecti on
> TCM ground pi ns 53 and 57 hi gh resi stance or
poor connecti on
> Hi gh resi stance i n Transmi ssi on Control Rel ay
contacts
> TCM
Nameof code: P0711(7A) - Transmi ssi on temper-
ature sensor performance
When monitored: Every 7 mi l l i seconds wi th the
engi ne runni ng and no l oss of pri me DTC set.
Set condition: A temperature readi ng of 80°F i s
not reached i n the speci fi ed peri od of ti me
Theory of operation: The temperature sensor
(thermi stor) i s used to sense the temperature of the
transmi ssi on fl ui d. Transmi ssi on fl ui d tempera-
ture can affect shi ft qual i ty, torque converter l ock-
up, and when and i f some di agnosti cs are run. A
fai l ed temperature sensor coul d affect the OBD I I
di agnosti cs, therefore when a faul t i s detected i n
the temperature sensor ci rcui t, transmi ssi on tem-
perature wi l l be based on a cal cul ated temperature
val ue.
Transmission Effects: When the faul t i s set,
cal cul ated temperature i s substi tuted for mea-
sured temperature, however the faul t code i s
stored onl y after three consecuti ve occurrences of
the faul t.
Possible causes:
> Temperature sensor
> Temperature sensor wi ri ng ci rcui t.
> I nternal control l er
Nameof code: P0712(7B) - Transmi ssi on temper-
ature sensor l ow
When monitored: Every 7 mi l l i seconds wi th the
engi ne runni ng and no l oss of pri me DTC set.
Set condition: Sensor output vol tage l ess than
0.078v.
Theory of operation: The temperature sensor
(thermi stor) i s used to sense the temperature of the
transmi ssi on fl ui d. Transmi ssi on fl ui d tempera-
ture can affect shi ft qual i ty, torque converter l ock-
up, and when and i f some di agnosti cs are run. A
fai l ed temperature sensor coul d affect the OBD I I
di agnosti cs, therefore when a faul t i s detected i n
the temperature sensor ci rcui t, transmi ssi on tem-
perature wi l l be based on a cal cul ated temperature
val ue.
Transmission effects: When the faul t i s set,
cal cul ated temperature i s substi tuted for mea-
sured temperature, however the faul t code i s
stored onl y after three consecuti ve occurrences of
the faul t.
Possible causes:
> Temperature sensor
> Temperature sensor wi ri ng ci rcui t.
> I nternal control l er
Nameof code: P0713(7C) - Transmi ssi on temper-
ature sensor hi gh
When monitored: Every 7 mi l l i seconds wi th the
engi ne runni ng and no l oss of pri me DTC set.
Set condition:Sensor output vol tage greater than
4.94v.
Theory of operation: The temperature sensor
(thermi stor) i s used to sense the temperature of the
transmi ssi on fl ui d. Transmi ssi on fl ui d tempera-
ture can affect shi ft qual i ty, torque converter l ock-
up, and when and i f some di agnosti cs are run. A
fai l ed temperature sensor coul d affect the OBD I I
di agnosti cs, therefore when a faul t i s detected i n
the temperature sensor ci rcui t, transmi ssi on tem-
perature wi l l be based on a cal cul ated temperature
val ue.
Transmission effects: When the faul t i s set,
cal cul ated temperature i s substi tuted for mea-
sured temperature, however the faul t code i s
stored onl y after three consecuti ve occurrences of
the faul t.
Possible causes:
> Temperature sensor
> Temperature sensor wi ri ng ci rcui t.
> I nternal control l er
Nameof code: P0714(7D) - Transmi ssi on temper-
ature sensor i ntermi ttent
When monitored: Every 7 mi l l i seconds wi th the
engi ne runni ng and no l oss of pri me DTC set.
Set condition: Temperature readi ng change
greater than maxi mum change al l owed per l oop.
Theory of operation: The temperature sensor
(thermi stor) i s used to sense the temperature of the
transmi ssi on fl ui d. Transmi ssi on fl ui d tempera-
ture can affect shi ft qual i ty, torque converter l ock-
up, and when and i f some di agnosti cs are run. A
fai l ed temperature sensor coul d affect the OBD I I
17
GENERAL INFORMATION
di agnosti cs, therefore when a faul t i s detected i n
the temperature sensor ci rcui t, transmi ssi on tem-
perature wi l l be based on a cal cul ated temperature
val ue.
Transmission effects: When the faul t i s set,
cal cul ated temperature i s substi tuted for mea-
sured temperature, however the faul t code i s
stored onl y after three consecuti ve occurrences of
the faul t.
Possible causes:
> Temperature sensor
> Temperature sensor wi ri ng ci rcui t.
> I nternal control l er
3. 3. 9 QUICK LEARN
The Qui ck Learn functi on customi zes adapti ve
parameters of the TCM to the transmi ssi on char-
acteri sti cs of a vehi cl e. Thi s gi ves the customer
i mproved “as recei ved” shi ft qual i ty compared to
the i ni ti al parameters stored i n the TCM.
Notes about Qui ck Learn Features
The nature of the Qui ck Learn functi on requi res
that certai n features must be taken i nto consi der-
ati on.
> Qui ck Learn shoul d general l y not be used as
a repai r procedure unl ess di rected by a repai r
or di agnosti c procedure. I f the transmi ssi on
system i s exhi bi ti ng a probl em that you thi nk
i s caused by an i nval i d CVI , you shoul d try to
rel earn the val ue by performi ng the appropri -
ate dri vi ng maneuvers. I n most cases, i f qui ck
l earn makes a vehi cl e shi ft better, the vehi cl e
wi l l return wi th the same probl em.
> Before performi ng Qui ck Learn, i t i s i mpera-
ti ve that the vehi cl e be shi fted i nto OD wi th
the engi ne runni ng and the oi l l evel set to the
correct l evel . Thi s step wi l l purge ai r from the
cl utch ci rcui ts to prevent erroneous cl utch
vol ume val ues whi ch coul d cause poor i ni ti al
shi ft qual i ty.
> I f an unused TCM i s i nstal l ed on a vehi cl e
wi th a HOT engi ne, Qui ck Learn wi l l cause
the TCM to report a col d cal cul ated oi l tem-
perature. Thi s requi res moni tori ng the cal cu-
l ated oi l temperature usi ng the DRBI I I ௡. I f
the temperature i s bel ow 15°C (60°F), the
transmi ssi on must be run at i dl e or dri ven i n
gear unti l i t goes above 15°C (60°F). I f the
temperature i s above 93°C (200°F), the trans-
mi ssi on must cool to bel ow 93°C (200°F).
> Fi rst gear i s engaged i n overdri ve after Qui ck
Learn i s compl eted. Pl ace the vehi cl e i n park
after performi ng Qui ck Learn.
The Qui ck Learn functi on shoul d be performed:
– Upon i nstal l ati on of a new servi ce TCM
– After repl acement or rebui l d of i nternal trans-
mi ssi on components or the torque converter
– I f one or more of the cl utch vol umes i ndexes
(CVI ’S) contai n skewed readi ngs because of
abnormal condi ti ons.
To perform the Qui ck Learn procedure, the fol l ow-
i ng condi ti ons must be met.
– I t i s i mperati ve that the vehi cl e be shi fted i nto
OD wi th the engi ne runni ng and the oi l l evel
set to the correct l evel . Thi s step wi l l purge
the ai r i n the cl utch ci rcui ts to prevent erro-
neous cl utch vol ume val ues, whi ch coul d
cause poor i ni ti al shi ft qual i ty.
– The brakes must be appl i ed.
– The engi ne must be i dl i ng.
– The throttl e angl e (TP sensor) must be l ess
than 3 degrees.
– The shi ft l ever posi ti on must stay i n neutral
unti l prompted to shi ft i nto OD.
– The shi ft l ever must stay i n OD after the-
“Shi ft to Overdri ve” prompt unti l the DRBI I I ௡
i ndi cates the procedure i s compl ete.
– The oi l temperature must be between 15°C
(60°F) and 93°C (200°F).
NOTE: The above conditions must be
maintained during the procedure to keep the
procedure from being aborted.
The Qui ck Learn procedure i s performed wi th
the DRBI I I ௡ by sel ecti ng “Transmi ssi on” system
then “Mi scel l aneous” functi ons, then “Qui ck
Learn”. Fol l ow the procedure i nstructi ons di s-
pl ayed on the DRBI I I ௡.
3. 3. 10 CLUTCH VOLUMES
The LR cl utch vol ume i s updated when doi ng a
2-1 or 3-1 coast down shi ft. The transmi ssi on
temperature must be between 21-49°C (70-120°F).
The cl utch vol ume shoul d be between 35 and 83.
The 2/4 cl utch vol ume i s updated when doi ng a
1-2 shi ft. The transmi ssi on temperature must be
above 43°C (110°F). The cl utch vol ume shoul d be
between 20 and 77.
The OD cl utch vol ume i s updated when doi ng a
2-3 shi ft. The transmi ssi on temperature must be
above 43°C (110°F). The cl utch vol ume shoul d be
between 40 and 150.
The UD cl utch vol ume i s updated when doi ng a
4-3 or 4-2 shi ft. The transmi ssi on temperature
must be above 43°C (110°F). The cl utch vol ume
shoul d be between 24 and 70.
18
GENERAL INFORMATION
3. 3. 11 ELECTRONIC PINION FACTOR (IF
APPLICABLE)
Usi ng the fol l owi ng steps, the pi ni on factor can
be checked and/or reset usi ng the DRBI I I ௡:
1. Sel ect Transmi ssi on system, then Mi scel l a-
neous functi ons, then Pi ni on Factor. The
DRBI I I ௡ wi l l di spl ay the current ti re si ze.
2. I f the ti re si ze i s i ncorrect, press the Enter key
and then sel ect the correct si ze.
3. Press the Page Back key to exi t the reset
procedure.
Notes About El ectroni c Pi ni on Factor Features
The nature of the el ectroni c pi ni on factor requi res
that certai n features must be taken i nto consi der-
ati on.
> I f no pi ni on factor i s stored i n an i nstal l ed
TCM, the vehi cl e speedometer wi l l not oper-
ate, engi ne speed wi l l be l i mi ted to 2300
RPM, and catal yst damage may occur.
> Sel ecti ng a wrong ti re si ze wi l l cause the
speedometer to be i naccurate and wi l l al so
cause any speed rel ated features to operate
i mproperl y.
NOTE: After replacing the TCM, you must
reprogram pinion factor
3. 4 USING THE DRBIIIா
Refer to the DRBI I I ௡ users gui de for i nstructi ons
and assi stance wi th readi ng troubl e codes, erasi ng
troubl e codes, and other DRBI I I ௡ functi ons.
3. 5 DRBIIIா ERROR MESSAGES
Under normal operati on, the DRBI I I ௡ wi l l di s-
pl ay one of onl y two error messages:
– User-Requested WARM Boot
– User-Requested COLD Boot
I f the DRBI I I ௡ shoul d di spl ay any other error
message, record the enti re di spl ay and cal l the
S.T.A.R.. Center.
3. 5. 1 DRBIIIா DOES NOT POWER UP
(BLANK SCREEN)
I f the LED’s do not l i ght or no sound i s emi tted at
start up, check for l oose cabl e connecti ons or a bad
cabl e. Check the vehi cl e battery vol tage. A mi ni -
mum of 11 vol ts i s requi red to adequatel y power
the DRBI I I ௡.
I f al l connecti ons are proper between the
DRBI I I ௡ and the vehi cl e or other devi ces, and the
vehi cl e battery i s ful l y charged, an i noperati ve
DRBI I I ௡ may be the resul t of faul ty cabl e or vehi cl e
wi ri ng. For a bl ank screen, refer to the appropri ate
Body Di agnosti c manual .
3. 5. 2 DISPLAY IS NOT VISIBLE
Low temperatures wi l l affect the vi si bi l i ty of the
di spl ay. Adjust the contrast to compensate for thi s
condi ti on.
3. 6 TRANSMISSION SIMULATOR (MILLER
TOOL # 8333) AND ELECTRONIC
TRANSMISSION ADAPTER KIT
(MILLER TOOL #8333-1A)
NOTE: Remove the starter Relay when using
the transmission simulator
¼ Failure to remove the Starter Relay can
cause a PCM - No Response condition.
¼ The removal of the Starter Relay will also
prevent the engine from starting in gear.
¼ The Transmission Simulator will not
accurately diagnose intermittent faults.
The transmi ssi on si mul ator, si mpl y put, i s an
el ectroni c devi ce that si mul ates the el ectroni c func-
ti ons of any EATX or NGC control l ed transmi ssi on.
The Si mul ators basi c functi on i s to ai d the techni -
ci an i n determi ni ng i f an i nternal transmi ssi on
probl em exi sts or i f the probl em resi des i n the
vehi cl e wi ri ng or control modul e. I t i s onl y useful
for el ectri cal probl ems. I t wi l l not ai d i n the di ag-
nosi s of a fai l ed mechani cal component, but i t can
tel l you that the control modul e and wi ri ng are
worki ng properl y and that the probl em i s i nternal .
The i gni ti on swi tch shoul d be i n the l ock posi ti on
before attempti ng to i nstal l the si mul ator. Fol l ow
al l i nstructi ons i ncl uded wi th the si mul ator. I f the
feedback from the si mul ator i s i n doubt, you can
veri fy i t’s operati on by i nstal l i ng i t on a known
good vehi cl e. A “known good vehi cl e” woul d be
defi ned as a vehi cl e that does not set any DTC’s
and dri ves and shi fts as expected.
19
GENERAL INFORMATION
One i mportant poi nt to remember i s that the
Si mul ator recei ves i t’s power from the Trans Rel ay
Output ci rcui t. I f the transmi ssi on system i s i n
Li mp-i n (Rel ay open), the si mul ator wi l l not oper-
ate. Thi s i s not real l y an i ndi cati on of a probl em,
but an addi ti onal symptom. I f the si mul ator does
not power up (“P” l ed l i t), thi s i s an i ndi cati on that
the probl em i s sti l l present wi th the si mul ator
hooked up. Thi s i ndi cates that the probl em i s i n the
wi ri ng or control modul e and not the transmi ssi on.
Mi l l er Tool # 8333-1A consi sts of the adapter
cabl es and overl ay necessary to adapt the si mul a-
tor to TE/AE/LE/RLE transmi ssi ons.
4.0 DISCLAIMERS, SAFETY,
AND WARNINGS
4. 1 DISCLAIMERS
Al l i nformati on, i l l ustrati ons, and speci fi cati ons
contai ned i n thi s manual are based on the l atest
i nformati on avai l abl e at the ti me of publ i cati on.
The ri ght i s reserved to make changes at any ti me
wi thout noti ce.
4. 2 SAFETY
4. 2. 1 TECHNICIAN SAFETY INFORMATION
WARNING: ENGINES PRODUCE CARBON
MONOXIDE THAT IS ODORLESS, CAUSES
SLOWER REACTION TIME, AND CAN LEAD
TO SERIOUS INJURY. WHEN THE ENGINE IS
OPERATING KEEP SERVICE AREAS WELL
VENTILATED OR ATTACH THE VEHICLE
EXHAUST SYSTEM TO THE SHOP EXHAUST
REMOVAL SYSTEM.
Set the parki ng brake and bl ock the wheel s
before testi ng or repai ri ng the vehi cl e. I f i s espe-
ci al l y i mportant to bl ock the wheel s on front-wheel
dri ve vehi cl es: the parki ng brake does not hol d the
dri ve wheel s.
Some operati ons i n thi s manual requi re that
hydraul i c tubes, hoses, and fi tti ngs, di sconnected
for i nspecti on or testi ng purposes. These systems,
when ful l y charged, contai n fl ui d at hi gh pressure.
Before di sconnecti ng any hydraul i c tubes, hoses,
and fi tti ngs, be sure that the system i s ful l y de-
pressuri zed.
When servi ci ng a vehi cl e, al ways wear eye pro-
tecti on, and remove any metal jewel ry such as
watchbands or bracel ets that mi ght make an i nad-
vertent el ectri cal contact.
When di agnosi ng a Transmi ssi on system prob-
l em, i t i s i mportant to fol l ow approved procedures
where appl i cabl e. These procedures can be found i n
the servi ce i nformati on. Fol l owi ng these proce-
dures i s very i mportant to the safety of i ndi vi dual s
performi ng di agnosti c tests.
4. 2. 2 VEHICLE PREPARATION FOR
TESTING
Make sure the vehi cl e bei ng tested has a ful l y
charged battery. I f i t does not, fal se di agnosti c
DTC’s or error messages may occur. I t i s extremel y
i mportant that accurate shi ft l ever posi ti on data i s
avai l abl e to the TCM. The accuracy of any DTC
found i n memory i s doubtful unl ess the Shi ft Lever
Test, performed on the DRBI I I ௡ Scan Tool , passes
wi thout fai l ure.
4. 2. 3 SERVICING SUB-ASSEMBLIES
Some components of the Transmi ssi on system are
i ntended to be servi ced i n assembl y onl y. Attempt-
i ng to remove or repai r certai n system sub-
components may resul t i n personal i njury and/or
i mproper system operati on. Onl y those components
wi th approved repai r and i nstal l ati on procedures i n
the servi ce i nformati on shoul d be servi ced.
4. 2. 4 DRBIIIா SAFETY INFORMATION
WARNING: EXCEEDING THE LIMITS OF THE
DRBIIIா MULTIMETER IS DANGEROUS. IT
CAN EXPOSE YOU TO SERIOUS OR
POSSIBLY FATAL INJURY. CAREFULLY
READ AND UNDERSTAND THE CAUTIONS
AND THE SPECIFICATION LIMITS.
• Fol l ow the vehi cl e manufacturer’s servi ce speci -
fi cati ons at al l ti mes.
• Do not use the DRBI I I ௡ i f i t has been damaged.
• Do not use the test l eads i f the i nsul ati on i s
damaged or i f metal i s exposed.
• To avoi d el ectri cal shock, do not touch the test
l eads, ti ps or the ci rcui t bei ng tested.
• Choose the proper range and functi on for the
measurement. Do not try vol tage or current mea-
surements that may exceed the rated capaci ty.
• Do not exceed the l i mi ts shown i n the tabl e.
FUNCTION INPUT LIMIT
Vol ts 0 - 500 vol ts peak AC
0 - 500 vol ts DC
Ohms (resi stance)* 0 - 1.12 megohms
Frequency Measured
Frequency Generated
0 - 10 kHz
Temperature -58 - 1100°F
-50 - 600°C
*Ohms cannot be measured i f vol tage i s present.
Ohms can be measured onl y i n a non-powered ci rcui t.
20
GENERAL INFORMATION
• Vol tage between any termi nal and ground must
not exceed 500v DC or 500v peak AC.
• Use cauti on when measured vol tage above 25v
DC or 25v AC.
• The ci rcui t bei ng tested must be protected by a
10A fuse or ci rcui t breaker.
• Use the l ow current shunt to measure ci rcui ts up
to 10A. Use the hi gh current cl amp to measure
ci rcui ts exceedi ng 10A.
• When testi ng for the presence of vol tage or
current, make sure the meter i s functi oni ng
correctl y. Take a readi ng of a known vol tage or
current before accepti ng a zero readi ng.
• When measuri ng current, connect the meter i n
seri es wi th the l oad.
• Di sconnect the l i ve test l ead before di sconnect-
i ng the common test l ead.
• When usi ng the meter functi on, keep the
DRBI I I ௡ away from spark pl ug or coi l wi res to
avoi d measuri ng error from outsi de i nterference.
4. 3 WARNINGS
4. 3. 1 VEHICLE DAMAGE WARNINGS
Before di sconnecti ng any control modul e, make
sure the i gni ti on i s “l ock” posi ti on. Fai l ure to do so
coul d damage the modul e.
When testi ng vol tage or conti nui ty at any control
modul e, use the termi nal si de (not the wi re end) of
the connector. Do not probe a wi re through the
i nsul ati on: thi s wi l l damage the wi re and eventu-
al l y cause the wi re to fai l because of corrosi on.
Be careful when performi ng el ectri cal tests so as
to prevent acci dental shorti ng of termi nal s. Such
mi stakes can damage fuses or components. Al so, a
second DTC coul d be set, maki ng di agnosi s of the
ori gi nal probl em more di ffi cul t.
When repl aci ng a bl own fuse, i t i s i mportant to
use onl y a fuse havi ng the correct amperage rati ng.
The use of a fuse wi th a rati ng other than i ndi cated
may resul t i n a dangerous el ectri cal system over-
l oad. I f a properl y rated fuse conti nues to bl ow, i t
i ndi cates a probl em i n the ci rcui t that must be
corrected.
4. 3. 2 ROAD TESTING A COMPLAINT
VEHICLE
Some compl ai nts wi l l requi re a test dri ve as part
of the repai r veri fi cati on procedure. The purpose of
the test dri ve i s to try to dupl i cate the di agnosti c
DTC or symptom condi ti on.
CAUTION: Before road testing a vehicle, be
sure that all components are reassembled.
During the test drive, do not try to read the
DRBIIIா screen while in motion. Do not hang
the DRBIIIா from the rear view mirror or
operate it yourself. Have an assistant
available to operate the DRBIIIா.
Road testi ng i s an essenti al step i n the di agnos-
ti c process that must not be overl ooked. Al ong wi th
the di agnosti c i nformati on obtai ned from the
DRBI I I ௡ Scan Tool and the ori gi nal customer con-
cern, the road test hel ps veri fy the probl em was
current and any repai rs performed, fi xed the vehi -
cl e correctl y. Al ways operate and observe the vehi -
cl e under actual dri vi ng condi ti ons.
Just as i mportant as the road test i s, there are
prel i mi nary i nspecti ons that shoul d be performed
pri or to the road test. Al ways check the fl ui d l evel
and condi ti on before taki ng the vehi cl e on a road
test. Determi ne i f an i ncorrect fl ui d type i s bei ng
used, i mproper fl ui d wi l l resul t i n errati c transmi s-
si on operati on. Some of the condi ti ons of i ncorrect
fl ui d l evel are as fol l ows:
• Del ayed engagement
• Poor shi fti ng or errati c shi fti ng
• Excessi ve noi se
• Overheati ng
The next step i s to veri fy that the shi fter i s
correctl y adjusted. I f the shi fter i s i ncorrectl y ad-
justed, a number of compl ai nts can resul t.
The TCM moni tors the Shi ft Lever Posi ti on
(SLP) Sensor conti nuousl y. I f the shi fter i s i ncor-
rectl y adjusted, the TCM wi l l sense a shi ft l ever
posi ti on that i s not correct for the gear chosen by
the dri ver. Thi s may cause a DTC to be set.
The fol l owi ng compl ai nts may al so be the resul t
of an i ncorrectl y adjusted or worn shi fter:
• Del ayed cl utch engagement
• Errati c shi fts
• Vehi cl e wi l l dri ve i n neutral
• Engi ne wi l l not crank i n park or neutral
• Shi fter wi l l be abl e to be moved wi thout the key
i n the i gni ti on
• Not abl e to remove the i gni ti on key i n park
• Parki ng pawl wi l l not engage properl y
The shi fter shoul d al so be adjusted when repl ac-
i ng the Transmi ssi on, repai ri ng the val ve body, or
when repai ri ng any component between the shi ft
l ever and the Transmi ssi on.
Some questi ons to ask yoursel f when performi ng
the road test are as fol l ows:
• I s the compl ai nt or concern what you thi nk the
probl em i s, based on the dri vers descri pti on of
the probl em?
21
GENERAL INFORMATION
• I s the Transmi ssi on operati ng normal l y, or i s
there a real probl em?
• When does the probl em occur?
• I s the probl em onl y i n one gear range?
• What temperature does the probl em occur?
• Does the vehi cl e have to si t over ni ght for the
probl em to occur?
• Does the transmi ssi on go i nto Li mp-i n mode?
4. 3. 3 ELECTRONIC PINION FACTOR
WARNINGS (IF APPLICABLE)
The pi ni on factor must be set when repl aci ng the
TCM.
NOTE: The pinion factor is a fixed number
and cannot be changed or updated in some
vehicle applications. If the pinion factor is
not set or incorrectly set, any speed related
functions will not operate correctly i.e.
speedometer, speed control, rolling door
locks, other control modules will be affected
that depend on speed information.
4. 3. 4 BULLETINS AND RECALLS
Al ways perform al l Safety Recal l s and Techni cal
Servi ce Bul l eti ns that are appl i cabl e to the prob-
l em.
5.0 REQUIRED TOOLS AND
EQUIPMENT
> DRBI I I ௡ (di agnosti c read-out box) − Must be
at l atest rel ease l evel .
> Transmi ssi on Si mul ator (Mi l l er #8333)
> El ectroni c Transmi ssi on Adapter Ki t (Mi l l er
#8333-1A)
> Jumper wi res
> Test Li ght (mi ni mum of 25 ohms of resi s-
tance)
> Ohmmeter
> Vol tmeter
> Pressure gauge (0-300 PSI )
6.0 GLOSSARY OF TERMS
6. 1 ACRONYMS
BCM -Body Control Modul e
CKT -Ci rcui t
CVI -Cl utch Vol ume I ndex
DLC -Data Li nk Connector
DRBIII௡ -Di agnosti c Readout Box
DTC -Di agnosti c Troubl e Code
EATX -El ectroni c Automati c Transmi ssi on
EMCC -El ectroni cal l y Modul ated Con-
verter Cl utch
FCM -Front Control Modul e (part of the
I PM system)
IOD -I gni ti on off-draw
IPM -I ntel l i gent Power Modul e
IRT -I ntel l i gent Recovery Ti mer
ISS -I nput Speed Sensor
LED -Li ght Emi tti ng Di ode
LR -Low/reverse Cl utch or Pressure
Swi tch
LU -Lockup
MIC -Mechani cal I nstrument Cl uster
MIL -Mal functi on I ndi cator Lamp
OBDII -On Board Di agnosti cs
OD -Overdri ve Cl utch or Pressure
Swi tch
OSS -Output Speed Sensor
PCM -Powertrai n Control Modul e
PEMCC -Parti al El ectroni cal l y Modul ated
Converter Cl utch
PLU -Parti al Lockup
REV -Reverse Cl utch
SLPK -Sol enoi d Pack
SSV -Sol enoi d Swi tch Val ve
SW -Swi tch
TCC -Torque Converter Cl utch
TCM -Transmi ssi on Control Modul e
TP -Throttl e Posi ti on
TRD -Torque Reducti on
TRS -Transmi ssi on Range Sensor
UD -Underdri ve Cl utch
2/4 -2nd and 4th gear Cl utch or Pres-
sure Swi tch
6. 2 DEFINITIONS
OBDII (EURO STAGE III OBD) Trip - A vehi cl e
start and dri ve cycl e such that al l once per tri p
di agnosti c moni tors have run.
Key Start - A vehi cl e start and run cycl e of at l east
20 seconds.
Warm-up Cycle - A vehi cl e start and run cycl e
such that the engi ne cool ant must ri se to at l east
71°C (160°F) and must ri se by at l east 4.4°C (40°F)
from i ni ti al start up. To count as a warm-up cycl e,
no DTC may occur duri ng the cycl e.
22
GENERAL INFORMATION
7.0
DIAGNOSTIC INFORMATION AND
PROCEDURES
23
Symptom:
*NO RESPONSE FROM TRANSMISSION CONTROL MODULE
POSSIBLE CAUSES
NO RESPONSE FROM TRANSMI SSI ON CONTROL MODULE
FUSED I GNI TI ON SWI TCH OUTPUT (RUN/ST) CI RCUI T OPEN
FUSED I GNI TI ON SWI TCH OUTPUT (START) CI RCUI T OPEN
FUSED I GNI TI ON SWI TCH OUTPUT (START) CI RCUI T SHORT
FUSED B(+) CI RCUI T OPEN
GROUND CI RCUI T(S) OPEN
OPEN PCI BUS CI RCUI T
TRANSMI SSI ON CONTROL MODULE
TEST ACTION APPLICABILITY
1 I gni ti on on, engi ne not runni ng.
Note: As soon as one or more module communicates with the DRB, answer
the question.
Wi th the DRB, attempt to communi cate wi th the Ai rbag Control Modul e (ACM).
Wi th the DRB, attempt to communi cate wi th the I nstrument Cl uster.
Was the DRB abl e to I /D or establ i sh communi cati ons wi th ei ther of the modul es?
Al l
Yes → Go To 2
No → Refer to the Body Communi cati on category and perform the
symptom PCI Bus Communi cati on Fai l ure.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
2 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the TCM harness connector.
I gni ti on on, engi ne not runni ng.
Usi ng a 12-vol t test l i ght connected to ground, check the Fused I gni ti on Swi tch
Output (Run/St) ci rcui t.
NOTE: The test light must illuminate brightly. Compare the brightness to
that of a direct connection to the battery.
Does the test l i ght i l l umi nate bri ghtl y?
Al l
Yes → Go To 3
No → Repai r the Fused I gni ti on Swi tch Output (Run/St) ci rcui t for an
open. Refer to the wi ri ng di agrams l ocati on i n the Servi ce I nfor-
mati on.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
24
COMMUNICATION
TEST ACTION APPLICABILITY
3 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the TCM harness connector.
Remove the starter rel ay from the PDC.
Usi ng a 12-vol t test l i ght connected to ground, check the Fused I gni ti on Swi tch
Output (Start) ci rcui t.
NOTE: The test light must illuminate brightly. Compare the brightness to
that of a direct connection to the battery.
Observe the test l i ght whi l e momentari l y turni ng the i gni ti on swi tch to the Start
posi ti on.
Does the test l i ght i l l umi nate bri ghtl y?
Al l
Yes → Go To 4
No → Repai r the Fused I gni ti on Swi tch Output (Start) ci rcui t for an
open. Refer to the wi ri ng di agrams l ocated i n the Servi ce I nfor-
mati on.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
4 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the TCM harness connector.
Wi th a vol tmeter i n the mi l l i vol t scal e, measure the vol tage of the Fused I gni ti on
Swi tch Output (Start) ci rcui t.
NOTE:Anoresponsecondition can exist if voltageispresent on thiscircuit
with the ignition switch in any position except for the Start position.
NOTE: Voltage up to .080 millivolts can cause this condition.
NOTE: Check for after market components that could causethis condition.
Perform thi s step wi th the I gni ti on Swi tch i n every posi ti on except for the Start
posi ti on.
I s any vol tage present?
Al l
Yes → Repai r the Fused I gni ti on Swi tch Output (Start) ci rcui t for a
short to vol tage. Refer to the wi ri ng di agrams l ocated i n the
Servi ce I nformati on.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 5
Note: Reinstall the original Starter Relay.
5 Turn the i gni ti on off.
Di sconnect the TCM harness connector.
Usi ng a 12-vol t test l i ght connected to ground, check the Fused B(+) ci rcui t.
NOTE: The test light must illuminate brightly. Compare the brightness to
that of a direct connection to the battery.
Does the test l i ght i l l umi nate bri ghtl y?
Al l
Yes → Go To 6
No → Repai r the Fused B(+) ci rcui t for an open. Refer to the wi ri ng
di agrams l ocated i n the Servi ce I nformati on.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
25
COMMUNICATION
*NORESPONSE FROMTRANSMISSION CONTROL MODULE —Continued
TEST ACTION APPLICABILITY
6 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the TCM harness connector.
Usi ng a 12-vol t test l i ght connected to 12-vol ts, check each ground ci rcui t i n the TCM
harness connector.
NOTE: The test light must illuminate brightly. Compare the brightness to
that of a direct connection to the battery.
Does the test l i ght i l l umi nate bri ghtl y at al l the ground ci rcui ts?
Al l
Yes → Go To 7
No → Repai r the Ground ci rcui t(s) for an open. Check the mai n ground
connecti on to engi ne bl ock and/or chassi s. Refer to the wi ri ng
di agrams l ocated i n the Servi ce I nformati on.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
7 Note: Ensure there is PCI Bus communication with other modules on the
vehicle before proceeding. If not, refer to the symptomlist fromthe menu
and repair as necessary.
Di sconnect the TCM harness connector.
Use Scope i nput cabl e CH7058, Cabl e to Probe adapter CH7062, and the red and
bl ack test probes.
Connect the scope i nput cabl e to the channel one connector on the DRB. Attach the
red and bl ack l eads and the cabl e to probe adapter to the scope i nput cabl e.
Wi th the DRBI I I ௡ sel ect Pep Modul e Tool s.
Sel ect l ab scope.
Sel ect Li ve Data.
Sel ect 12 vol t square wave.
Press F2 for Scope.
Press F2 and use the down arrow to set vol tage range to 20 vol ts. Set Probe to x10.
Press F2 agai n when compl ete.
Connect the Bl ack l ead to the chassi s ground. Connect the Red l ead to the PCI Bus
ci rcui t i n the TCM connector.
Turn the i gni ti on on.
Observe the vol tage di spl ay on the DRB Lab Scope.
Does the vol tage pul se from 0 to approxi matel y 7.5 vol ts?
Al l
Yes → Go To 8
No → Repai r the PCI Bus ci rcui t for an open.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
8 Usi ng the schemati cs as a gui de, i nspect the wi ri ng and connectors. Repai r as
necessary. Pay parti cul ar attenti on to al l power and ground ci rcui ts.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace the Transmi ssi on Control Modul e i n accordance wi th the
servi ce i nformati on. WI TH THE DRBI I I ௡ PERFORM QUI CK
LEARN.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
26
COMMUNICATION
*NORESPONSE FROMTRANSMISSION CONTROL MODULE —Continued
Symptom:
P0122-THROTTLE POSITION SENSOR/APPS LOW
When Monitored and Set Condition:
P0122-THROTTLE POSITION SENSOR/APPS LOW
When Moni tored: Conti nuousl y wi th the i gni ti on on and engi ne runni ng.
Set Condi ti on: Thi s DTC wi l l set i f the moni tored TPS vol tage drops bel ow .078 vol ts for
the peri od of 0.48 seconds.
POSSIBLE CAUSES
ENGI NE TPS DTC’S PRESENT
TPS SI GNAL CI RCUI T HI GH RESI STANCE
TRANSMI SSI ON CONTROL MODULE
I NTERMI TTENT WI RI NG AND CONNECTORS
TEST ACTION APPLICABILITY
1 NOTE: Low fluid level can be the cause of many Transmission problems. If
the fluid level is low, locate and repair the leak, then check and adjust the
fluid level per the Service Information.
NOTE: Always perform diagnostics with a fully charged battery to avoid
false symptoms.
Wi th the DRBI I I ௡, read the engi ne DTC’s. Check and repai r al l engi ne DTC’s pri or
to performi ng Transmi ssi on Symptom Di agnosti cs.
Wi th the DRBI I I ௡, read Transmi ssi on DTC’s. Record al l DTC’s and 1 Tri p Fai l ures.
NOTE: Diagnose 1 Trip Failures as a fully matured DTC.
Usi ng the wi ri ng di agram/schemati c as a gui de, i nspect the wi ri ng and connectors.
Repai r as necessary.
Perform the Shi ft Lever Posi ti on Test. I f the test does not pass, refer to Symptom test
for P0706 Check Shi fter Si gnal .
For Gear Rati o DTC’s, check and record al l CVI ’s.
Most DTC’s set on start up but some must be set by dri vi ng the vehi cl e such that al l
di agnosti c moni tors have run.
NOTE: Verify flash level of Transmission Control Module. Some problems
are corrected by software upgrades to the Transmission Control Module.
NOTE: Check for applicable TSB’s related to the symptom.
Perform thi s procedure pri or to Symptom di agnosi s.
Al l
Conti nue
Go To 2
2 Wi th the DRBI I I ௡, check Engi ne DTC’s.
Are there any Engi ne TPS rel ated DTCs present?
Al l
Yes → Refer to the Powertrai n category and perform the appropri ate
symptom.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 3
27
TRANSMISSION - 42RLE
TEST ACTION APPLICABILITY
3 Wi th the DRBI I I ௡ i n Transmi ssi on Sensors, read the TPS vol tage.
I s the TPS vol tage bel ow 0.5 vol ts?
Al l
Yes → Go To 4
No → Go To 6
4 I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡ i n Transmi ssi on Sensors, record the TPS vol tage.
Whi l e back probi ng the TCM harness connector, measure the vol tage of the TPS
Si gnal ci rcui t.
Compare the vol tage readi ngs between the DRBI I I ௡ and the readi ng from the di gi tal
mul ti meter.
Are the vol tages wi thi n 0.1 vol t of each other?
Al l
Yes → Repai r the TPS si gnal ci rcui t between the TCM harness connector
and the spl i ce for hi gh resi stance.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 5
5 Usi ng the schemati cs as a gui de, i nspect the wi ri ng and connectors. Repai r as
necessary. Pay parti cul ar attenti on to al l power and ground ci rcui ts.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace the Transmi ssi on Control Modul e per the Servi ce i nfor-
mati on. WI TH THE DRBI I I ௡ PERFORM QUI CK LEARN.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
6 The condi ti ons necessary to set thi s DTC are not present at thi s ti me.
Usi ng the schemati cs as a gui de, i nspect the wi ri ng and connectors speci fi c to thi s
ci rcui t.
Wi ggl e the wi res whi l e checki ng for shorts and open ci rcui ts.
Pay parti cul ar attenti on to the poi nt where the TPS si gnal and sensor ground ci rcui ts
spl i ce off from the engi ne ci rcui ts.
Wi th the DRBI I I ௡, check the EATX EVENT DATA to hel p i denti fy the condi ti ons i n
whi ch the DTC was set.
Were there any probl ems found?
Al l
Yes → Repai r as necessary.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Test Compl ete.
28
TRANSMISSION - 42RLE
P0122-THROTTLE POSITION SENSOR/APPS LOW— Continued
Symptom:
P0123-THROTTLE POSITION SENSOR/APPS HIGH
When Monitored and Set Condition:
P0123-THROTTLE POSITION SENSOR/APPS HIGH
When Moni tored: Conti nuousl y wi th the i gni ti on on and engi ne runni ng.
Set Condi ti on: Thi s DTC wi l l set i f the moni tored TPS vol tage ri ses above 4.94 vol ts for
the peri od of 0.48 seconds.
POSSIBLE CAUSES
ENGI NE TPS DTC’S PRESENT
SENSOR GROUND CI RCUI T OPEN TO TCM
TPS SI GNAL CI RCUI T OPEN TO TCM
TRANSMI SSI ON CONTROL MODULE
I NTERMI TTENT WI RI NG AND CONNECTORS
TEST ACTION APPLICABILITY
1 NOTE: Low fluid level can be the cause of many Transmission problems. If
the fluid level is low, locate and repair the leak, then check and adjust the
fluid level per the Service Information.
NOTE: Always perform diagnostics with a fully charged battery to avoid
false symptoms.
Wi th the DRBI I I ௡, read the engi ne DTC’s. Check and repai r al l engi ne DTC’s pri or
to performi ng Transmi ssi on Symptom Di agnosti cs.
Wi th the DRBI I I ௡, read Transmi ssi on DTC’s. Record al l DTC’s and 1 Tri p Fai l ures.
NOTE: Diagnose 1 Trip Failures as a fully matured DTC.
Usi ng the wi ri ng di agram/schemati c as a gui de, i nspect the wi ri ng and connectors.
Repai r as necessary.
Perform the Shi ft Lever Posi ti on Test. I f the test does not pass, refer to Symptom test
for P0706 Check Shi fter Si gnal .
For Gear Rati o DTC’s, check and record al l CVI ’s.
Most DTC’s set on start up but some must be set by dri vi ng the vehi cl e such that al l
di agnosti c moni tors have run.
NOTE: Verify flash level of Transmission Control Module. Some problems
are corrected by software upgrades to the Transmission Control Module.
NOTE: Check for applicable TSB’s related to the symptom.
Perform thi s procedure pri or to Symptom di agnosi s.
Al l
Conti nue
Go To 2
2 Wi th the DRBI I I ௡, check Engi ne DTC’s.
Are there any Engi ne TPS rel ated DTCs present?
Al l
Yes → Refer to the Powertrai n category and perform the appropri ate
symptom.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 3
29
TRANSMISSION - 42RLE
TEST ACTION APPLICABILITY
3 Wi th the DRBI I I ௡ i n Transmi ssi on Sensors, read the TPS vol tage.
I s the TPS vol tage above 4.5 vol ts?
Al l
Yes → Go To 4
No → Go To 7
4 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the TPS harness connector.
Di sconnect the TCM harness connector.
Note: Check connectors - Clean/repair as necessary.
Measure the resi stance of the TPS Si gnal Ci rcui t from the TCM harness connector to
the TPS harness connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 5
No → Repai r the TPS Si gnal ci rcui t between the TCM harness connec-
tor and the spl i ce for an open.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
5 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the TPS harness connector.
Di sconnect the TCM harness connector.
Note: Check connectors - Clean/repair as necessary.
Measure the resi stance of the Sensor Ground ci rcui t between the TPS harness
connector and the Transmi ssi on Control Modul e harness connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 6
No → Repai r the Sensor Ground ci rcui t between the TCM harness
connector and the spl i ce for an open.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
6 Usi ng the schemati cs as a gui de, i nspect the wi ri ng and connectors. Repai r as
necessary. Pay parti cul ar attenti on to al l power and ground ci rcui ts.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace the Transmi ssi on Control Modul e per the Servi ce I nfor-
mati on. WI TH THE DRBI I I ௡ PERFORM QUI CK LEARN.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
7 The condi ti ons necessary to set thi s DTC are not present at thi s ti me.
Usi ng the schemati cs as a gui de, i nspect the wi ri ng and connectors speci fi c to thi s
ci rcui t.
Wi ggl e the wi res whi l e checki ng for shorts and open ci rcui ts.
Pay parti cul ar attenti on to the poi nt where the TPS si gnal and sensor ground ci rcui ts
spl i ce off from the engi ne ci rcui ts.
Wi th the DRBI I I ௡, check the EATX EVENT DATA to hel p i denti fy the condi ti ons i n
whi ch the DTC was set.
Were there any probl ems found?
Al l
Yes → Repai r as necessary.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Test Compl ete.
30
TRANSMISSION - 42RLE
P0123-THROTTLE POSITION SENSOR/APPS HIGH — Continued
Symptom:
P0124- THROTTLE POSITION SENSOR/APPS INTERMITTENT
When Monitored and Set Condition:
P0124- THROTTLE POSITION SENSOR/APPS INTERMITTENT
When Moni tored: Conti nuousl y wi th the i gni ti on on and engi ne runni ng.
Set Condi ti on: Thi s DTC wi l l set wi th a throttl e angl e between 6° and 120.6° wi th a 5° or
hi gher change under 7.0 mi l l i seconds.
POSSIBLE CAUSES
ENGI NE TPS DTC’S PRESENT
THROTTLE POSI TI ON SENSOR
TRANSMI SSI ON CONTROL MODULE
TEST ACTION APPLICABILITY
1 NOTE: Low fluid level can be the cause of many Transmission problems. If
the fluid level is low, locate and repair the leak, then check and adjust the
fluid level per the Service Information.
NOTE: Always perform diagnostics with a fully charged battery to avoid
false symptoms.
Wi th the DRBI I I ௡, read the engi ne DTC’s. Check and repai r al l engi ne DTC’s pri or
to performi ng Transmi ssi on Symptom Di agnosti cs.
Wi th the DRBI I I ௡, read Transmi ssi on DTC’s. Record al l DTC’s and 1 Tri p Fai l ures.
NOTE: Diagnose 1 Trip Failures as a fully matured DTC.
Usi ng the wi ri ng di agram/schemati c as a gui de, i nspect the wi ri ng and connectors.
Repai r as necessary.
Perform the Shi ft Lever Posi ti on Test. I f the test does not pass, refer to Symptom test
for P0706 Check Shi fter Si gnal .
For Gear Rati o DTC’s, check and record al l CVI ’s.
Most DTC’s set on start up but some must be set by dri vi ng the vehi cl e such that al l
di agnosti c moni tors have run.
NOTE: Verify flash level of Transmission Control Module. Some problems
are corrected by software upgrades to the Transmission Control Module.
NOTE: Check for applicable TSB’s related to the symptom.
Perform thi s procedure pri or to Symptom di agnosi s.
Al l
Conti nue
Go To 2
2 Wi th the DRBI I I ௡, check Engi ne DTC’s.
Are any Engi ne TPS rel ated DTC’s present?
Al l
Yes → Refer to the Powertrai n category and perform the appropri ate
symptom.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 3
31
TRANSMISSION - 42RLE
TEST ACTION APPLICABILITY
3 I gni ti on On, Engi ne Not Runni ng.
Wi th the DRBI I I ௡, under Transmi ssi on Sensors, moni tor the TPS vol tage i n the
fol l owi ng step.
Sl owl y open and cl ose the throttl e whi l e checki ng for errati c vol tage changes.
Di d the TPS vol tage change smooth and consi stent?
Al l
Yes → Go To 4
No → Repl ace the Throttl e Posi ti on Sensor per the Servi ce I nformati on.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
4 Usi ng the schemati cs as a gui de, i nspect the wi ri ng and connectors. Repai r as
necessary. Pay parti cul ar attenti on to al l power and ground ci rcui ts.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace the Transmi ssi on Control Modul e per the Servi ce I nfor-
mati on. WI TH THE DRBI I I ௡ PERFORM QUI CK LEARN.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
32
TRANSMISSION - 42RLE
P0124- THROTTLE POSITION SENSOR/APPS INTERMITTENT —
Continued
Symptom:
P0218-HIGH TEMPERATURE OPERATION ACTIVATED
When Monitored and Set Condition:
P0218-HIGH TEMPERATURE OPERATION ACTIVATED
When Moni tored: Whenever the engi ne i s runni ng.
Set Condi ti on: I mmedi atel y when the Overheat shi ft schedul e i s acti vated 116 C (240 F)
Transmi ssi on oi l temp.
POSSIBLE CAUSES
ENGI NE COOLI NG SYSTEM MALFUNCTI ON
TRANSMI SSI ON OI L COOLER PLUGGED
HI GH TEMPERATURE OPERATI ONS ACTI VATED
TEST ACTION APPLICABILITY
1 NOTE: Low fluid level can be the cause of many Transmission problems. If
the fluid level is low, locate and repair the leak, then check and adjust the
fluid level per the Service Information.
NOTE: Always perform diagnostics with a fully charged battery to avoid
false symptoms.
Wi th the DRBI I I ௡, read the engi ne DTC’s. Check and repai r al l engi ne DTC’s pri or
to performi ng Transmi ssi on Symptom Di agnosti cs.
Wi th the DRBI I I ௡, read Transmi ssi on DTC’s. Record al l DTC’s and 1 Tri p Fai l ures.
NOTE: Diagnose 1 Trip Failures as a fully matured DTC.
Usi ng the wi ri ng di agram/schemati c as a gui de, i nspect the wi ri ng and connectors.
Repai r as necessary.
Perform the Shi ft Lever Posi ti on Test. I f the test does not pass, refer to Symptom test
for P0706 Check Shi fter Si gnal .
For Gear Rati o DTC’s, check and record al l CVI ’s.
Most DTC’s set on start up but some must be set by dri vi ng the vehi cl e such that al l
di agnosti c moni tors have run.
NOTE: Verify flash level of Transmission Control Module. Some problems
are corrected by software upgrades to the Transmission Control Module.
NOTE: Check for applicable TSB’s related to the symptom.
Perform thi s procedure pri or to Symptom di agnosi s.
Al l
Conti nue
Go To 2
33
TRANSMISSION - 42RLE
TEST ACTION APPLICABILITY
2 Thi s DTC i s an i nformati onal DTC desi gned to ai d the Techni ci an i n di agnosi ng shi ft
qual i ty compl ai nts.
Thi s DTC i ndi cates that the Transmi ssi on has been operati ng i n the ЉOverheatЉ shi ft
schedul e whi ch may generate a customer compl ai nt.
The customer dri vi ng patterns may i ndi cate the need for an addi ti onal Transmi ssi on
Oi l Cool er.
Wi th the DRBI I I ௡, check the EATX EVENT DATA to hel p i denti fy the condi ti ons i n
whi ch the DTC was set.
Were there any probl ems found?
Al l
Yes → Repai r the cause of the Transmi ssi on Overheati ng per the Servi ce
I nformati on. I f i ndi cated i nstal l an addi ti onal Transmi ssi on Oi l
Cool er.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 3
3 Perform Engi ne Cool i ng System di agnosti cs per the Servi ce I nformati on
I s the Engi ne Cool i ng System functi oni ng properl y?
Al l
Yes → Go To 4
No → Repai r the cause of the Engi ne Overheati ng. Refer to the Servi ce
I nformati on for addi ti onal repai r i nformati on.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
4 I f there are no possi bl e causes remai ni ng, vi ew repai r. Al l
Repai r
Fl ush or repl ace the Transmi ssi on Oi l cool er as necessary per the
Servi ce I nformati on.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
34
TRANSMISSION - 42RLE
P0218-HIGH TEMPERATURE OPERATION ACTIVATED — Continued
Symptom:
P0562-LOWBATTERY VOLTAGE
When Monitored and Set Condition:
P0562-LOWBATTERY VOLTAGE
When Moni tored: Wi th the engi ne runni ng and the TCM has cl osed the Transmi ssi on
Control Rel ay.
Set Condi ti on: I f battery vol tage at TCM Transmi ssi on Control Rel ay Output Sense
ci rcui t i s l ess than 10.0 vol ts for 15 seconds. *Thi s DTC general l y i ndi cates a gradual l y
fal l i ng battery vol tage or resi sti ve connecti ons to the TCM.
POSSIBLE CAUSES
RELATED CHARGI NG SYSTEM DTCS
I NTERMI TTENT WI RI NG AND CONNECTORS
FUSED B+ CI RCUI T OPEN OR HI GH RESI STANCE
GROUND CI RCUI T OPEN OR HI GH RESI STANCE
TRANS CONTROL RELAY OUTPUT TO TCM OPEN OR HI GH RESI STANCE
TRANSMI SSI ON CONTROL RELAY OPEN OR HI GH RESI STANCE
TRANSMI SSI ON CONTROL MODULE
TEST ACTION APPLICABILITY
1 NOTE: Low fluid level can be the cause of many Transmission problems. If
the fluid level is low, locate and repair the leak, then check and adjust the
fluid level per the Service Information.
NOTE: Always perform diagnostics with a fully charged battery to avoid
false symptoms.
Wi th the DRBI I I ௡, read the engi ne DTC’s. Check and repai r al l engi ne DTC’s pri or
to performi ng Transmi ssi on Symptom Di agnosti cs.
Wi th the DRBI I I ௡, read Transmi ssi on DTC’s. Record al l DTC’s and 1 Tri p Fai l ures.
NOTE: Diagnose 1 Trip Failures as a fully matured DTC.
Usi ng the wi ri ng di agram/schemati c as a gui de, i nspect the wi ri ng and connectors.
Repai r as necessary.
Perform the Shi ft Lever Posi ti on Test. I f the test does not pass, refer to Symptom test
for P0706 Check Shi fter Si gnal .
For Gear Rati o DTC’s, check and record al l CVI ’s.
Most DTC’s set on start up but some must be set by dri vi ng the vehi cl e such that al l
di agnosti c moni tors have run.
NOTE: Verify flash level of Transmission Control Module. Some problems
are corrected by software upgrades to the Transmission Control Module.
NOTE: Check for applicable TSB’s related to the symptom.
Perform thi s procedure pri or to Symptom di agnosi s.
Al l
Conti nue
Go To 2
35
TRANSMISSION - 42RLE
TEST ACTION APPLICABILITY
2 Wi th the DRBI I I ௡, read the PCM DTC’s.
Are there any Chargi ng System rel ated DTC’s stored i n the PCM?
Al l
Yes → Refer to the Chargi ng System category and repai r any PCM
Chargi ng System DTC’s fi rst. NOTE: After repai ri ng the PCM
chargi ng system DTC’s, perform the Transmi ssi on Veri fi cati on
test to veri fy the transmi ssi on was not damaged.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 3
3 NOTE: Generator, battery, and charging system must be fully functional
before performing this test.
Wi th the DRBI I I ௡, read Transmi ssi on DTC’s.
Wi th the DRBI I I ௡, Check the STARTS SI NCE SET counter for P0562.
Note: This counter only applies to the last DTC set.
I s the Starts Si nce Set counter for P0562 set at 0?
Al l
Yes → Go To 4
No → Go To 9
4 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the TCM harness connector.
Note: Check connectors - Clean/repair as necessary.
Usi ng a 12-vol t test l i ght connected to 12-vol ts, check the ground ci rcui ts i n the TCM
harness connector.
NOTE: The test light must illuminate brightly. Compare the brightness to
that of a direct connection to the battery.
Does the test l i ght i l l umi nate bri ghtl y for al l the ground ci rcui ts?
Al l
Yes → Go To 5
No → Repai r the Ground ci rcui t(s) for an open or hi gh resi stance.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
5 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the TCM harness connector.
Remove the Transmi ssi on Control Rel ay.
Note: Check connectors - Clean/repair as necessary.
Connect a jumper wi re between the Fused B+ ci rcui t and the Transmi ssi on Control
Rel ay Output i n the Transmi ssi on Control Rel ay connector i n the PDC.
I gni ti on on, engi ne not runni ng.
Usi ng a 12-vol t test l i ght connected to ground, check the Fused B+ ci rcui t i n the TCM
harness connector.
NOTE: The test light must illuminate brightly. Compare the brightness to
that of a direct connection to the battery.
Does the test l i ght i l l umi nate bri ghtl y?
Al l
Yes → Go To 6
No → Repai r the Fused B+ ci rcui t for an open or hi gh resi stance. I f the
fuse i s open make sure to check for a short to ground.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
36
TRANSMISSION - 42RLE
P0562-LOWBATTERY VOLTAGE — Continued
TEST ACTION APPLICABILITY
6 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the TCM harness connector.
Remove the Transmi ssi on Control Rel ay from the PDC.
Note: Check connectors - Clean/repair as necessary.
Connect a jumper wi re between the Fused B+ ci rcui t and the Transmi ssi on Control
Rel ay Output ci rcui t i n the Transmi ssi on Control Rel ay connector i n the PDC.
I gni ti on on, engi ne not runni ng.
Usi ng a 12-vol t test l i ght connected to ground, check both Transmi ssi on Control
Rel ay Output ci rcui ts i n the TCM harness connector.
NOTE: The test light must illuminate brightly. Compare the brightness to
that of a direct connection to the battery.
Does the test l i ght i l l umi nate bri ghtl y?
Al l
Yes → Go To 7
No → Repai r the Transmi ssi on Control Rel ay Output ci rcui t for an open
or hi gh resi stance.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
7 Turn the i gni ti on off to the l ock posi ti on.
I nstal l a substi tute Rel ay i n pl ace of the Transmi ssi on Control Rel ay.
Start the engi ne.
Usi ng a vol tmeter, measure the battery vol tage.
Wi th the DRBI I I ௡, moni tor the Transmi ssi on Swi tched Battery Vol tage.
Compare the DRBI I I ௡ Transmi ssi on Swi tched Battery vol tage to the actual battery
vol tage.
I s the DRBI I I ௡ vol tage wi thi n 2.0 vol ts of the battery vol tage?
Al l
Yes → Repl ace the Transmi ssi on Control Rel ay.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 8
8 Usi ng the schemati cs as a gui de, i nspect the wi ri ng and connectors. Repai r as
necessary. Pay parti cul ar attenti on to al l power and ground ci rcui ts.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace the Transmi ssi on Control Modul e per the Servi ce I nfor-
mati on. WI TH THE DRBI I I ௡ PERFORM QUI CK LEARN.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
9 The condi ti ons necessary to set thi s DTC are not present at thi s ti me.
Usi ng the schemati cs as a gui de, i nspect the wi ri ng and connectors speci fi c to thi s
ci rcui t.
Wi ggl e the wi ri ng whi l e checki ng for shorts and open ci rcui ts.
Were there any probl ems found?
Al l
Yes → Repai r as necessary.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Test Compl ete.
37
TRANSMISSION - 42RLE
P0562-LOWBATTERY VOLTAGE — Continued
Symptom:
P0604-INTERNAL TCM
When Monitored and Set Condition:
P0604-INTERNAL TCM
When Moni tored:
Set Condi ti on: The TCM i s reporti ng i nternal errors and must be repl aced.
POSSIBLE CAUSES
TCM - I NTERNAL ERROR
TEST ACTION APPLICABILITY
1 Usi ng the schemati cs as a gui de, i nspect the wi ri ng and connectors. Repai r as
necessary. Pay parti cul ar attenti on to al l power and ground ci rcui ts.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace the Transmi ssi on Control Modul e per the Servi ce I nfor-
mati on. WI TH THE DRBI I I ௡ PERFORM QUI CK LEARN.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
38
TRANSMISSION - 42RLE
Symptom:
P0605-INTERNAL TCM
When Monitored and Set Condition:
P0605-INTERNAL TCM
When Moni tored:
Set Condi ti on: The TCM i s reporti ng i nternal errors and must be repl aced.
POSSIBLE CAUSES
TCM - I NTERNAL ERROR
TEST ACTION APPLICABILITY
1 Usi ng the schemati cs as a gui de, i nspect the wi ri ng and connectors. Repai r as
necessary. Pay parti cul ar attenti on to al l power and ground ci rcui ts.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace the Transmi ssi on Control Modul e per the Servi ce I nfor-
mati on. WI TH THE DRBI I I ௡ PERFORM QUI CK LEARN.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
39
TRANSMISSION - 42RLE
Symptom:
P0613-INTERNAL TCM
When Monitored and Set Condition:
P0613-INTERNAL TCM
When Moni tored:
Set Condi ti on: The TCM i s reporti ng i nternal errors and must be repl aced.
POSSIBLE CAUSES
TCM - I NTERNAL ERROR
TEST ACTION APPLICABILITY
1 NOTE: Make sure this DTC is set in the TCM before making repair.
Usi ng the schemati cs as a gui de, i nspect the wi ri ng and connectors. Repai r as
necessary. Pay parti cul ar attenti on to al l power and ground ci rcui ts.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace the Transmi ssi on Control Modul e per the Servi ce I nfor-
mati on. WI TH THE DRBI I I ௡ PERFORM QUI CK LEARN.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
40
TRANSMISSION - 42RLE
Symptom:
P0706-CHECK SHIFTER SIGNAL
When Monitored and Set Condition:
P0706-CHECK SHIFTER SIGNAL
When Moni tored: Conti nuousl y wi th the i gni ti on key on.
Set Condi ti on: 3 occurrences i n one key start of an i nval i d PRNDL code whi ch l asts for
more than 0.1 second.
POSSIBLE CAUSES
CONDI TI ON P0706 PRESENT
TRS T1 SENSE CI RCUI T OPEN
TRS T3 SENSE CI RCUI T OPEN
TRS T41 SENSE CI RCUI T OPEN
TRS T42 SENSE CI RCUI T OPEN
TRS T1 SENSE CI RCUI T SHORT TO GROUND
TRS T3 SENSE CI RCUI T SHORT TO GROUND
TRS T41 SENSE CI RCUI T SHORT TO GROUND
TRS T42 SENSE CI RCUI T SHORT TO GROUND
TRS T1 SENSE CI RCUI T SHORT TO VOLTAGE
TRS T3 SENSE CI RCUI T SHORT TO VOLTAGE
TRS T41 SENSE CI RCUI T SHORT TO VOLTAGE
TRS T42 SENSE CI RCUI T SHORT TO VOLTAGE
TRANSMI SSI ON RANGE SENSOR
TRANSMI SSI ON CONTROL MODULE
I NTERMI TTENT WI RI NG AND CONNECTORS
41
TRANSMISSION - 42RLE
TEST ACTION APPLICABILITY
1 NOTE: Low fluid level can be the cause of many Transmission problems. If
the fluid level is low, locate and repair the leak, then check and adjust the
fluid level per the Service Information.
NOTE: Always perform diagnostics with a fully charged battery to avoid
false symptoms.
Wi th the DRBI I I ௡, read the engi ne DTC’s. Check and repai r al l engi ne DTC’s pri or
to performi ng Transmi ssi on Symptom Di agnosti cs.
Wi th the DRBI I I ௡, read Transmi ssi on DTC’s. Record al l DTC’s and 1 Tri p Fai l ures.
NOTE: Diagnose 1 Trip Failures as a fully matured DTC.
Usi ng the wi ri ng di agram/schemati c as a gui de, i nspect the wi ri ng and connectors.
Repai r as necessary.
Perform the Shi ft Lever Posi ti on Test. I f the test does not pass, refer to Symptom test
for P0706 Check Shi fter Si gnal .
For Gear Rati o DTC’s, check and record al l CVI ’s.
Most DTC’s set on start up but some must be set by dri vi ng the vehi cl e such that al l
di agnosti c moni tors have run.
NOTE: Verify flash level of Transmission Control Module. Some problems
are corrected by software upgrades to the Transmission Control Module.
NOTE: Check for applicable TSB’s related to the symptom.
Perform thi s procedure pri or to Symptom di agnosi s.
Al l
Conti nue
Go To 2
2 Usi ng the DRBI I I ௡, perform the Shi ft Lever Posi ti on Test.
Sel ect the test outcome from the fol l owi ng:
Al l
Test passes
Go To 3
Test fai l s wi th DTC
Go To 4
Test fai l s wi thout DTC
Adjust the shi ft l i nkage per the Servi ce I nformati on.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
3 The condi ti ons necessary to set thi s DTC are not present at thi s ti me.
Usi ng the schemati cs as a gui de, i nspect the wi ri ng and connectors speci fi c to thi s
ci rcui t.
Wi ggl e the wi ri ng whi l e checki ng for shorts and open ci rcui ts.
Wi th the DRBI I I ௡, check the EATX EVENT DATA to hel p i denti fy the condi ti ons i n
whi ch the DTC was set.
Were there any probl ems found?
Al l
Yes → Repai r as necessary.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Test Compl ete.
42
TRANSMISSION - 42RLE
P0706-CHECK SHIFTER SIGNAL — Continued
TEST ACTION APPLICABILITY
4 Turn the i gni ti on off to the l ock posi ti on.
CAUTION: Remove the Starter Relay from the PDC. This will prevent the
vehicle frombeing started in gear.
I nstal l the Transmi ssi on Si mul ator, Mi l l er tool #8333 and the El ectroni c Transmi s-
si on Adapter ki t 8333-1.
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, perform the Shi ft Lever Posi ti on Test.
When the DRBI I I ௡ i nstructs you to put the Gear Sel ector i n a parti cul ar posi ti on,
you must do so usi ng the Transmi ssi on Si mul ator. The LED for the gear posi ti on i n
questi on must be i l l umi nated pri or to hi tti ng ЉenterЉ on the DRBI I I ௡.
Di d the test pass?
Al l
Yes → Go To 5
No → Go To 6
NOTE: Disconnect the Transmission Simulator and reconnect all the har-
ness connectors.
5 I f there are no possi bl e causes remai ni ng, vi ew repai r. Al l
Repai r
Repl ace the Transmi ssi on Range Sensor per the Servi ce I nforma-
ti on.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
6 I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡ i n I nputs/Outputs, read the TRS Sense ci rcui ts C1 thru C4.
Move the shi ft l ever thru al l gear posi ti ons, pausi ng momentari l y i n each gear
posi ti on. Watch for one of the ci rcui ts to not change state.
Pi ck the one that di d not change state.
Al l
TRS T1 sense (C4)
Go To 7
TRS T3 sense (C3)
Go To 10
TRS T41 sense (C1)
Go To 13
TRS T42 sense (C2)
Go To 16
7 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the TRS harness connector.
Di sconnect the TCM harness connector.
Note: Check connectors - Clean/repair as necessary.
Measure the resi stance of the TRS T1 Sense ci rcui t from the TCM harness connector
to the TRS harness connector.
I s the resi stance above 5.0 ohms?
Al l
Yes → Repai r the TRS T1 Sense ci rcui t for an open.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 8
43
TRANSMISSION - 42RLE
P0706-CHECK SHIFTER SIGNAL — Continued
TEST ACTION APPLICABILITY
8 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the TRS harness connector.
Di sconnect the TCM harness connector.
Note: Check connectors - Clean/repair as necessary.
Measure the resi stance between ground and the TRS T1 ci rcui t i n the TCM harness
connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Repai r the TRS T1 Sense ci rcui t for a short to ground.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 9
9 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the TRS harness connector.
Di sconnect the TCM harness connector.
Remove the Transmi ssi on Control Rel ay from the PDC.
Note: Check connectors - Clean/repair as necessary.
Connect a jumper wi re between the Fused B+ ci rcui t and the Transmi ssi on Control
Rel ay Output ci rcui t i n the Transmi ssi on Control Rel ay connector i n the PDC.
I gni ti on on, engi ne not runni ng.
Measure the vol tage of the TRS T1 Sense ci rcui t.
I s the vol tage above 0.5 vol t?
Al l
Yes → Repai r the TRS T1 Sense ci rcui t for a short to vol tage.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 19
10 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the TRS harness connector.
Di sconnect the TCM harness connector.
Note: Check connectors - Clean/repair as necessary.
Measure the resi stance of the TRS T3 Sense ci rcui t from the TCM harness connector
to the TRS harness connector.
I s the resi stance above 5.0 ohms?
Al l
Yes → Repai r the TRS T3 Sense ci rcui t for an open.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 11
11 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the TRS harness connector.
Di sconnect the TCM harness connector.
Note: Check connectors - Clean/repair as necessary.
Measure the resi stance between ground and the TRS T3 Sense ci rcui t i n the TCM
harness connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Repai r the TRS T3 Sense ci rcui t for a short to ground.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 12
44
TRANSMISSION - 42RLE
P0706-CHECK SHIFTER SIGNAL — Continued
TEST ACTION APPLICABILITY
12 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the TRS harness connector.
Di sconnect the TCM harness connector.
Remove the Transmi ssi on Control Rel ay from the PDC.
Note: Check connectors - Clean/repair as necessary.
Connect a jumper wi re between the Fused B+ ci rcui t and the Transmi ssi on Control
Rel ay Output ci rcui t i n the Transmi ssi on Control Rel ay connector i n the PCM.
I gni ti on on, engi ne not runni ng.
Measure the vol tage of the TRS T3 Sense ci rcui t.
I s the vol tage above 0.5 vol t?
Al l
Yes → Repai r the TRS T3 Sense ci rcui t for a short to vol tage.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 19
13 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the TRS harness connector.
Di sconnect the TCM harness connector.
Note: Check connectors - Clean/repair as necessary.
Measure the resi stance of the TRS T41 Sense ci rcui t from the TCM connector to the
TRS connector.
I s the resi stance above 5.0 ohms?
Al l
Yes → Repai r the TRS T41 Sense ci rcui t for an open.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 14
14 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the TRS harness connector.
Di sconnect the TCM harness connector.
Note: Check connectors - Clean/repair as necessary.
Measure the resi stance between ground and the TRS T41 Sense ci rcui t i n the TCM
harness connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Repai r the TRS T41 Sense ci rcui t for a short to ground.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 15
15 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the TRS harness connector.
Di sconnect the TCM harness connector.
Remove the Transmi ssi on Control Rel ay from the PDC.
Note: Check connectors - Clean/repair as necessary.
Connect a jumper wi re between the Fused B+ ci rcui t and the Transmi ssi on Control
Rel ay Output ci rcui t i n the Transmi ssi on Control Rel ay connector i n the PDC.
I gni ti on on, engi ne not runni ng.
Measure the vol tage of the TRS T41 Sense ci rcui t.
I s the vol tage above 0.5 vol t?
Al l
Yes → Repai r the TRS T41 Sense ci rcui t for a short to vol tage.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 19
45
TRANSMISSION - 42RLE
P0706-CHECK SHIFTER SIGNAL — Continued
TEST ACTION APPLICABILITY
16 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the TRS harness connector.
Di sconnect the TCM harness connector.
Note: Check connectors - Clean/repair as necessary.
Measure the resi stance of the TRS T42 Sense ci rcui t from the TCM harness
connector to the TRS harness connector.
I s the resi stance above 5.0 ohms?
Al l
Yes → Repai r the TRS T42 Sense ci rcui t for an open.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 17
17 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the TRS harness connector.
Di sconnect the TCM harness connector.
Note: Check connectors - Clean/repair as necessary.
Measure the resi stance between ground and the TRS T42 Sense ci rcui t i n the TCM
harness connector.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Repai r the TRS T42 Sense ci rcui t for a short to ground.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 18
18 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the TRS harness connector.
Di sconnect the TCM harness connector.
Remove the Transmi ssi on Control Rel ay from the PDC.
Note: Check connectors - Clean/repair as necessary.
Connect a jumper wi re between the Fused B+ ci rcui t and the Transmi ssi on Control
Rel ay Output ci rcui t i n the Transmi ssi on Control Rel ay connector i n the PDC.
I gni ti on on, engi ne not runni ng.
Measure the vol tage of the TRS T42 Sense ci rcui t.
I s the vol tage above 0.5 vol t?
Al l
Yes → Repai r the TRS T42 Sense ci rcui t for a short to vol tage.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 19
19 Usi ng the schemati cs as a gui de, i nspect the wi ri ng and connectors. Repai r as
necessary. Pay parti cul ar attenti on to al l power and ground ci rcui ts.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace the Transmi ssi on Control Modul e per the Servi ce I nfor-
mati on. WI TH THE DRBI I I ௡ PERFORM QUI CK LEARN.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
46
TRANSMISSION - 42RLE
P0706-CHECK SHIFTER SIGNAL — Continued
Symptom:
P0711-TRANSMISSION TEMPERATURE SENSOR PERFORMANCE
When Monitored and Set Condition:
P0711-TRANSMISSION TEMPERATURE SENSOR PERFORMANCE
When Moni tored: Conti nuousl y wi th the i gni ti on on and engi ne runni ng.
Set Condi ti on: Thi s DTC wi l l set when the desi red transmi ssi on temperature does not
reach a normal operati ng temperature wi thi n a gi ven ti me frame. Ti me i s vari abl e due to
ambi ent temperature. Approxi mate ti mes are starti ng temperature to warm up ti me: (-40°
F /-40° C - 35 mi n) (-20° F /-28° C - 25 mi n) (20° F /-6.6° C - 20 mi n) (60° F /15.5 ° C - 10
mi n)
POSSIBLE CAUSES
RELATED DTC’S PRESENT
TRANSMI SSI ON TEMPERATURE SENSOR
TRANSMI SSI ON CONTROL MODULE
I NTERMI TTENT WI RI NG AND CONNECTORS
TEST ACTION APPLICABILITY
1 NOTE: Low fluid level can be the cause of many Transmission problems. If
the fluid level is low, locate and repair the leak, then check and adjust the
fluid level per the Service Information.
NOTE: Always perform diagnostics with a fully charged battery to avoid
false symptoms.
Wi th the DRBI I I ௡, read the engi ne DTC’s. Check and repai r al l engi ne DTC’s pri or
to performi ng Transmi ssi on Symptom Di agnosti cs.
Wi th the DRBI I I ௡, read Transmi ssi on DTC’s. Record al l DTC’s and 1 Tri p Fai l ures.
NOTE: Diagnose 1 Trip Failures as a fully matured DTC.
Usi ng the wi ri ng di agram/schemati c as a gui de, i nspect the wi ri ng and connectors.
Repai r as necessary.
Perform the Shi ft Lever Posi ti on Test. I f the test does not pass, refer to Symptom test
for P0706 Check Shi fter Si gnal .
For Gear Rati o DTC’s, check and record al l CVI ’s.
Most DTC’s set on start up but some must be set by dri vi ng the vehi cl e such that al l
di agnosti c moni tors have run.
NOTE: Verify flash level of Transmission Control Module. Some problems
are corrected by software upgrades to the Transmission Control Module.
NOTE: Check for applicable TSB’s related to the symptom.
Perform thi s procedure pri or to Symptom di agnosi s.
Al l
Conti nue
Go To 2
47
TRANSMISSION - 42RLE
TEST ACTION APPLICABILITY
2 Wi th the DRBI I I ௡, check Transmi ssi on DTC’s.
Are there any other Transmi ssi on Temperature Sensor rel ated DTCs present?
Al l
Yes → Refer to the Transmi ssi on category and perform the appropri ate
symptom.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 3
3 Wi th the DRBI I I ௡, Check the STARTS SI NCE SET counter for P0711.
NOTE: This counter only applies to the last DTC set.
I s the STARTS SI NCE SET counter 2 or l ess?
Al l
Yes → Go To 4
No → Go To 7
4 Turn the i gni ti on off to the l ock posi ti on.
Remove the Starter Rel ay.
NOTE: Failure to remove Starter Relay can cause a Transmission - No
Response condition.
I nstal l the Transmi ssi on Si mul ator, Mi l l er tool #8333 and the El ectroni c Transmi s-
si on Adapter ki t 8333-1.
Note: Check connectors - Clean/repair as necessary.
I gni ti on on, engi ne not runni ng.
Wi th the Transmi ssi on Si mul ator, turn the I nput/Output swi tch to OFF.
Wi th the DRBI I I ௡, moni tor the TRANS TEMP VOLTS whi l e turni ng the Thermi stor
Vol tage swi tch to al l three posi ti ons on the Transmi ssi on Si mul ator.
Compare the DRBI I I ௡ readi ngs wi th the numbers l i sted on the Transmi ssi on
Si mul ator.
Do the readi ngs on the Transmi ssi on Si mul ator match the DRBI I I ௡ readi ngs ± 0.2
vol ts?
Al l
Yes → Go To 5
No → Go To 6
5 I f there are no possi bl e causes remai ni ng, vi ew repai r. Al l
Repai r
Repl ace Transmi ssi on Sol enoi d/TRS Assembl y per the Servi ce
I nformati on.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
6 Usi ng the schemati cs as a gui de, i nspect the wi ri ng and connectors. Repai r as
necessary. Pay parti cul ar attenti on to al l power and ground ci rcui ts.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace the Transmi ssi on Control Modul e per the Servi ce I nfor-
mati on. WI TH THE DRBI I I ௡ PERFORM QUI CK LEARN.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
48
TRANSMISSION - 42RLE
P0711-TRANSMISSION TEMPERATURE SENSOR PERFORMANCE —
Continued
TEST ACTION APPLICABILITY
7 The condi ti ons necessary to set thi s DTC are not present at thi s ti me.
Usi ng the schemati cs as a gui de, i nspect the wi ri ng and connectors speci fi c to thi s
ci rcui t.
Wi ggl e the wi res whi l e checki ng for shorts and open ci rcui ts.
Wi th the DRBI I I ௡, check the EATX EVENT DATA to hel p i denti fy the condi ti ons i n
whi ch the DTC was set.
Were there any probl ems found?
Al l
Yes → Repai r as necessary.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Test Compl ete.
49
TRANSMISSION - 42RLE
P0711-TRANSMISSION TEMPERATURE SENSOR PERFORMANCE —
Continued
Symptom:
P0712-TRANSMISSION TEMPERATURE SENSOR LOW
When Monitored and Set Condition:
P0712-TRANSMISSION TEMPERATURE SENSOR LOW
When Moni tored: Conti nuousl y wi th the i gni ti on on and engi ne runni ng.
Set Condi ti on: The DTC wi l l set when the moni tored Temperature Sensor vol tage drops
bel ow 0.078 vol ts for the peri od of 0.45 seconds.
POSSIBLE CAUSES
RELATED DTC’S PRESENT
TRANSMI SSI ON TEMPERATURE SENSOR SI GNAL CI RCUI T SHORT TO GROUND
TRANSMI SSI ON TEMPERATURE SENSOR
TRANSMI SSI ON CONTROL MODULE
I NTERMI TTENT WI RI NG AND CONNECTORS
TEST ACTION APPLICABILITY
1 NOTE: Low fluid level can be the cause of many Transmission problems. If
the fluid level is low, locate and repair the leak, then check and adjust the
fluid level per the Service Information.
NOTE: Always perform diagnostics with a fully charged battery to avoid
false symptoms.
Wi th the DRBI I I ௡, read the engi ne DTC’s. Check and repai r al l engi ne DTC’s pri or
to performi ng Transmi ssi on Symptom Di agnosti cs.
Wi th the DRBI I I ௡, read Transmi ssi on DTC’s. Record al l DTC’s and 1 Tri p Fai l ures.
NOTE: Diagnose 1 Trip Failures as a fully matured DTC.
Usi ng the wi ri ng di agram/schemati c as a gui de, i nspect the wi ri ng and connectors.
Repai r as necessary.
Perform the Shi ft Lever Posi ti on Test. I f the test does not pass, refer to Symptom test
for P0706 Check Shi fter Si gnal .
For Gear Rati o DTC’s, check and record al l CVI ’s.
Most DTC’s set on start up but some must be set by dri vi ng the vehi cl e such that al l
di agnosti c moni tors have run.
NOTE: Verify flash level of Transmission Control Module. Some problems
are corrected by software upgrades to the Transmission Control Module.
NOTE: Check for applicable TSB’s related to the symptom.
Perform thi s procedure pri or to Symptom di agnosi s.
Al l
Conti nue
Go To 2
2 Wi th the DRBI I I ௡, check Transmi ssi on DTC’s.
Are there any Speed Sensor DTCs present?
Al l
Yes → Refer to the Transmi ssi on category and perform the appropri ate
symptom.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 3
50
TRANSMISSION - 42RLE
TEST ACTION APPLICABILITY
3 Wi th the DRBI I I ௡, Check the STARTS SI NCE SET counter for P0712.
NOTE: This counter only applies to the last DTC set.
I s the STARTS SI NCE SET counter 2 or l ess?
Al l
Yes → Go To 4
No → Go To 8
4 Turn the i gni ti on off to the l ock posi ti on.
Remove the Starter Rel ay.
NOTE: Failure to remove Starter Relay can cause a Transmission - No
Response condition.
I nstal l the Transmi ssi on Si mul ator, Mi l l er tool #8333 and the El ectroni c Transmi s-
si on Adapter ki t 8333-1.
Note: Check connectors - Clean/repair as necessary.
I gni ti on on, engi ne not runni ng.
Wi th the Transmi ssi on Si mul ator, turn the I nput/Output swi tch to OFF.
Wi th the DRBI I I ௡, moni tor the TRANS TEMP VOLTS whi l e turni ng the Thermi stor
Vol tage swi tch to al l three posi ti ons on the Transmi ssi on Si mul ator.
Compare the DRBI I I ௡ readi ngs wi th the numbers l i sted on the Transmi ssi on
Si mul ator.
Do the readi ngs on the Transmi ssi on Si mul ator match the DRBI I I ௡ readi ngs ± 0.2
vol ts?
Al l
Yes → Go To 5
No → Go To 6
5 I f there are no possi bl e causes remai ni ng, vi ew repai r. Al l
Repai r
Repl ace Transmi ssi on Sol enoi d/TRS Assembl y per the Servi ce
I nformati on.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
6 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the TCM harness connector..
Di sconnect the Transmi ssi on Sol enoi d/TRS Assembl y harness connector.
Note: Check connectors - Clean/repair as necessary.
Measure the resi stance between ground and the Transmi ssi on Temperature Sensor
Si gnal ci rcui t.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Repai r the Transmi ssi on Temperature Sensor Si gnal ci rcui t for a
short to ground.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 7
7 Usi ng the schemati cs as a gui de, i nspect the wi ri ng and connectors. Repai r as
necessary. Pay parti cul ar attenti on to al l power and ground ci rcui ts.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace the Transmi ssi on Control Modul e per the Servi ce I nfor-
mati on. WI TH THE DRBI I I ௡ PERFORM QUI CK LEARN.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
51
TRANSMISSION - 42RLE
P0712-TRANSMISSION TEMPERATURE SENSOR LOW— Continued
TEST ACTION APPLICABILITY
8 The condi ti ons necessary to set thi s DTC are not present at thi s ti me.
Usi ng the schemati cs as a gui de, i nspect the wi ri ng and connectors speci fi c to thi s
ci rcui t.
Wi ggl e the wi res whi l e checki ng for shorts and open ci rcui ts.
Wi th the DRBI I I ௡, check the EATX EVENT DATA to hel p i denti fy the condi ti ons i n
whi ch the DTC was set.
Were there any probl ems found?
Al l
Yes → Repai r as necessary.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Test Compl ete.
52
TRANSMISSION - 42RLE
P0712-TRANSMISSION TEMPERATURE SENSOR LOW— Continued
Symptom:
P0713-TRANSMISSION TEMPERATURE SENSOR HIGH
When Monitored and Set Condition:
P0713-TRANSMISSION TEMPERATURE SENSOR HIGH
When Moni tored: Conti nuousl y wi th the i gni ti on on and engi ne runni ng.
Set Condi ti on: The DTC wi l l set when the moni tored Temperature Sensor vol tage ri ses
above 4.94 vol ts for the peri od of 0.45 seconds.
POSSIBLE CAUSES
TRANSMI SSI ON TEMPERATURE SENSOR SI GNAL CI RCUI T OPEN
TRANSMI SSI ON TEMPERATURE SENSOR SI GNAL CI RCUI T SHORT TO VOLTAGE
TRANSMI SSI ON TEMPERATURE SENSOR
TRANSMI SSI ON CONTROL MODULE
I NTERMI TTENT WI RI NG AND CONNECTORS
TEST ACTION APPLICABILITY
1 NOTE: Low fluid level can be the cause of many Transmission problems. If
the fluid level is low, locate and repair the leak, then check and adjust the
fluid level per the Service Information.
NOTE: Always perform diagnostics with a fully charged battery to avoid
false symptoms.
Wi th the DRBI I I ௡, read the engi ne DTC’s. Check and repai r al l engi ne DTC’s pri or
to performi ng Transmi ssi on Symptom Di agnosti cs.
Wi th the DRBI I I ௡, read Transmi ssi on DTC’s. Record al l DTC’s and 1 Tri p Fai l ures.
NOTE: Diagnose 1 Trip Failures as a fully matured DTC.
Usi ng the wi ri ng di agram/schemati c as a gui de, i nspect the wi ri ng and connectors.
Repai r as necessary.
Perform the Shi ft Lever Posi ti on Test. I f the test does not pass, refer to Symptom test
for P0706 Check Shi fter Si gnal .
For Gear Rati o DTC’s, check and record al l CVI ’s.
Most DTC’s set on start up but some must be set by dri vi ng the vehi cl e such that al l
di agnosti c moni tors have run.
NOTE: Verify flash level of Transmission Control Module. Some problems
are corrected by software upgrades to the Transmission Control Module.
NOTE: Check for applicable TSB’s related to the symptom.
Perform thi s procedure pri or to Symptom di agnosi s.
Al l
Conti nue
Go To 2
2 Wi th the DRBI I I ௡, Check the STARTS SI NCE SET counter for P0713.
NOTE: This counter only applies to the last DTC set.
I s the STARTS SI NCE SET counter 2 or l ess?
Al l
Yes → Go To 3
No → Go To 8
53
TRANSMISSION - 42RLE
TEST ACTION APPLICABILITY
3 Turn the i gni ti on off to the l ock posi ti on.
Remove the Starter Rel ay.
NOTE: Failure to remove Starter Relay can cause a Transmission - No
Response condition.
I nstal l the Transmi ssi on Si mul ator, Mi l l er tool #8333 and the El ectroni c Transmi s-
si on Adapter ki t 8333-1.
Note: Check connectors - Clean/repair as necessary.
I gni ti on on, engi ne not runni ng.
Wi th the Transmi ssi on Si mul ator, turn the I nput/Output swi tch to OFF.
Wi th the DRBI I I ௡, moni tor the TRANS TEMP VOLTS whi l e turni ng the Thermi stor
Vol tage swi tch to al l three posi ti ons on the Transmi ssi on Si mul ator.
Compare the DRBI I I ௡ readi ngs wi th the numbers l i sted on the Transmi ssi on
Si mul ator.
Do the readi ngs on the Transmi ssi on Si mul ator match the DRBI I I ௡ readi ngs ± 0.2
vol ts?
Al l
Yes → Go To 4
No → Go To 5
4 I f there are no possi bl e causes remai ni ng, vi ew repai r. Al l
Repai r
Repl ace Transmi ssi on Sol enoi d/TRS Assembl y per the Servi ce
I nformati on.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
5 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the TCM harness connector..
Di sconnect the Transmi ssi on Sol enoi d /TRS Assembl y harness connector
Note: Check connectors - Clean/repair as necessary.
Measure the resi stance of the Transmi ssi on Temperature Sensor Si gnal ci rcui t from
the TCM harness connector to the Transmi ssi on Sol enoi d/TRS Assembl y harness
connector.
I s the resi stance above 5.0 ohms?
Al l
Yes → Repai r the Transmi ssi on Temperature Sensor Si gnal ci rcui t for
an open.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 6
6 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the TCM harness connector.
Remove the Transmi ssi on Control Rel ay.
Note: Check connectors - Clean/repair as necessary.
Connect a jumper wi re between the Fused B+ ci rcui t and the Transmi ssi on Control
Rel ay Output ci rcui t i n the Transmi ssi on Control Rel ay connector.
I gni ti on on, engi ne not runni ng.
Measure the vol tage of the Transmi ssi on Temperature Sensor Si gnal ci rcui t i n the
TCM harness connector.
I s the vol tage above 0.5 vol ts?
Al l
Yes → Repai r the Transmi ssi on Temperature Sensor Si gnal ci rcui t for a
short to vol tage.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 7
54
TRANSMISSION - 42RLE
P0713-TRANSMISSION TEMPERATURE SENSOR HIGH — Continued
TEST ACTION APPLICABILITY
7 Usi ng the schemati cs as a gui de, i nspect the wi ri ng and connectors. Repai r as
necessary. Pay parti cul ar attenti on to al l power and ground ci rcui ts.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace the Transmi ssi on Control Modul e per the Servi ce i nfor-
mati on. WI TH THE DRBI I I ௡ PERFORM QUI CK LEARN.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
8 The condi ti ons necessary to set thi s DTC are not present at thi s ti me.
Usi ng the schemati cs as a gui de, i nspect the wi ri ng and connectors speci fi c to thi s
ci rcui t.
Wi ggl e the wi res whi l e checki ng for shorts and open ci rcui ts.
Wi th the DRBI I I ௡, check the EATX EVENT DATA to hel p i denti fy the condi ti ons i n
whi ch the DTC was set.
Were there any probl ems found?
Al l
Yes → Repai r as necessary.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Test Compl ete.
55
TRANSMISSION - 42RLE
P0713-TRANSMISSION TEMPERATURE SENSOR HIGH — Continued
Symptom:
P0714-TRANSMISSION TEMPERATURE SENSOR INTERMITTENT
When Monitored and Set Condition:
P0714-TRANSMISSION TEMPERATURE SENSOR INTERMITTENT
When Moni tored: Conti nuousl y wi th the i gni ti on on and engi ne runni ng.
Set Condi ti on: The DTC wi l l set when the moni tored Temperature Sensor vol tage
fl uctuates or changes abruptl y wi thi n a predetermi ned peri od of ti me.
POSSIBLE CAUSES
RELATED DTC’S PRESENT
TRANSMI SSI ON TEMPERATURE SENSOR
TRANSMI SSI ON CONTROL MODULE
I NTERMI TTENT WI RI NG AND CONNECTORS
TEST ACTION APPLICABILITY
1 NOTE: Low fluid level can be the cause of many Transmission problems. If
the fluid level is low, locate and repair the leak, then check and adjust the
fluid level per the Service Information.
NOTE: Always perform diagnostics with a fully charged battery to avoid
false symptoms.
Wi th the DRBI I I ௡, read the engi ne DTC’s. Check and repai r al l engi ne DTC’s pri or
to performi ng Transmi ssi on Symptom Di agnosti cs.
Wi th the DRBI I I ௡, read Transmi ssi on DTC’s. Record al l DTC’s and 1 Tri p Fai l ures.
NOTE: Diagnose 1 Trip Failures as a fully matured DTC.
Usi ng the wi ri ng di agram/schemati c as a gui de, i nspect the wi ri ng and connectors.
Repai r as necessary.
Perform the Shi ft Lever Posi ti on Test. I f the test does not pass, refer to Symptom test
for P0706 Check Shi fter Si gnal .
For Gear Rati o DTC’s, check and record al l CVI ’s.
Most DTC’s set on start up but some must be set by dri vi ng the vehi cl e such that al l
di agnosti c moni tors have run.
NOTE: Verify flash level of Transmission Control Module. Some problems
are corrected by software upgrades to the Transmission Control Module.
NOTE: Check for applicable TSB’s related to the symptom.
Perform thi s procedure pri or to Symptom di agnosi s.
Al l
Conti nue
Go To 2
2 Wi th the DRBI I I ௡, check Transmi ssi on DTC’s.
Are there any Speed Sensor and/or other Temperature Sensor DTCs present?
Al l
Yes → Refer to the Transmi ssi on category and perform the appropri ate
symptom.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 3
56
TRANSMISSION - 42RLE
TEST ACTION APPLICABILITY
3 Wi th the DRBI I I ௡, Check the STARTS SI NCE SET counter for P0714.
NOTE: This counter only applies to the last DTC set.
I s the STARTS SI NCE SET counter 2 or l ess?
Al l
Yes → Go To 4
No → Go To 7
4 Turn the i gni ti on off to the l ock posi ti on.
Remove the Starter Rel ay.
NOTE: Failure to remove Starter Relay can cause a Transmission - No
Response condition.
I nstal l the Transmi ssi on Si mul ator, Mi l l er tool #8333 and the El ectroni c Transmi s-
si on Adapter ki t 8333-1.
Note: Check connectors - Clean/repair as necessary.
I gni ti on on, engi ne not runni ng.
Wi th the Transmi ssi on Si mul ator, turn the I nput/Output swi tch to OFF.
Wi th the DRBI I I ௡, moni tor the TRANS TEMP VOLTS whi l e turni ng the Thermi stor
Vol tage swi tch to al l three posi ti ons on the Transmi ssi on Si mul ator.
Compare the DRBI I I ௡ readi ngs wi th the numbers l i sted on the Transmi ssi on
Si mul ator.
Do the readi ngs on the Transmi ssi on Si mul ator match a non-fl uctuati ng DRBI I I ௡
readi ng ± 0.2 vol ts?
Al l
Yes → Go To 5
No → Go To 6
5 I f there are no possi bl e causes remai ni ng, vi ew repai r. Al l
Repai r
Repl ace Transmi ssi on Sol enoi d/TRS Assembl y per the Servi ce
I nformati on.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
6 Usi ng the schemati cs as a gui de, i nspect the wi ri ng and connectors. Repai r as
necessary. Pay parti cul ar attenti on to al l power and ground ci rcui ts.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace the Transmi ssi on Control Modul e per the Servi ce I nfor-
mati on. WI TH THE DRBI I I ௡ PERFORM QUI CK LEARN.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
7 The condi ti ons necessary to set thi s DTC are not present at thi s ti me.
Usi ng the schemati cs as a gui de, i nspect the wi ri ng and connectors speci fi c to thi s
ci rcui t.
Wi ggl e the wi res whi l e checki ng for shorts and open ci rcui ts.
Wi th the DRBI I I ௡, check the EATX EVENT DATA to hel p i denti fy the condi ti ons i n
whi ch the DTC was set.
Were there any probl ems found?
Al l
Yes → Repai r as necessary.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Test Compl ete.
57
TRANSMISSION - 42RLE
P0714-TRANSMISSION TEMPERATURE SENSOR INTERMITTENT —
Continued
Symptom:
P0715-INPUT SPEED SENSOR ERROR
When Monitored and Set Condition:
P0715-INPUT SPEED SENSOR ERROR
When Moni tored: The transmi ssi on gear rati o i s moni tored conti nuousl y whi l e the
transmi ssi on i s i n gear.
Set Condi ti on: I f there i s an excessi ve change i n i nput RPM i n any gear.
POSSIBLE CAUSES
I NPUT SPEED SENSOR SI GNAL CI RCUI T OPEN
SPEED SENSOR GROUND CI RCUI T OPEN
I NPUT SPEED SENSOR SI GNAL CI RCUI T SHORT TO GROUND
I NPUT SPEED SENSOR SI GNAL CI RCUI T SHORT TO VOLTAGE
SPEED SENSOR GROUND CI RCUI T SHORT TO VOLTAGE
I NPUT SPEED SENSOR ERROR
TRANSMI SSI ON CONTROL MODULE
I NTERMI TTENT WI RI NG AND CONNECTORS
TEST ACTION APPLICABILITY
1 NOTE: Low fluid level can be the cause of many Transmission problems. If
the fluid level is low, locate and repair the leak, then check and adjust the
fluid level per the Service Information.
NOTE: Always perform diagnostics with a fully charged battery to avoid
false symptoms.
Wi th the DRBI I I ௡, read the engi ne DTC’s. Check and repai r al l engi ne DTC’s pri or
to performi ng Transmi ssi on Symptom Di agnosti cs.
Wi th the DRBI I I ௡, read Transmi ssi on DTC’s. Record al l DTC’s and 1 Tri p Fai l ures.
NOTE: Diagnose 1 Trip Failures as a fully matured DTC.
Usi ng the wi ri ng di agram/schemati c as a gui de, i nspect the wi ri ng and connectors.
Repai r as necessary.
Perform the Shi ft Lever Posi ti on Test. I f the test does not pass, refer to Symptom test
for P0706 Check Shi fter Si gnal .
For Gear Rati o DTC’s, check and record al l CVI ’s.
Most DTC’s set on start up but some must be set by dri vi ng the vehi cl e such that al l
di agnosti c moni tors have run.
NOTE: Verify flash level of Transmission Control Module. Some problems
are corrected by software upgrades to the Transmission Control Module.
NOTE: Check for applicable TSB’s related to the symptom.
Perform thi s procedure pri or to Symptom di agnosi s.
Al l
Conti nue
Go To 2
58
TRANSMISSION - 42RLE
TEST ACTION APPLICABILITY
2 Start the engi ne i n park.
Wi th the DRBI I I ௡, read the I nput RPM.
I s the I nput RPM readi ng bel ow 400 RPM?
Al l
Yes → Go To 3
No → Go To 11
3 Turn the i gni ti on off to the l ock posi ti on.
CAUTION: Remove the Starter Relay from the PDC. This will prevent the
vehicle frombeing started in gear.
I nstal l the Transmi ssi on Si mul ator, Mi l l er tool #8333 and the El ectroni c Transmi s-
si on Adapter ki t 8333-1.
I gni ti on on, engi ne not runni ng.
Wi th the Transmi ssi on Si mul ator, set the ЉI nput/Output SpeedЉ swi tch to ЉONЉ and
the rotary swi tch to the Љ3000/1250Љ posi ti on.
Wi th the DRBI I I ௡, moni tor the I nput and Output RPM.
Does the I nput RPM read 3000 RPM and the Output RPM read 1250 RPM +/- 50
RPM?
Al l
Yes → Go To 4
No → Go To 5
NOTE: Disconnect the Transmission Simulator and reconnect all harness
connectors.
4 I f there are no possi bl e causes remai ni ng, vi ew repai r. Al l
Repai r
Repl ace the I nput Speed Sensor per the Servi ce I nformati on.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
5 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the TCM harness connector.
Di sconnect the I nput Speed Sensor harness connector.
Note: Check connectors - Clean/repair as necessary.
Measure the resi stance of the I nput Speed Sensor Si gnal ci rcui t from the TCM
harness connector to the I nput Speed Sensor harness connector.
I s the resi stance above 5.0 ohms?
Al l
Yes → Repai r the I nput Speed Sensor Si gnal ci rcui t for an open.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 6
6 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the TCM harness connector.
Di sconnect the I nput Speed Sensor harness connector.
Note: Check connectors - Clean/repair as necessary.
Measure the resi stance between ground and the I nput Speed Sensor si gnal ci rcui t.
I s the resi stance Bel ow 5.0 ohms?
Al l
Yes → Repai r the I nput Speed Sensor Si gnal ci rcui t for a short to
ground.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 7
59
TRANSMISSION - 42RLE
P0715-INPUT SPEED SENSOR ERROR — Continued
TEST ACTION APPLICABILITY
7 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the I nput Speed Sensor harness connector.
Di sconnect the TCM harness connector.
Remove the Transmi ssi on Control Rel ay from the PDC.
Note: Check connectors - Clean/repair as necessary.
Connect a jumper wi re between the Fused B+ ci rcui t and the Transmi ssi on Control
Rel ay Output ci rcui t i n the Transmi ssi on Control Rel ay connector.
I gni ti on on, engi ne not runni ng.
Measure the vol tage of the I nput Speed Sensor Si gnal ci rcui t i n the TCM harness
connector.
I s the vol tage above 0.5 vol ts?
Al l
Yes → Repai r the I nput Speed Sensor Si gnal ci rcui t for a short to
vol tage.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 8
8 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the TCM harness connector.
Di sconnect the I nput Speed Sensor harness connector.
Note: Check connectors - Clean/repair as necessary.
Measure the resi stance of the Speed Sensor Ground ci rcui t from the TCM harness
connector to the I nput Speed Sensor harness connector.
I s the resi stance above 5.0 ohms?
Al l
Yes → Repai r the Speed Sensor Ground ci rcui t for an open.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 9
9 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the TCM harness connector.
Di sconnect the TRS harness connector.
Remove the Transmi ssi on Control Rel ay from the PDC.
Note: Check connectors - Clean/repair as necessary.
Connect a jumper wi re between the Fused B+ ci rcui t and the Transmi ssi on Control
Rel ay Output ci rcui t i n the Transmi ssi on Control Rel ay connector i n the PDC.
I gni ti on on, engi ne not runni ng.
Measure the vol tage of the Speed Sensor Ground ci rcui t i n the TCM harness
connector.
I s the vol tage above 0.5 vol ts?
Al l
Yes → Repai r the Speed Sensor Ground ci rcui t for a short to vol tage.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 10
10 Usi ng the schemati cs as a gui de, i nspect the wi ri ng and connectors. Repai r as
necessary. Pay parti cul ar attenti on to al l power and ground ci rcui ts.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace the Transmi ssi on Control Modul e per the Servi ce I nfor-
mati on. WI TH THE DRBI I I ௡ PERFORM QUI CK LEARN.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
60
TRANSMISSION - 42RLE
P0715-INPUT SPEED SENSOR ERROR — Continued
TEST ACTION APPLICABILITY
11 The condi ti ons necessary to set thi s DTC are not present at thi s ti me.
Usi ng the schemati cs as a gui de, i nspect the wi ri ng and connectors speci fi c to thi s
ci rcui t.
Wi ggl e the wi ri ng whi l e checki ng for shorts and open ci rcui ts.
Wi th the DRBI I I ௡, check the EATX EVENT DATA to hel p i denti fy the condi ti ons i n
whi ch the DTC was set.
Were there any probl ems found?
Al l
Yes → Repai r as necessary.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Test Compl ete.
61
TRANSMISSION - 42RLE
P0715-INPUT SPEED SENSOR ERROR — Continued
Symptom:
P0720-OUTPUT SPEED SENSOR ERROR
When Monitored and Set Condition:
P0720-OUTPUT SPEED SENSOR ERROR
When Moni tored: The transmi ssi on gear rati o i s moni tored conti nuousl y whi l e the
transmi ssi on i s i n gear.
Set Condi ti on: I f there i s an excessi ve change i n output RPM i n any gear.
POSSIBLE CAUSES
I NTERMI TTENT WI RI NG AND CONNECTORS
OUTPUT SPEED SENSOR SI GNAL CI RCUI T OPEN
SPEED SENSOR GROUND CI RCUI T OPEN
OUTPUT SPEED SENSOR SI GNAL CI RCUI T SHORT TO GROUND
OUTPUT SPEED SENSOR SI GNAL CI RCUI T SHORT TO VOLTAGE
SPEED SENSOR GROUND CI RCUI T SHORT TO VOLTAGE
OUTPUT SPEED SENSOR ERROR
TRANSMI SSI ON CONTROL MODULE
TEST ACTION APPLICABILITY
1 NOTE: Low fluid level can be the cause of many Transmission problems. If
the fluid level is low, locate and repair the leak, then check and adjust the
fluid level per the Service Information.
NOTE: Always perform diagnostics with a fully charged battery to avoid
false symptoms.
Wi th the DRBI I I ௡, read the engi ne DTC’s. Check and repai r al l engi ne DTC’s pri or
to performi ng Transmi ssi on Symptom Di agnosti cs.
Wi th the DRBI I I ௡, read Transmi ssi on DTC’s. Record al l DTC’s and 1 Tri p Fai l ures.
NOTE: Diagnose 1 Trip Failures as a fully matured DTC.
Usi ng the wi ri ng di agram/schemati c as a gui de, i nspect the wi ri ng and connectors.
Repai r as necessary.
Perform the Shi ft Lever Posi ti on Test. I f the test does not pass, refer to Symptom test
for P0706 Check Shi fter Si gnal .
For Gear Rati o DTC’s, check and record al l CVI ’s.
Most DTC’s set on start up but some must be set by dri vi ng the vehi cl e such that al l
di agnosti c moni tors have run.
NOTE: Verify flash level of Transmission Control Module. Some problems
are corrected by software upgrades to the Transmission Control Module.
NOTE: Check for applicable TSB’s related to the symptom.
Perform thi s procedure pri or to Symptom di agnosi s.
Al l
Conti nue
Go To 2
62
TRANSMISSION - 42RLE
TEST ACTION APPLICABILITY
2 Start the engi ne i n park.
Rai se the dri ve wheel s off of the ground.
WARNING: PROPERLY SUPPORT THE VEHICLE.
Pl ace transmi ssi on i n dri ve, rel ease foot from brake.
WARNING: BE SURE TO KEEP HANDS AND FEET CLEAR OF ROTATING
WHEELS.
Note: The drive wheels must be turning at this point.
Wi th the DRBI I I ௡, read the Output RPM
I s the Output RPM bel ow 100 RPM?
Al l
Yes → Go To 3
No → Go To 11
3 Turn the i gni ti on off to the l ock posi ti on.
CAUTION: Remove the Starter Relay from the PDC. This will prevent the
vehicle frombeing started in gear.
I nstal l the Transmi ssi on Si mul ator, Mi l l er tool #8333 and the El ectroni c Transmi s-
si on Adapter ki t 8333-1.
I gni ti on on, engi ne not runni ng.
Wi th the Transmi ssi on Si mul ator, set the ЉI nput/Output SpeedЉ swi tch to ЉONЉ and
the rotary swi tch to the Љ3000/1250Љ posi ti on.
Wi th the DRBI I I ௡, read the I nput RPM and Output RPM.
Does the I nput RPM read 3000 and the Output RPM read 1250 ± 50 RPM?
Al l
Yes → Go To 4
No → Go To 5
4 I f there are no possi bl e causes remai ni ng, vi ew repai r. Al l
Repai r
Repl ace the Output Speed Sensor per the Servi ce I nformati on.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
5 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the TCM harness connector.
Di sconnect the Output Speed Sensor harness connector.
Note: Check connectors - Clean/repair as necessary.
Measure the resi stance of the Output Speed Sensor Si gnal ci rcui t from the TCM
harness connector to the Output Speed Sensor harness connector.
I s the resi stance above 5.0 ohms?
Al l
Yes → Repai r the Output Speed Sensor Si gnal ci rcui t for an open.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 6
63
TRANSMISSION - 42RLE
P0720-OUTPUT SPEED SENSOR ERROR — Continued
TEST ACTION APPLICABILITY
6 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the TCM harness connector.
Di sconnect the Output Speed Sensor harness connector.
Note: Check connectors - Clean/repair as necessary.
Measure the resi stance between ground and the Output Speed Sensor Si gnal ci rcui t.
I s the resi stance Bel ow 5.0 ohms?
Al l
Yes → Repai r the Output Speed Sensor Si gnal ci rcui t for a short to
ground.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 7
7 Turn i gni ti on off to the l ock posi ti on.
Di sconnect the TCM harness connector.
Di sconnect the Transmi ssi on Si mul ator.
Remove the Transmi ssi on Control Rel ay from the PDC.
Note: Check connectors - Clean/repair as necessary.
Connect a jumper wi re between the Fused B(+) and Transmi ssi on Control Rel ay
Output ci rcui ts i n the Transmi ssi on Control Rel ay connector (I n PDC).
I gni ti on on, engi ne not runni ng.
Measure the vol tage of the Output Speed Sensor Si gnal ci rcui t i n the TCM connector.
I s the vol tage above 3.0 vol ts?
Al l
Yes → Repai r Output Speed Sensor Si gnal ci rcui t short to vol tage.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 8
8 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the TCM harness connector.
Di sconnect the Output Speed Sensor harness connector.
Note: Check connectors - Clean/repair as necessary.
Measure the resi stance of the Speed Sensor Ground ci rcui t from the TCM harness
connector to the Output Speed Sensor harness connector.
I s the resi stance above 5.0 ohms?
Al l
Yes → Repai r the Speed Sensor Ground ci rcui t for an open.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 9
9 Turn i gni ti on off to the l ock posi ti on.
Di sconnect the TCM harness connector.
Di sconnect the TRS harness connector.
Remove the Transmi ssi on Control Rel ay from the PDC.
Note: Check connectors - Clean/repair as necessary.
Connect a jumper wi re between the Fused B(+) and Transmi ssi on Control Rel ay
Output ci rcui ts i n the Transmi ssi on Control Rel ay connector (I n PDC).
I gni ti on on, engi ne not runni ng.
Measure the vol tage of the Speed Sensor Ground ci rcui t i n the TCM connector.
I s the vol tage above 3.0 vol ts?
Al l
Yes → Repai r the Speed Sensor Ground ci rcui t for a short to vol tage.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 10
64
TRANSMISSION - 42RLE
P0720-OUTPUT SPEED SENSOR ERROR — Continued
TEST ACTION APPLICABILITY
10 Usi ng the schemati cs as a gui de, i nspect the wi ri ng and connectors. Repai r as
necessary. Pay parti cul ar attenti on to al l power and ground ci rcui ts.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace the Transmi ssi on Control Modul e per the Servi ce I nfor-
mati on. WI TH THE DRBI I I ௡ PERFORM QUI CK LEARN.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
11 The condi ti ons necessary to set thi s DTC are not present at thi s ti me.
Usi ng the schemati cs as a gui de, i nspect the wi ri ng and connectors speci fi c to thi s
ci rcui t.
Wi ggl e the wi ri ng whi l e checki ng for shorts and open ci rcui ts.
Wi th the DRBI I I ௡, check the EATX EVENT DATA to hel p i denti fy the condi ti ons i n
whi ch the DTC was set.
Were there any probl ems found?
Al l
Yes → Repai r as necessary.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Test Compl ete.
65
TRANSMISSION - 42RLE
P0720-OUTPUT SPEED SENSOR ERROR — Continued
Symptom:
P0725-ENGINE SPEED SENSOR CIRCUIT
When Monitored and Set Condition:
P0725-ENGINE SPEED SENSOR CIRCUIT
When Moni tored: Whenever the engi ne i s runni ng.
Set Condi ti on: Engi ne RPM l ess than 390 or greater than 8000 for more than 2 seconds
whi l e the engi ne i s runni ng.
POSSIBLE CAUSES
I NTERMI TTENT WI RI NG & CONNECTORS CONDI TI ONS
EATX RPM SI GNAL CI RCUI T OPEN
EATX RPM SI GNAL CI RCUI T SHORTED TO GROUND
EATX RPM SI GNAL CI RCUI T SHORTED TO VOLTAGE
TRANSMI SSI ON CONTROL MODULE
POWERTRAI N CONTROL MODULE
TEST ACTION APPLICABILITY
1 NOTE: Low fluid level can be the cause of many Transmission problems. If
the fluid level is low, locate and repair the leak, then check and adjust the
fluid level per the Service Information.
NOTE: Always perform diagnostics with a fully charged battery to avoid
false symptoms.
Wi th the DRBI I I ௡, read the engi ne DTC’s. Check and repai r al l engi ne DTC’s pri or
to performi ng Transmi ssi on Symptom Di agnosti cs.
Wi th the DRBI I I ௡, read Transmi ssi on DTC’s. Record al l DTC’s and 1 Tri p Fai l ures.
NOTE: Diagnose 1 Trip Failures as a fully matured DTC.
Usi ng the wi ri ng di agram/schemati c as a gui de, i nspect the wi ri ng and connectors.
Repai r as necessary.
Perform the Shi ft Lever Posi ti on Test. I f the test does not pass, refer to Symptom test
for P0706 Check Shi fter Si gnal .
For Gear Rati o DTC’s, check and record al l CVI ’s.
Most DTC’s set on start up but some must be set by dri vi ng the vehi cl e such that al l
di agnosti c moni tors have run.
NOTE: Verify flash level of Transmission Control Module. Some problems
are corrected by software upgrades to the Transmission Control Module.
NOTE: Check for applicable TSB’s related to the symptom.
Perform thi s procedure pri or to Symptom di agnosi s.
Al l
Conti nue
Go To 2
66
TRANSMISSION - 42RLE
TEST ACTION APPLICABILITY
2 NOTE: This code is not a Transmission Input Speed Sensor DTC
Wi th the DRBI I I ௡, Check the STARTS SI NCE SET counter.
NOTE: This counter only applies to the last DTC set.
I s the STARTS SI NCE SET counter set at 0?
Al l
Yes → Go To 3
No → Go To 8
3 Turn i gni ti on off to the l ock posi ti on.
Di sconnect the Powertrai n Control Modul e (PCM) harness connector.
Di sconnect the TCM harness connector.
Note: Check connectors - Clean/repair as necessary.
Measure the resi stance of the EATX RPM si gnal ci rcui t between the TCM connector
and the PCM connector.
I s the resi stance above 5.0 ohms?
Al l
Yes → Repai r the open EATX RPM Si gnal ci rcui t.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 4
4 Turn i gni ti on off to the l ock posi ti on.
Di sconnect the Powertrai n Control Modul e (PCM) harness connector.
Di sconnect the TCM harness connector.
Note: Check connectors - Clean/repair as necessary.
Measure the resi stance between the EATX RPM Si gnal ci rcui t and ground.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Repai r the EATX RPM Si gnal ci rcui t for a short to ground.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 5
5 Turn i gni ti on off to the l ock posi ti on.
Di sconnect the PCM harness connector.
Note: Check connectors - Clean/repair as necessary.
I gni ti on on, engi ne not runni ng.
Measure the vol tage of the EATX RPM Si gnal ci rcui t i n the PCM connector.
I s the vol tage above 10.0 vol ts?
Al l
Yes → Repai r the EATX RPM Si gnal ci rcui t for a short to vol tage.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 6
6 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the PCM harness connector.
Note: Check connectors - Clean/repair as necessary.
I gni ti on on, engi ne not runni ng.
Measure the vol tage of the EATX RPM Si gnal ci rcui t.
I s the vol tage between 4.5 and 5.5 vol ts?
Al l
Yes → Repl ace and program the Powertrai n Control Modul e per the
Servi ce I nformati on.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 7
67
TRANSMISSION - 42RLE
P0725-ENGINE SPEED SENSOR CIRCUIT — Continued
TEST ACTION APPLICABILITY
7 Usi ng the schemati cs as a gui de, i nspect the wi ri ng and connectors. Repai r as
necessary. Pay parti cul ar attenti on to al l power and ground ci rcui ts.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace the Transmi ssi on Control Modul e per the Servi ce I nfor-
mati on. WI TH THE DRBI I I ௡ PERFORM QUI CK LEARN.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
8 The condi ti ons necessary to set the DTC are not present at thi s ti me. Usi ng the
schemati cs as a gui de, i nspect the wi ri ng and connectors speci fi c to thi s ci rcui t.
Wi ggl e the wi res whi l e checki ng for shorts and open ci rcui ts.
Check the power and ground ci rcui ts of the Transmi ssi on Control Modul e.
Check the vehi cl es battery condi ti on.
Were any probl ems found?
Al l
Yes → Repai r wi ri ng and/or connectors as necessary.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Test Compl ete.
68
TRANSMISSION - 42RLE
P0725-ENGINE SPEED SENSOR CIRCUIT — Continued
Symptom:
P0731-GEAR RATIO ERROR IN 1ST
When Monitored and Set Condition:
P0731-GEAR RATIO ERROR IN 1ST
When Moni tored: The Transmi ssi on Gear Rati o i s moni tored conti nuousl y whi l e the
Transmi ssi on i s i n gear.
Set Condi ti on: I f the rati o of the i nput RPM to the output RPM does not match the
current Gear Rati o.
POSSIBLE CAUSES
RELATED DTC’S PRESENT
I NTERMI TTENT GEAR RATI O ERRORS
I NTERNAL TRANSMI SSI ON
TEST ACTION APPLICABILITY
1 NOTE: Low fluid level can be the cause of many Transmission problems. If
the fluid level is low, locate and repair the leak, then check and adjust the
fluid level per the Service Information.
NOTE: Always perform diagnostics with a fully charged battery to avoid
false symptoms.
Wi th the DRBI I I ௡, read the engi ne DTC’s. Check and repai r al l engi ne DTC’s pri or
to performi ng Transmi ssi on Symptom Di agnosti cs.
Wi th the DRBI I I ௡, read Transmi ssi on DTC’s. Record al l DTC’s and 1 Tri p Fai l ures.
NOTE: Diagnose 1 Trip Failures as a fully matured DTC.
Usi ng the wi ri ng di agram/schemati c as a gui de, i nspect the wi ri ng and connectors.
Repai r as necessary.
Perform the Shi ft Lever Posi ti on Test. I f the test does not pass, refer to Symptom test
for P0706 Check Shi fter Si gnal .
For Gear Rati o DTC’s, check and record al l CVI ’s.
Most DTC’s set on start up but some must be set by dri vi ng the vehi cl e such that al l
di agnosti c moni tors have run.
NOTE: Verify flash level of Transmission Control Module. Some problems
are corrected by software upgrades to the Transmission Control Module.
NOTE: Check for applicable TSB’s related to the symptom.
Perform thi s procedure pri or to Symptom di agnosi s.
Al l
Conti nue
Go To 2
2 Wi th the DRBI I I ௡, read Transmi ssi on DTC’s
I f any of these DTC’s are present, perform thei r respecti ve tests fi rst.
Are the DTC’s P0944, P0715, P0720, or P1794 present al so?
Al l
Yes → Refer to the Transmi ssi on category and perform the appropri ate
symptom. I f any of these DTC’s are present, they wi l l cause a gear
rati o error. Perform the test for Loss of Pri me fi rst i f i t i s present.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 3
69
TRANSMISSION - 42RLE
TEST ACTION APPLICABILITY
3 Wi th the DRBI I I ௡, perform the 1st Gear Cl utch Test. Fol l ow the i nstructi ons on the
DRBI I I ௡.
I ncrease the throttl e angl e, TPS Degree, to 30° for no more than a few seconds.
CAUTION: Do not overheat the transmission.
Di d the Cl utch Test pass, I nput Speed remai n at 0?
Al l
Yes → Go To 4
No → Go To 5
4 The condi ti ons to set thi s DTC are not present at thi s ti me.
Check the gearshi ft l i nkage adjustment.
Gear rati o DTC’s can be set by probl ems i n the I nput and Output Speed Sensor
ci rcui ts. I f the vehi cl e passes the cl utch test and sti l l sets gear rati o DTC(’s), check
the Speed Sensors for proper operati on.
NOTE: Remove the Starter Relay from the PDC. This will prevent the
vehicle frombeing started in gear.
Check the Speed Sensor wi ri ng and connectors for good connecti on, then perform a
wi ggl e test usi ng the Transmi ssi on Si mul ator, Mi l l er tool #8333 and the El ectroni c
Transmi ssi on Adapter ki t 8333-1A.
Thi s DTC can al so be set under extreme temperature condi ti ons, thi s i s usual l y
caused by an i nternal probl em. Veri fy i f the probl em i s onl y experi enced under
extreme hot or col d condi ti ons.
Wi th the DRBI I I ௡, check the EATX EVENT DATA to hel p i denti fy the condi ti ons i n
whi ch the DTC was set.
Were there any probl ems found?
Al l
Yes → Repai r as necessary.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Test Compl ete.
5 I f there are no possi bl e causes remai ni ng, vi ew repai r. Al l
Repai r
Repai r i nternal transmi ssi on per the Servi ce I nformati on. Check
al l components rel ated to the Underdri ve and L/R cl utches.
I nspect the Oi l Pump per the Servi ce I nformati on and repai r or
repl ace as necessary.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
70
TRANSMISSION - 42RLE
P0731-GEAR RATIO ERROR IN 1ST — Continued
Symptom:
P0732-GEAR RATIO ERROR IN 2ND
When Monitored and Set Condition:
P0732-GEAR RATIO ERROR IN 2ND
When Moni tored: The Transmi ssi on Gear Rati o i s moni tored conti nuousl y whi l e the
Transmi ssi on i s i n Gear.
Set Condi ti on: I f the rati o of the i nput RPM to the output RPM does not match the
current Gear Rati o.
POSSIBLE CAUSES
RELATED DTC’S PRESENT
RELATED PRESSURE SWI TCH DTC’S PRESENT
I NTERMI TTENT GEAR RATI O ERRORS
TRANSMI SSI ON - I NTERNAL
TEST ACTION APPLICABILITY
1 NOTE: Low fluid level can be the cause of many Transmission problems. If
the fluid level is low, locate and repair the leak, then check and adjust the
fluid level per the Service Information.
NOTE: Always perform diagnostics with a fully charged battery to avoid
false symptoms.
Wi th the DRBI I I ௡, read the engi ne DTC’s. Check and repai r al l engi ne DTC’s pri or
to performi ng Transmi ssi on Symptom Di agnosti cs.
Wi th the DRBI I I ௡, read Transmi ssi on DTC’s. Record al l DTC’s and 1 Tri p Fai l ures.
NOTE: Diagnose 1 Trip Failures as a fully matured DTC.
Usi ng the wi ri ng di agram/schemati c as a gui de, i nspect the wi ri ng and connectors.
Repai r as necessary.
Perform the Shi ft Lever Posi ti on Test. I f the test does not pass, refer to Symptom test
for P0706 Check Shi fter Si gnal .
For Gear Rati o DTC’s, check and record al l CVI ’s.
Most DTC’s set on start up but some must be set by dri vi ng the vehi cl e such that al l
di agnosti c moni tors have run.
NOTE: Verify flash level of Transmission Control Module. Some problems
are corrected by software upgrades to the Transmission Control Module.
NOTE: Check for applicable TSB’s related to the symptom.
Perform thi s procedure pri or to Symptom di agnosi s.
Al l
Conti nue
Go To 2
71
TRANSMISSION - 42RLE
TEST ACTION APPLICABILITY
2 Wi th the DRBI I I ௡, read Transmi ssi on DTC’s
I f any of these DTC’s are present, perform thei r respecti ve tests fi rst.
Are the DTC’s P0944, P0715, P0720, or P1794 present al so?
Al l
Yes → Refer to the Transmi ssi on category and perform the appropri ate
symptom. I f any of these DTC’s are present, they wi l l cause a gear
rati o error. Perform the test for Loss of Pri me fi rst i f i t i s present.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 3
3 Wi th the DRBI I I ௡, perform the 2nd Gear Cl utch Test. Fol l ow the i nstructi ons on the
DRBI I I ௡.
I ncrease the Throttl e Angl e, TPS Degree, to 30° for no more than a few seconds.
CAUTION: Do not overheat the transmission.
Di d the Cl utch Test pass, I nput Speed remai n at 0?
Al l
Yes → Go To 4
No → Go To 5
4 The condi ti ons to set thi s DTC are not present at thi s ti me.
Check the gearshi ft l i nkage adjustment.
Gear rati o DTC’s can be set by probl ems i n the I nput and Output Speed Sensor
ci rcui ts. I f the vehi cl e passes the cl utch test and sti l l sets Gear Rati o DTC(s), check
the Speed Sensors for proper operati on.
NOTE: Remove the Starter Relay from the PDC. This will prevent the
vehicle frombeing started in gear.
Check the Speed Sensor wi ri ng and connectors for good connecti on, then perform a
wi ggl e test usi ng the Transmi ssi on Si mul ator, Mi l l er tool #8333 and the El ectroni c
Transmi ssi on Adapter ki t 8333-1A.
Thi s DTC can al so be set under extreme temperature condi ti ons, thi s i s usual l y
caused by an i nternal probl em. Veri fy i f the probl em i s onl y experi enced under
extreme hot or col d condi ti ons.
Wi th the DRBI I I ௡, check the EATX EVENT DATA to hel p i denti fy the condi ti ons i n
whi ch the DTC was set.
Were there any probl ems found?
Al l
Yes → Repai r as necessary.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Test Compl ete.
5 Wi th the DRBI I I ௡, read Transmi ssi on DTC’s.
I s the DTC P0845 and/or P0846 present al so?
Al l
Yes → Repl ace the Sol enoi d/Pressure Swi tch Assembl y per the Servi ce
I nformati on.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 6
72
TRANSMISSION - 42RLE
P0732-GEAR RATIO ERROR IN 2ND — Continued
TEST ACTION APPLICABILITY
6 I f there are no possi bl e causes remai ni ng, vi ew repai r. Al l
Repai r
Repai r i nternal transmi ssi on probl em. Check al l of the compo-
nents rel ated to the Underdri ve and 2/4 cl utches. I nspect the Oi l
Pump per the Servi ce I nformati on and repai r or repl ace as
necessary.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
73
TRANSMISSION - 42RLE
P0732-GEAR RATIO ERROR IN 2ND — Continued
Symptom:
P0733-GEAR RATIO ERROR IN 3RD
When Monitored and Set Condition:
P0733-GEAR RATIO ERROR IN 3RD
When Moni tored: The Transmi ssi on Gear Rati o i s moni tored conti nuousl y whi l e the
Transmi ssi on i s i n Gear.
Set Condi ti on: I f the rati o of the i nput RPM to the output RPM does not match the
current Gear Rati o.
POSSIBLE CAUSES
RELATED DTC’S PRESENT
TRANSMI SSI ON SOLENOI D PRESSURE SWI TCH ASSEMBLY
I NTERNAL TRANSMI SSI ON
I NTERMI TTENT GEAR RATI O ERRORS
TEST ACTION APPLICABILITY
1 NOTE: Low fluid level can be the cause of many Transmission problems. If
the fluid level is low, locate and repair the leak, then check and adjust the
fluid level per the Service Information.
NOTE: Always perform diagnostics with a fully charged battery to avoid
false symptoms.
Wi th the DRBI I I ௡, read the engi ne DTC’s. Check and repai r al l engi ne DTC’s pri or
to performi ng Transmi ssi on Symptom Di agnosti cs.
Wi th the DRBI I I ௡, read Transmi ssi on DTC’s. Record al l DTC’s and 1 Tri p Fai l ures.
NOTE: Diagnose 1 Trip Failures as a fully matured DTC.
Usi ng the wi ri ng di agram/schemati c as a gui de, i nspect the wi ri ng and connectors.
Repai r as necessary.
Perform the Shi ft Lever Posi ti on Test. I f the test does not pass, refer to Symptom test
for P0706 Check Shi fter Si gnal .
For Gear Rati o DTC’s, check and record al l CVI ’s.
Most DTC’s set on start up but some must be set by dri vi ng the vehi cl e such that al l
di agnosti c moni tors have run.
NOTE: Verify flash level of Transmission Control Module. Some problems
are corrected by software upgrades to the Transmission Control Module.
NOTE: Check for applicable TSB’s related to the symptom.
Perform thi s procedure pri or to Symptom di agnosi s.
Al l
Conti nue
Go To 2
74
TRANSMISSION - 42RLE
TEST ACTION APPLICABILITY
2 Wi th the DRBI I I ௡, read Transmi ssi on DTC’s
I f any of these DTC’s are present, perform thei r respecti ve tests fi rst.
Are the DTC’s P0944, P0715, P0720, or P1794 present al so?
Al l
Yes → Refer to the Transmi ssi on category and perform the appropri ate
symptom. I f any of these DTC’s are present, they wi l l cause a gear
rati o error. Perform the test for Loss of Pri me fi rst i f i t i s present.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 3
3 Wi th the DRBI I I ௡, perform the 3rd gear cl utch test. Fol l ow the i nstructi ons on the
DRBI I I ௡.
I ncrease the throttl e angl e, TPS Degree, to 30° for no more than a few seconds.
CAUTION: Do not overheat the transmission.
Di d the Cl utch Test pass, I nput Speed remai n at 0?
Al l
Yes → Go To 4
No → Go To 5
4 The condi ti ons to set thi s DTC are not present at thi s ti me.
Check the gearshi ft l i nkage adjustment.
Gear rati o DTC’s can be set by probl ems i n the I nput and Output Speed Sensor
ci rcui ts. I f the vehi cl e passes the cl utch test and sti l l sets Rear Rati o DTC(s), check
the Speed Sensors for proper operati on.
NOTE: Remove the Starter Relay from the PDC. This will prevent the
vehicle frombeing started in gear.
Check the speed sensor wi ri ng and connectors for good connecti on, then perform a
wi ggl e test usi ng the Transmi ssi on Si mul ator, Mi l l er tool #8333 and the El ectroni c
Transmi ssi on Adapter ki t 8333-1A.
Thi s DTC can al so be set under extreme temperature condi ti ons, thi s i s usual l y
caused by an i nternal probl em. Veri fy i f the probl em i s onl y experi enced under
extreme hot or col d condi ti ons.
Wi th the DRBI I I ௡, check the EATX EVENT DATA to hel p i denti fy the condi ti ons i n
whi ch the DTC was set.
Were there any probl ems found?
Al l
Yes → Repai r as necessary.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Test Compl ete.
5 Wi th the DRBI I I ௡, read Transmi ssi on DTC’s.
I s the DTC P0870 and/or P0871 present al so?
Al l
Yes → Repl ace the Transmi ssi on Sol enoi d/Pressure Swi tch Assembl y per
the Servi ce I nformati on.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 6
75
TRANSMISSION - 42RLE
P0733-GEAR RATIO ERROR IN 3RD — Continued
TEST ACTION APPLICABILITY
6 I f there are no possi bl e causes remai ni ng, vi ew repai r. Al l
Repai r
Repai r i nternal transmi ssi on per the Servi ce I nformati on. Check
al l of the components rel ated to the Underdri ve and Overdri ve
cl utches. I nspect the Oi l Pump per the Servi ce I nformati on and
repai r or repl ace as necessary.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
76
TRANSMISSION - 42RLE
P0733-GEAR RATIO ERROR IN 3RD — Continued
Symptom:
P0734-GEAR RATIO ERROR IN 4TH
When Monitored and Set Condition:
P0734-GEAR RATIO ERROR IN 4TH
When Moni tored: The Transmi ssi on Gear Rati o i s moni tored conti nuousl y whi l e the
Transmi ssi on i s i n Gear.
Set Condi ti on: I f the rati o of the i nput RPM to the output RPM does not match the
current Gear Rati o.
POSSIBLE CAUSES
RELATED DTC’S PRESENT
RELATED PRESSURE SWI TCH DTC’S PRESENT
I NTERMI TTENT GEAR RATI O ERRORS
TRANSMI SSI ON - I NTERNAL
TEST ACTION APPLICABILITY
1 NOTE: Low fluid level can be the cause of many Transmission problems. If
the fluid level is low, locate and repair the leak, then check and adjust the
fluid level per the Service Information.
NOTE: Always perform diagnostics with a fully charged battery to avoid
false symptoms.
Wi th the DRBI I I ௡, read the engi ne DTC’s. Check and repai r al l engi ne DTC’s pri or
to performi ng Transmi ssi on Symptom Di agnosti cs.
Wi th the DRBI I I ௡, read Transmi ssi on DTC’s. Record al l DTC’s and 1 Tri p Fai l ures.
NOTE: Diagnose 1 Trip Failures as a fully matured DTC.
Usi ng the wi ri ng di agram/schemati c as a gui de, i nspect the wi ri ng and connectors.
Repai r as necessary.
Perform the Shi ft Lever Posi ti on Test. I f the test does not pass, refer to Symptom test
for P0706 Check Shi fter Si gnal .
For Gear Rati o DTC’s, check and record al l CVI ’s.
Most DTC’s set on start up but some must be set by dri vi ng the vehi cl e such that al l
di agnosti c moni tors have run.
NOTE: Verify flash level of Transmission Control Module. Some problems
are corrected by software upgrades to the Transmission Control Module.
NOTE: Check for applicable TSB’s related to the symptom.
Perform thi s procedure pri or to Symptom di agnosi s.
Al l
Conti nue
Go To 2
77
TRANSMISSION - 42RLE
TEST ACTION APPLICABILITY
2 Wi th the DRBI I I ௡, read Transmi ssi on Control Modul e DTC’s
I f any of these DTC’s are present, perform thei r respecti ve tests fi rst.
Are the DTC’s P0944, P0715, P0720, or P1794 present al so?
Al l
Yes → Refer to the Transmi ssi on category and perform the appropri ate
symptom. I f any of these DTC’s are present, they wi l l cause a gear
rati o error. Perform the test for Loss of Pri me fi rst i f i t i s present.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 3
3 Wi th the DRBI I I ௡, perform the 4th gear cl utch test. Fol l ow the i nstructi ons on the
DRBI I I ௡.
I ncrease the throttl e angl e, TPS Degree, to 30° for no more than a few seconds.
CAUTION: Do not overheat the transmission.
Di d the Cl utch Test pass, I nput Speed remai n at 0?
Al l
Yes → Go To 4
No → Go To 5
4 The condi ti ons to set thi s DTC are not present at thi s ti me.
Check the gearshi ft l i nkage adjustment.
Gear Rati o DTC’s can be set by probl ems i n the I nput and Output Speed Sensor
ci rcui ts. I f the vehi cl e passes the cl utch test and sti l l sets Gear Rati o DTC(s), check
the Speed Sensors for proper operati on.
NOTE: Remove the Starter Relay from the PDC. This will prevent the
vehicle frombeing started in gear.
Check the Speed Sensor wi ri ng and connectors for good connecti on, then perform a
wi ggl e test usi ng the Transmi ssi on Si mul ator, Mi l l er tool #8333 and the El ectroni c
Transmi ssi on Adapter ki t 8333-1A.
Thi s DTC can al so be set under extreme temperature condi ti ons, thi s i s usual l y
caused by an i nternal probl em. Veri fy i f the probl em i s onl y experi enced under
extreme hot or col d condi ti ons.
Wi th the DRBI I I ௡, check the EATX EVENT DATA to hel p i denti fy the condi ti ons i n
whi ch the DTC was set.
Were there any probl ems found?
Al l
Yes → Repai r as necessary.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Test Compl ete.
5 Wi th the DRBI I I ௡, read Transmi ssi on DTC’s.
I s the DTC P0845 and/or P0846 present al so?
Al l
Yes → Repl ace the Sol enoi d/Pressure Swi tch Assembl y per the Servi ce
I nformati on.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 6
78
TRANSMISSION - 42RLE
P0734-GEAR RATIO ERROR IN 4TH — Continued
TEST ACTION APPLICABILITY
6 I f there are no possi bl e causes remai ni ng, vi ew repai r. Al l
Repai r
Repai r i nternal transmi ssi on probl em. Check al l of the compo-
nents rel ated to the Overdri ve and 2/4 cl utches. I nspect the Oi l
Pump per the Servi ce I nformati on and repai r or repl ace as
necessary.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
79
TRANSMISSION - 42RLE
P0734-GEAR RATIO ERROR IN 4TH — Continued
Symptom:
P0736-GEAR RATIO ERROR IN REVERSE
When Monitored and Set Condition:
P0736-GEAR RATIO ERROR IN REVERSE
When Moni tored: The Transmi ssi on Gear Rati o i s moni tored conti nuousl y whi l e the
Transmi ssi on i s i n Gear.
Set Condi ti on: I f the rati o of the i nput RPM to the output RPM does not match the
current Gear Rati o.
POSSIBLE CAUSES
RELATED DTC’S PRESENT
I NTERMI TTENT GEAR RATI O ERRORS
TRANSMI SSI ON - I NTERNAL
TEST ACTION APPLICABILITY
1 NOTE: Low fluid level can be the cause of many Transmission problems. If
the fluid level is low, locate and repair the leak, then check and adjust the
fluid level per the Service Information.
NOTE: Always perform diagnostics with a fully charged battery to avoid
false symptoms.
Wi th the DRBI I I ௡, read the engi ne DTC’s. Check and repai r al l engi ne DTC’s pri or
to performi ng Transmi ssi on Symptom Di agnosti cs.
Wi th the DRBI I I ௡, read Transmi ssi on DTC’s. Record al l DTC’s and 1 Tri p Fai l ures.
NOTE: Diagnose 1 Trip Failures as a fully matured DTC.
Usi ng the wi ri ng di agram/schemati c as a gui de, i nspect the wi ri ng and connectors.
Repai r as necessary.
Perform the Shi ft Lever Posi ti on Test. I f the test does not pass, refer to Symptom test
for P0706 Check Shi fter Si gnal .
For Gear Rati o DTC’s, check and record al l CVI ’s.
Most DTC’s set on start up but some must be set by dri vi ng the vehi cl e such that al l
di agnosti c moni tors have run.
NOTE: Verify flash level of Transmission Control Module. Some problems
are corrected by software upgrades to the Transmission Control Module.
NOTE: Check for applicable TSB’s related to the symptom.
Perform thi s procedure pri or to Symptom di agnosi s.
Al l
Conti nue
Go To 2
2 Wi th the DRBI I I ௡, read Transmi ssi on DTC’s
I f any of these DTC’s are present, perform thei r respecti ve tests fi rst.
Are the DTC’s P0944, P0715, P0720, P1794, or present al so?
Al l
Yes → Refer to the Transmi ssi on category and perform the appropri ate
symptom. I f any of these DTC’s are present, they wi l l cause a gear
rati o error. Perform the test for Loss of Pri me fi rst i f i t i s present.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 3
80
TRANSMISSION - 42RLE
TEST ACTION APPLICABILITY
3 Wi th the DRBI I I ௡, perform the Reverse gear cl utch test. Fol l ow the i nstructi ons on
the DRBI I I ௡.
I ncrease the throttl e angl e, TPS Degree, to 30° for no more than a few seconds.
CAUTION: Do not overheat the Transmission.
Di d the Cl utch Test pass, I nput Speed remai n at 0?
Al l
Yes → Go To 4
No → Go To 5
4 The condi ti ons to set thi s DTC are not present at thi s ti me.
Check the gearshi ft l i nkage adjustment.
Gear Rati o DTC’s can be set by probl ems i n the I nput and Output Speed Sensor
ci rcui ts. I f the vehi cl e passes the cl utch test and sti l l sets Gear Rati o DTC(s), check
the Speed Sensors for proper operati on.
NOTE: Remove the Starter Relay from the PDC. This will prevent the
vehicle frombeing started in gear.
Check the speed sensor wi ri ng and connectors for good connecti on, then perform a
wi ggl e test usi ng the Transmi ssi on Si mul ator, Mi l l er tool #8333 and the El ectroni c
Transmi ssi on Adapter ki t 8333-1A.
Thi s DTC can al so be set under extreme temperature condi ti ons, thi s i s usual l y
caused by an i nternal probl em. Veri fy i f the probl em i s onl y experi enced under
extreme hot or col d condi ti ons.
Wi th the DRBI I I ௡, check the EATX EVENT DATA to hel p i denti fy the condi ti ons i n
whi ch the DTC was set.
Were there any probl ems found?
Al l
Yes → Repai r as necessary.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Test Compl ete.
5 I f there are no possi bl e causes remai ni ng, vi ew repai r. Al l
Repai r
Repai r i nternal transmi ssi on probl em. Check al l of the compo-
nents rel ated to the Reverse and L/R cl utches. I nspect the Oi l
Pump per the Servi ce I nformati on and repai r or repl ace as
necessary.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
81
TRANSMISSION - 42RLE
P0736-GEAR RATIO ERROR IN REVERSE — Continued
Symptom:
P0740-TORQUE CONVERTER CLUTCH CONTROL CIRCUIT
When Monitored and Set Condition:
P0740-TORQUE CONVERTER CLUTCH CONTROL CIRCUIT
When Moni tored: Duri ng El ectroni cal l y Modul ated Converter Cl utch (EMCC) Operati on.
Set Condi ti on: A) Transmi ssi on must be i n EMCC, wi th i nput speed > than 1750 RPM.
TCC/L-R sol achi eves the maxi mum duty cycl e & can’t pul l engi ne RPM wi thi n 60 RPM of
i nput speed. B) Transmi ssi ons i s i n FEMCC & engi ne sl i ps TCC > than 100 RPM for 10
seconds.
POSSIBLE CAUSES
RELATED DTC’S PRESENT
I NTERNAL TRANSMI SSI ON
I NTERMI TTENT WI RI NG AND CONNECTORS
TEST ACTION APPLICABILITY
1 NOTE: Low fluid level can be the cause of many Transmission problems. If
the fluid level is low, locate and repair the leak, then check and adjust the
fluid level per the Service Information.
NOTE: Always perform diagnostics with a fully charged battery to avoid
false symptoms.
Wi th the DRBI I I ௡, read the engi ne DTC’s. Check and repai r al l engi ne DTC’s pri or
to performi ng Transmi ssi on Symptom Di agnosti cs.
Wi th the DRBI I I ௡, read Transmi ssi on DTC’s. Record al l DTC’s and 1 Tri p Fai l ures.
NOTE: Diagnose 1 Trip Failures as a fully matured DTC.
Usi ng the wi ri ng di agram/schemati c as a gui de, i nspect the wi ri ng and connectors.
Repai r as necessary.
Perform the Shi ft Lever Posi ti on Test. I f the test does not pass, refer to Symptom test
for P0706 Check Shi fter Si gnal .
For Gear Rati o DTC’s, check and record al l CVI ’s.
Most DTC’s set on start up but some must be set by dri vi ng the vehi cl e such that al l
di agnosti c moni tors have run.
NOTE: Verify flash level of Transmission Control Module. Some problems
are corrected by software upgrades to the Transmission Control Module.
NOTE: Check for applicable TSB’s related to the symptom.
Perform thi s procedure pri or to Symptom di agnosi s.
Al l
Conti nue
Go To 2
2 I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, read Transmi ssi on DTC’s
I s the DTC P0750 and/or P0841 present al so?
Al l
Yes → Refer to the Transmi ssi on category and perform the appropri ate
symptom.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 3
82
TRANSMISSION - 42RLE
TEST ACTION APPLICABILITY
3 I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, record and erase Transmi ssi on DTCs.
Dri ve the vehi cl e unti l i t i s ful l y warmed up to at l east 43° C or 110° F.
Perform the fol l owi ng steps 3 ti mes.
Wi th the DRBI I I ௡, moni tor TPS degree.
Dri ve the vehi cl e to the speed of 83 Km/h or 50 MPH and al l ow 4th gear to engage for
at l east 10 seconds.
Cl ose the throttl e, then ti p back i n unti l the throttl e angl e, TPS degrees, i s between
25 and 29 degrees.
NOTE: If you go over 30TPS degrees, you must back off of thethrottleand
retry.
Di d the TCC engage duri ng any of the attempts?
Al l
Yes → Go To 4
No → Go To 5
4 The condi ti ons necessary to set the DTC are not present at thi s ti me.
Usi ng the schemati cs as a gui de, i nspect the wi ri ng and connectors speci fi c to thi s
ci rcui t.
Wi ggl e the wi res whi l e checki ng for shorts and open ci rcui ts.
Thi s DTC can al so be set under extreme temperature condi ti ons, thi s i s usual l y
caused by an i nternal probl em. Veri fy i f the probl em i s onl y experi enced under
extreme hot or col d condi ti ons.
Wi th the DRBI I I ௡, check the EATX EVENT DATA to hel p i denti fy the condi ti ons i n
whi ch the DTC was set.
Were there any probl ems found?
Al l
Yes → Repai r as necessary.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Test Compl ete.
5 I f there are no possi bl e causes remai ni ng, vi ew repai r. Al l
Repai r
Perform the Hydraul i c Pressure test i n the Servi ce I nformati on.
Repai r the i nternal transmi ssi on components and torque conver-
tor per the Servi ce I nformati on.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
83
TRANSMISSION - 42RLE
P0740-TORQUE CONVERTER CLUTCH CONTROL CIRCUIT — Continued
Symptom:
P0750-LR SOLENOID CIRCUIT
When Monitored and Set Condition:
P0750-LR SOLENOID CIRCUIT
When Moni tored: I ni ti al l y at power-up, then every 10 seconds thereafter. The sol enoi ds
wi l l al so be tested i mmedi atel y after a Gear Rati o or Pressure Swi tch error i s detected.
Set Condi ti on: Three consecuti ve sol enoi d conti nui ty test fai l ures, or one fai l ure i f a test
i s run i n response to a Gear Rati o or Pressure Swi tch error.
POSSIBLE CAUSES
RELATED RELAY DTC’S PRESENT
TRANSMI SSI ON CONTROL RELAY OUTPUT CI RCUI T OPEN
L/R SOLENOI D CONTROL CI RCUI T OPEN
L/R SOLENOI D CONTROL CI RCUI T SHORT TO GROUND
L/R SOLENOI D CONTROL CI RCUI T SHORT TO VOLTAGE
L/R SOLENOI D
TRANSMI SSI ON CONTROL MODULE
I NTERMI TTENT WI RI NG AND CONNECTORS
TEST ACTION APPLICABILITY
1 NOTE: Low fluid level can be the cause of many Transmission problems. If
the fluid level is low, locate and repair the leak, then check and adjust the
fluid level per the Service Information.
NOTE: Always perform diagnostics with a fully charged battery to avoid
false symptoms.
Wi th the DRBI I I ௡, read the engi ne DTC’s. Check and repai r al l engi ne DTC’s pri or
to performi ng Transmi ssi on Symptom Di agnosti cs.
Wi th the DRBI I I ௡, read Transmi ssi on DTC’s. Record al l DTC’s and 1 Tri p Fai l ures.
NOTE: Diagnose 1 Trip Failures as a fully matured DTC.
Usi ng the wi ri ng di agram/schemati c as a gui de, i nspect the wi ri ng and connectors.
Repai r as necessary.
Perform the Shi ft Lever Posi ti on Test. I f the test does not pass, refer to Symptom test
for P0706 Check Shi fter Si gnal .
For Gear Rati o DTC’s, check and record al l CVI ’s.
Most DTC’s set on start up but some must be set by dri vi ng the vehi cl e such that al l
di agnosti c moni tors have run.
NOTE: Verify flash level of Transmission Control Module. Some problems
are corrected by software upgrades to the Transmission Control Module.
NOTE: Check for applicable TSB’s related to the symptom.
Perform thi s procedure pri or to Symptom di agnosi s.
Al l
Conti nue
Go To 2
84
TRANSMISSION - 42RLE
TEST ACTION APPLICABILITY
2 I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, read Transmi ssi on DTC’s
Are there any Transmi ssi on Control Rel ay DTC’s present?
Al l
Yes → Refer to symptom l i st and perform the appropri ate symptom for
Transmi ssi on Control Rel ay rel ated DTC’s.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 3
3 Wi th the DRBI I I ௡, Check the STARTS SI NCE SET counter for P0750.
NOTE: This counter only applies to the last DTC set.
I s the STARTS SI NCE SET counter for P0750 set at 0?
Al l
Yes → Go To 4
No → Go To 11
4 Turn the i gni ti on off to the l ock posi ti on.
CAUTION: Remove the Starter Relay from the PDC. This will prevent the
vehicle frombeing started in gear.
I nstal l the Transmi ssi on Si mul ator, Mi l l er tool #8333 and the El ectroni c Transmi s-
si on Adapter ki t 8333-1.
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, actuate the L/R Sol enoi d.
Wi th the Transmi ssi on Si mul ator, moni tor the L/R Sol enoi d LED.
Di d the L/R Sol enoi d LED on the Transmi ssi on Si mul ator bl i nk on and off duri ng
actuati on?
Al l
Yes → Go To 5
No → Go To 6
5 I f there are no possi bl e causes remai ni ng, vi ew repai r. Al l
Repai r
Repl ace the Transmi ssi on Sol enoi d/Pressure Swi tch Assembl y per
the Servi ce I nformati on.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
6 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the TCM harness connector.
Di sconnect the Transmi ssi on Sol enoi d/Pressure Swi tch Assembl y harness connector.
Measure the resi stance of the L/R Sol enoi d Control ci rcui t from the TCM harness
connector to the Transmi ssi on Sol enoi d/Pressure Swi tch Assembl y harness connec-
tor.
I s the resi stance above 5.0 ohms?
Al l
Yes → Repai r the L/R Sol enoi d Control ci rcui t for an open.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 7
85
TRANSMISSION - 42RLE
P0750-LR SOLENOID CIRCUIT — Continued
TEST ACTION APPLICABILITY
7 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the TCM harness connector.
Di sconnect the Transmi ssi on Sol enoi d/Pressure Swi tch Assembl y harness connector.
Measure the resi stance between ground and the L/R Sol enoi d Control ci rcui t.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Repai r the L/R Sol enoi d Control ci rcui t for a short to ground.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 8
8 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the TCM harness connector.
Di sconnect the Transmi ssi on Sol enoi d/Pressure Swi tch Assembl y harness connector.
Remove the Transmi ssi on Control Rel ay from the PDC.
Note: Check connectors - Clean/repair as necessary.
Connect a jumper wi re between the Fused B+ ci rcui t and the Transmi ssi on Control
Rel ay Output ci rcui t i n the Transmi ssi on Control Rel ay connector i n the PDC.
I gni ti on on, engi ne not runni ng.
Measure the vol tage of the L/R Sol enoi d Control ci rcui t.
I s the vol tage above 0.5 vol t?
Al l
Yes → Repai r the L/R Sol enoi d Control ci rcui t for a short to vol tage.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 9
9 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the Transmi ssi on Sol enoi d/Pressure Swi tch Assembl y harness connector.
Remove the Transmi ssi on Control Rel ay from the PDC.
Note: Check connectors - Clean/repair as necessary.
Connect a jumper wi re between the Fused B+ ci rcui t and the Transmi ssi on Control
Rel ay Output ci rcui t i n the Transmi ssi on Control Rel ay connector i n the PDC.
I gni ti on on, engi ne not runni ng.
Usi ng a 12-vol t test l i ght connected to ground, check the Transmi ssi on Control Rel ay
Output ci rcui t.
NOTE: The test light must illuminate brightly. Compare the brightness to
that of a direct connection to the battery.
Does the test l i ght i l l umi nate bri ghtl y?
Al l
Yes → Go To 10
No → Repai r the Transmi ssi on Control Rel ay Output ci rcui t for an open
or hi gh resi stance.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
10 Usi ng the schemati cs as a gui de, i nspect the wi ri ng and connectors. Repai r as
necessary. Pay parti cul ar attenti on to al l power and ground ci rcui ts.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace the Transmi ssi on Control Modul e per the Servi ce I nfor-
mati on. WI TH THE DRBI I I ௡ PERFORM QUI CK LEARN.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
86
TRANSMISSION - 42RLE
P0750-LR SOLENOID CIRCUIT — Continued
TEST ACTION APPLICABILITY
11 The condi ti ons necessary to set thi s DTC are not present at thi s ti me.
Usi ng the schemati cs as a gui de, i nspect the wi ri ng and connectors speci fi c to thi s
ci rcui t.
Wi ggl e the wi ri ng whi l e checki ng for shorts and open ci rcui ts.
Wi th the DRBI I I ௡, check the EATX EVENT DATA to hel p i denti fy the condi ti ons i n
whi ch the DTC was set.
Were there any probl ems found?
Al l
Yes → Repai r as necessary.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Test Compl ete.
87
TRANSMISSION - 42RLE
P0750-LR SOLENOID CIRCUIT — Continued
Symptom:
P0755-2/4 SOLENOID CIRCUIT
When Monitored and Set Condition:
P0755-2/4 SOLENOID CIRCUIT
When Moni tored: I ni ti al l y at power-up, then every 10 seconds thereafter. They wi l l al so
be tested i mmedi atel y after a Gear Rati o or Pressure Swi tch error i s detected.
Set Condi ti on: Three consecuti ve Sol enoi d conti nui ty test fai l ures, or one fai l ure i f test i s
run i n response to a Gear Rati o or Pressure Swi tch error.
POSSIBLE CAUSES
RELATED RELAY DTC’S PRESENT
TRANSMI SSI ON CONTROL RELAY OUTPUT CI RCUI T OPEN
2/4 SOLENOI D CONTROL CI RCUI T OPEN
2/4 SOLENOI D CONTROL CI RCUI T SHORT TO GROUND
2/4 SOLENOI D CONTROL CI RCUI T SHORT TO VOLTAGE
2/4 SOLENOI D
TRANSMI SSI ON CONTROL MODULE
I NTERMI TTENT WI RI NG AND CONNECTORS
TEST ACTION APPLICABILITY
1 NOTE: Low fluid level can be the cause of many Transmission problems. If
the fluid level is low, locate and repair the leak, then check and adjust the
fluid level per the Service Information.
NOTE: Always perform diagnostics with a fully charged battery to avoid
false symptoms.
Wi th the DRBI I I ௡, read the engi ne DTC’s. Check and repai r al l engi ne DTC’s pri or
to performi ng Transmi ssi on Symptom Di agnosti cs.
Wi th the DRBI I I ௡, read Transmi ssi on DTC’s. Record al l DTC’s and 1 Tri p Fai l ures.
NOTE: Diagnose 1 Trip Failures as a fully matured DTC.
Usi ng the wi ri ng di agram/schemati c as a gui de, i nspect the wi ri ng and connectors.
Repai r as necessary.
Perform the Shi ft Lever Posi ti on Test. I f the test does not pass, refer to Symptom test
for P0706 Check Shi fter Si gnal .
For Gear Rati o DTC’s, check and record al l CVI ’s.
Most DTC’s set on start up but some must be set by dri vi ng the vehi cl e such that al l
di agnosti c moni tors have run.
NOTE: Verify flash level of Transmission Control Module. Some problems
are corrected by software upgrades to the Transmission Control Module.
NOTE: Check for applicable TSB’s related to the symptom.
Perform thi s procedure pri or to Symptom di agnosi s.
Al l
Conti nue
Go To 2
88
TRANSMISSION - 42RLE
TEST ACTION APPLICABILITY
2 Wi th the DRBI I I ௡, read Transmi ssi on Control Modul e DTC’s
Are there any Transmi ssi on Control Rel ay DTC’s present?.
Al l
Yes → Refer to symptom l i st and perform the appropri ate symptom for
Transmi ssi on Control Rel ay rel ated DTC’s.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 3
3 Wi th the DRBI I I ௡, Check the STARTS SI NCE SET counter.
NOTE: This counter only applies to the last DTC set.
I s the STARTS SI NCE SET counter for P0755 set at 0?
Al l
Yes → Go To 4
No → Go To 11
4 Turn the i gni ti on off to the l ock posi ti on.
CAUTION: Remove the Starter Relay from the PDC. This will prevent the
vehicle frombeing started in gear.
I nstal l the Transmi ssi on Si mul ator, Mi l l er tool #8333 and the El ectroni c Transmi s-
si on Adapter ki t 8333-1.
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, actuate the 2/4 Sol enoi d.
Wi th the Transmi ssi on Si mul ator, moni tor the 2/4 Sol enoi d LED.
Di d the 2/4 Sol enoi d LED on the Transmi ssi on Si mul ator bl i nk on and off duri ng
actuati on?
Al l
Yes → Go To 5
No → Go To 6
5 I f there are no possi bl e causes remai ni ng, vi ew repai r. Al l
Repai r
Repl ace the Transmi ssi on Sol enoi d/Pressure Swi tch Assembl y per
the Servi ce I nformati on.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
6 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the TCM harness connector.
Di sconnect the Transmi ssi on Sol enoi d/Pressure Swi tch Assembl y harness connector.
Note: Check connectors - Clean/repair as necessary.
Measure the resi stance of the 2/4 Sol enoi d Control ci rcui t from the TCM harness
connector to the Transmi ssi on Sol enoi d/Pressure Swi tch Assembl y harness connec-
tor.
I s the resi stance above 5.0 ohms?
Al l
Yes → Repai r the 2/4 Sol enoi d Control ci rcui t for an open.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 7
89
TRANSMISSION - 42RLE
P0755-2/4 SOLENOID CIRCUIT — Continued
TEST ACTION APPLICABILITY
7 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the TCM harness connector.
Di sconnect the Transmi ssi on Sol enoi d/Pressure Swi tch Assembl y harness connector.
Note: Check connectors - Clean/repair as necessary.
Measure the resi stance between ground and the 2/4 Sol enoi d Control ci rcui t.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Repai r the 2/4 Sol enoi d Control ci rcui t for a short to ground.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 8
8 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the TCM harness connector.
Di sconnect the Transmi ssi on Sol enoi d/Pressure Swi tch Assembl y harness connector.
Remove the Transmi ssi on Control Rel ay from the PDC.
Note: Check connectors - Clean/repair as necessary.
Connect a jumper wi re between the Fused B+ci rcui t and Transmi ssi on Control Rel ay
Output ci rcui t i n the Transmi ssi on Control Rel ay connector i n the PDC.
I gni ti on on, engi ne not runni ng.
Measure the vol tage of the 2/4 Sol enoi d Control ci rcui t.
I s the vol tage above 0.5 vol t?
Al l
Yes → Repai r the 2/4 Sol enoi d Control ci rcui t for a short to vol tage.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 9
9 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the Transmi ssi on Sol enoi d/Pressure Swi tch Assembl y harness connector.
Remove the Transmi ssi on Control Rel ay from the PDC.
Note: Check connectors - Clean/repair as necessary.
Connect a jumper wi re between the Fused B+ ci rcui t and the Transmi ssi on Control
Rel ay Output ci rcui t i n the Transmi ssi on Control Rel ay connector.
I gni ti on on, engi ne not runni ng.
Usi ng a 12-vol t test l i ght connected to ground, check the Transmi ssi on Control Rel ay
Output ci rcui t.
NOTE: The test light must illuminate brightly. Compare the brightness to
that of a direct connection to the battery.
Does the test l i ght i l l umi nate bri ghtl y?
Al l
Yes → Go To 10
No → Repai r the Transmi ssi on Control Rel ay Output ci rcui t for an open
or hi gh resi stance.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
10 Usi ng the schemati cs as a gui de, i nspect the wi ri ng and connectors. Repai r as
necessary. Pay parti cul ar attenti on to al l power and ground ci rcui ts.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace the Transmi ssi on Control Modul e per the Servi ce I nfor-
mati on. WI TH THE DRBI I I ௡ PERFORM QUI CK LEARN.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
90
TRANSMISSION - 42RLE
P0755-2/4 SOLENOID CIRCUIT — Continued
TEST ACTION APPLICABILITY
11 The condi ti ons necessary to set thi s DTC are not present at thi s ti me.
Usi ng the schemati cs as a gui de, i nspect the wi ri ng and connectors speci fi c to thi s
ci rcui t.
Wi ggl e the wi ri ng whi l e checki ng for shorts and open ci rcui ts.
Wi th the DRBI I I ௡, check the EATX EVENT DATA to hel p i denti fy the condi ti ons i n
whi ch the DTC was set.
Were there any probl ems found?
Al l
Yes → Repai r as necessary.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Test Compl ete.
91
TRANSMISSION - 42RLE
P0755-2/4 SOLENOID CIRCUIT — Continued
Symptom:
P0760-OD SOLENOID CIRCUIT
When Monitored and Set Condition:
P0760-OD SOLENOID CIRCUIT
When Moni tored: I ni ti al l y at power-up, then every 10 seconds thereafter. They wi l l al so
be tested i mmedi atel y after a Gear Rati o or Pressure Swi tch error i s detected.
Set Condi ti on: Three consecuti ve sol enoi d conti nui ty test fai l ures, or one fai l ure i f test i s
run i n response to a Gear Rati o or Pressure Swi tch error.
POSSIBLE CAUSES
RELATED RELAY DTC’S PRESENT
I NTERMI TTENT WI RI NG AND CONNECTORS
TRANSMI SSI ON CONTROL RELAY OUTPUT CI RCUI T OPEN
OD SOLENOI D CONTROL CI RCUI T OPEN
OD SOLENOI D CONTROL CI RCUI T SHORT TO GROUND
OD SOLENOI D CONTROL CI RCUI T SHORT TO VOLTAGE
OD SOLENOI D
TRANSMI SSI ON CONTROL MODULE
TEST ACTION APPLICABILITY
1 NOTE: Low fluid level can be the cause of many Transmission problems. If
the fluid level is low, locate and repair the leak, then check and adjust the
fluid level per the Service Information.
NOTE: Always perform diagnostics with a fully charged battery to avoid
false symptoms.
Wi th the DRBI I I ௡, read the engi ne DTC’s. Check and repai r al l engi ne DTC’s pri or
to performi ng Transmi ssi on Symptom Di agnosti cs.
Wi th the DRBI I I ௡, read Transmi ssi on DTC’s. Record al l DTC’s and 1 Tri p Fai l ures.
NOTE: Diagnose 1 Trip Failures as a fully matured DTC.
Usi ng the wi ri ng di agram/schemati c as a gui de, i nspect the wi ri ng and connectors.
Repai r as necessary.
Perform the Shi ft Lever Posi ti on Test. I f the test does not pass, refer to Symptom test
for P0706 Check Shi fter Si gnal .
For Gear Rati o DTC’s, check and record al l CVI ’s.
Most DTC’s set on start up but some must be set by dri vi ng the vehi cl e such that al l
di agnosti c moni tors have run.
NOTE: Verify flash level of Transmission Control Module. Some problems
are corrected by software upgrades to the Transmission Control Module.
NOTE: Check for applicable TSB’s related to the symptom.
Perform thi s procedure pri or to Symptom di agnosi s.
Al l
Conti nue
Go To 2
92
TRANSMISSION - 42RLE
TEST ACTION APPLICABILITY
2 Wi th the DRBI I I ௡, read Transmi ssi on Control Modul e DTC’s
Are there any Transmi ssi on Control Rel ay DTC’s present?
Al l
Yes → Refer to the Transmi ssi on category and perform the appropri ate
symptom.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 3
3 Wi th the DRBI I I ௡, Check the STARTS SI NCE SET counter for P0760.
NOTE: This counter only applies to the last DTC set.
I s the STARTS SI NCE SET counter for P0760 set at 0?
Al l
Yes → Go To 4
No → Go To 11
4 Turn the i gni ti on off to the l ock posi ti on.
CAUTION: Remove the Starter Relay from the PDC. This will prevent the
vehicle frombeing started in gear.
I nstal l the Transmi ssi on Si mul ator, Mi l l er tool #8333 and the El ectroni c Transmi s-
si on Adapter ki t 8333-1.
I gni ti on on, engi ne not runni ng.
Wi th the Transmi ssi on Si mul ator, moni tor the OD Sol enoi d LED.
Wi th the DRBI I I ௡, actuate the OD Sol enoi d.
Di d the OD Sol enoi d LED on the Transmi ssi on Si mul ator bl i nk on and off duri ng
actuati on?
Al l
Yes → Go To 5
No → Go To 6
5 I f there are no possi bl e causes remai ni ng, vi ew repai r. Al l
Repai r
Repl ace the Transmi ssi on Sol enoi d/Pressure Swi tch Assembl y per
the Servi ce I nformati on.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
6 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the TCM harness connector.
Di sconnect the Transmi ssi on Sol enoi d/Pressure Swi tch Assembl y harness connector.
Note: Check connectors - Clean/repair as necessary.
Measure the resi stance of the OD Sol enoi d Control ci rcui t from the TCM harness
connector to the Transmi ssi on Sol enoi d/Pressure Swi tch Assembl y harness connec-
tor.
I s the resi stance above 5.0 ohms?
Al l
Yes → Repai r the OD Sol enoi d Control ci rcui t for an open.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 7
93
TRANSMISSION - 42RLE
P0760-OD SOLENOID CIRCUIT — Continued
TEST ACTION APPLICABILITY
7 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the TCM harness connector.
Di sconnect the Transmi ssi on Sol enoi d/Pressure Swi tch Assembl y harness connector.
Note: Check connectors - Clean/repair as necessary.
Measure the resi stance between ground and the OD Sol enoi d Control ci rcui t.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Repai r the OD Sol enoi d Control ci rcui t for a short to ground.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 8
8 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the TCM harness connector.
Di sconnect the Transmi ssi on Sol enoi d/Pressure Swi tch Assembl y harness connector.
Remove the Transmi ssi on Control Rel ay from the PDC.
Note: Check connectors - Clean/repair as necessary.
Connect a jumper wi re between the Fused B+ ci rcui t and the Transmi ssi on Control
Rel ay Output ci rcui t i n the Transmi ssi on Control Rel ay connector i n the PDC.
I gni ti on on, engi ne not runni ng.
Measure the vol tage of the OD Sol enoi d Control ci rcui t.
I s the vol tage above 0.5 vol t?
Al l
Yes → Repai r the OD Sol enoi d Control ci rcui t for a short to vol tage.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 9
9 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the Transmi ssi on Sol enoi d/Pressure Swi tch Assembl y harness connector.
Remove the Transmi ssi on Control Rel ay from the PDC.
Note: Check connectors - Clean/repair as necessary.
Connect a jumper wi re between the Fused B+ ci rcui t and the Transmi ssi on Control
Rel ay Output ci rcui t i n the Transmi ssi on Control Rel ay connector i n the PDC.
I gni ti on on, engi ne not runni ng.
Usi ng a 12-vol t test l i ght connected to ground, check the Transmi ssi on Control Rel ay
Output ci rcui t.
NOTE: The test light must illuminate brightly. Compare the brightness to
that of a direct connection to the battery.
Does the test l i ght i l l umi nate bri ghtl y?
Al l
Yes → Go To 10
No → Repai r the Transmi ssi on Control Rel ay Output ci rcui t for an open
or hi gh resi stance.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
10 Usi ng the schemati cs as a gui de, i nspect the wi ri ng and connectors. Repai r as
necessary. Pay parti cul ar attenti on to al l power and ground ci rcui ts.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace the Transmi ssi on Control Modul e per the Servi ce I nfor-
mati on. WI TH THE DRBI I I ௡ PERFORM QUI CK LEARN.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
94
TRANSMISSION - 42RLE
P0760-OD SOLENOID CIRCUIT — Continued
TEST ACTION APPLICABILITY
11 The condi ti ons necessary to set thi s DTC are not present at thi s ti me.
Usi ng the schemati cs as a gui de, i nspect the wi ri ng and connectors speci fi c to thi s
ci rcui t.
Wi ggl e the wi ri ng whi l e checki ng for shorts and open ci rcui ts.
Wi th the DRBI I I ௡, check the EATX EVENT DATA to hel p i denti fy the condi ti ons i n
whi ch the DTC was set.
Were there any probl ems found?
Al l
Yes → Repai r as necessary.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Test Compl ete.
95
TRANSMISSION - 42RLE
P0760-OD SOLENOID CIRCUIT — Continued
Symptom:
P0765-UD SOLENOID CIRCUIT
When Monitored and Set Condition:
P0765-UD SOLENOID CIRCUIT
When Moni tored: I ni ti al l y at power-up, then every 10 seconds thereafter. They wi l l al so
be tested i mmedi atel y after a Gear Rati o or Pressure Swi tch error i s detected.
Set Condi ti on: Three consecuti ve Sol enoi d conti nui ty test fai l ures, or one fai l ure i f test i s
run i n response to a Gear Rati o or Pressure Swi tch error.
POSSIBLE CAUSES
RELATED RELAY DTC’S PRESENT
TRANSMI SSI ON CONTROL RELAY OUTPUT CI RCUI T OPEN
UD SOLENOI D CONTROL CI RCUI T OPEN
UD SOLENOI D CONTROL CI RCUI T SHORT TO GROUND
UD SOLENOI D CONTROL CI RCUI T SHORT TO VOLTAGE
UD SOLENOI D
TRANSMI SSI ON CONTROL MODULE
I NTERMI TTENT WI RI NG AND CONNECTORS
TEST ACTION APPLICABILITY
1 NOTE: Low fluid level can be the cause of many Transmission problems. If
the fluid level is low, locate and repair the leak, then check and adjust the
fluid level per the Service Information.
NOTE: Always perform diagnostics with a fully charged battery to avoid
false symptoms.
Wi th the DRBI I I ௡, read the engi ne DTC’s. Check and repai r al l engi ne DTC’s pri or
to performi ng Transmi ssi on Symptom Di agnosti cs.
Wi th the DRBI I I ௡, read Transmi ssi on DTC’s. Record al l DTC’s and 1 Tri p Fai l ures.
NOTE: Diagnose 1 Trip Failures as a fully matured DTC.
Usi ng the wi ri ng di agram/schemati c as a gui de, i nspect the wi ri ng and connectors.
Repai r as necessary.
Perform the Shi ft Lever Posi ti on Test. I f the test does not pass, refer to Symptom test
for P0706 Check Shi fter Si gnal .
For Gear Rati o DTC’s, check and record al l CVI ’s.
Most DTC’s set on start up but some must be set by dri vi ng the vehi cl e such that al l
di agnosti c moni tors have run.
NOTE: Verify flash level of Transmission Control Module. Some problems
are corrected by software upgrades to the Transmission Control Module.
NOTE: Check for applicable TSB’s related to the symptom.
Perform thi s procedure pri or to Symptom di agnosi s.
Al l
Conti nue
Go To 2
96
TRANSMISSION - 42RLE
TEST ACTION APPLICABILITY
2 Wi th the DRBI I I ௡, read Transmi ssi on Control Modul e DTC’s
Are there any Transmi ssi on Control Rel ay DTC’s present?
Al l
Yes → Refer to the Transmi ssi on category and perform the appropri ate
symptom.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 3
3 Wi th the DRBI I I ௡, Check the STARTS SI NCE SET counter.
NOTE: This counter only applies to the last DTC set.
I s the STARTS SI NCE SET counter for P0765 set at 0?
Al l
Yes → Go To 4
No → Go To 11
4 Turn the i gni ti on off to the l ock posi ti on.
CAUTION: Remove the Starter Relay from the PDC. This will prevent the
vehicle frombeing started in gear.
I nstal l the Transmi ssi on Si mul ator, Mi l l er tool #8333 and the El ectroni c Transmi s-
si on Adapter ki t 8333-1.
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, actuate the UD Sol enoi d.
Wi th the Transmi ssi on Si mul ator, moni tor the UD Sol enoi d LED.
Di d the UD Sol enoi d LED on the Transmi ssi on Si mul ator bl i nk on and off?
Al l
Yes → Go To 5
No → Go To 6
5 I f there are no possi bl e causes remai ni ng, vi ew repai r. Al l
Repai r
Repl ace Transmi ssi on Sol enoi d/Pressure Swi tch Assembl y per the
Servi ce I nformati on.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
6 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the TCM harness connector.
Di sconnect the Transmi ssi on Sol enoi d/Pressure Swi tch Assembl y harness connector.
Note: Check connectors - Clean/repair as necessary.
Measure the resi stance of the UD Sol enoi d Control ci rcui t from the TCM harness
connector to the Transmi ssi on Sol enoi d/Pressure Swi tch Assembl y harness connec-
tor.
I s the resi stance above 5.0 ohms?
Al l
Yes → Repai r the UD Sol enoi d Control ci rcui t for an open.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 7
97
TRANSMISSION - 42RLE
P0765-UD SOLENOID CIRCUIT — Continued
TEST ACTION APPLICABILITY
7 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the TCM harness connector.
Di sconnect the Transmi ssi on Sol enoi d/Pressure Swi tch Assembl y harness connector.
Note: Check connectors - Clean/repair as necessary.
Measure the resi stance between ground and the UD Sol enoi d Control ci rcui t.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Repai r the UD Sol enoi d Control ci rcui t for a short to ground.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 8
8 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the TCM harness connector.
Di sconnect the Transmi ssi on Sol enoi d/Pressure Swi tch Assembl y harness connector.
Remove the Transmi ssi on Control Rel ay from the PDC.
Connect a jumper wi re between the Fused B+ ci rcui ts and Transmi ssi on Control
Rel ay Output ci rcui t i n the Transmi ssi on Control Rel ay connector.
I gni ti on on, engi ne not runni ng.
Note: Check connectors - Clean/repair as necessary.
Measure the vol tage of the UD Sol enoi d Control ci rcui t.
I s the vol tage above 0.5 vol t?
Al l
Yes → Repai r the UD Sol enoi d Control ci rcui t for a short to vol tage.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 9
9 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the Transmi ssi on Sol enoi d/Pressure Swi tch Assembl y harness connector.
Remove the Transmi ssi on Control Rel ay.
Note: Check connectors - Clean/repair as necessary.
Connect a jumper wi re between the Fused B+ci rcui t and Transmi ssi on Control Rel ay
Output ci rcui t i n the Transmi ssi on Control Rel ay connector.
I gni ti on on, engi ne not runni ng.
Usi ng a 12-vol t test l i ght connected to ground, check the Transmi ssi on Control Rel ay
Output ci rcui t.
NOTE: The test light must illuminate brightly. Compare the brightness to
that of a direct connection to the battery.
Does the test l i ght i l l umi nate bri ghtl y?
Al l
Yes → Go To 10
No → Repai r the Transmi ssi on Control Rel ay Output ci rcui t for an open
or hi gh resi stance.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
10 Usi ng the schemati cs as a gui de, i nspect the wi ri ng and connectors. Repai r as
necessary. Pay parti cul ar attenti on to al l power and ground ci rcui ts.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace the Transmi ssi on Control Modul e per the Servi ce I nfor-
mati on. WI TH THE DRBI I I ௡ PERFORM QUI CK LEARN.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
98
TRANSMISSION - 42RLE
P0765-UD SOLENOID CIRCUIT — Continued
TEST ACTION APPLICABILITY
11 The condi ti ons necessary to set thi s DTC are not present at thi s ti me.
Usi ng the schemati cs as a gui de, i nspect the wi ri ng and connectors speci fi c to thi s
ci rcui t.
Wi ggl e the wi ri ng whi l e checki ng for shorts and open ci rcui ts.
Wi th the DRBI I I ௡, check the EATX EVENT DATA to hel p i denti fy the condi ti ons i n
whi ch the DTC was set.
Were there any probl ems found?
Al l
Yes → Repai r as necessary.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Test Compl ete.
99
TRANSMISSION - 42RLE
P0765-UD SOLENOID CIRCUIT — Continued
Symptom:
P0841-LR PRESSURE SWITCH SENSE CIRCUIT
When Monitored and Set Condition:
P0841-LR PRESSURE SWITCH SENSE CIRCUIT
When Moni tored: Whenever the engi ne i s runni ng.
Set Condi ti on: The appropri ate DTC i s set i f one of the Pressure Swi tches are open or
cl osed at the wrong ti me i n a gi ven gear .
POSSIBLE CAUSES
LOSS OF PRI ME DTC P0944 PRESENT
TRANSMI SSI ON CONTROL RELAY DTCS PRESENT
TCM AND WI RI NG
TRANSMI SSI ON CONTROL RELAY OUTPUT CI RCUI T OPEN
L/R PRESSURE SWI TCH SENSE CI RCUI T OPEN
L/R PRESSURE SWI TCH SENSE CI RCUI T SHORT TO GROUND
L/R PRESSURE SWI TCH SENSE CI RCUI T SHORT TO VOLTAGE
TRANSMI SSI ON CONTROL MODULE
I NTERMI TTENT WI RI NG AND CONNECTORS
TEST ACTION APPLICABILITY
1 NOTE: Low fluid level can be the cause of many Transmission problems. If
the fluid level is low, locate and repair the leak, then check and adjust the
fluid level per the Service Information.
NOTE: Always perform diagnostics with a fully charged battery to avoid
false symptoms.
Wi th the DRBI I I ௡, read the engi ne DTC’s. Check and repai r al l engi ne DTC’s pri or
to performi ng Transmi ssi on Symptom Di agnosti cs.
Wi th the DRBI I I ௡, read Transmi ssi on DTC’s. Record al l DTC’s and 1 Tri p Fai l ures.
NOTE: Diagnose 1 Trip Failures as a fully matured DTC.
Usi ng the wi ri ng di agram/schemati c as a gui de, i nspect the wi ri ng and connectors.
Repai r as necessary.
Perform the Shi ft Lever Posi ti on Test. I f the test does not pass, refer to Symptom test
for P0706 Check Shi fter Si gnal .
For Gear Rati o DTC’s, check and record al l CVI ’s.
Most DTC’s set on start up but some must be set by dri vi ng the vehi cl e such that al l
di agnosti c moni tors have run.
NOTE: Verify flash level of Transmission Control Module. Some problems
are corrected by software upgrades to the Transmission Control Module.
NOTE: Check for applicable TSB’s related to the symptom.
Perform thi s procedure pri or to Symptom di agnosi s.
Al l
Conti nue
Go To 2
100
TRANSMISSION - 42RLE
TEST ACTION APPLICABILITY
2 Wi th the DRBI I I ௡, check for other Transmi ssi on DTC’s.
I s the DTC P0944 present al so?
Al l
Yes → Refer to the Transmi ssi on category and perform the appropri ate
symptom.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 3
3 Wi th the DRBI I I ௡, read Transmi ssi on DTC’s
Are there any Transmi ssi on Control Rel ay DTC’s present al so?
Al l
Yes → Refer to the Transmi ssi on category and perform the appropri ate
symptom.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 4
4 Wi th the DRBI I I ௡, Check the STARTS SI NCE SET counter for P0841.
NOTE: This counter only applies to the last DTC set.
I s the STARTS SI NCE SET counter 2 or l ess?
Al l
Yes → Go To 5
No → Go To 11
5 Turn the i gni ti on off to the l ock posi ti on.
CAUTION: Remove the Starter Relay from the PDC. This will prevent the
vehicle frombeing started in gear.
I nstal l the Transmi ssi on Si mul ator, Mi l l er tool #8333 and the El ectroni c Transmi s-
si on Adapter ki t 8333-1.
Note: Check connectors - Clean/repair as necessary.
I gni ti on on, engi ne not runni ng.
On the Transmi ssi on Si mul ator sel ect L/R on the Pressure Swi tch sel ector swi tch.
Wi th the DRBI I I ௡, moni tor the L/R Pressure Swi tch state whi l e pressi ng the
Pressure Swi tch Test button on the Transmi ssi on Si mul ator.
Di d the Pressure Swi tch state change from OPEN to CLOSED when the test button
was pressed?
Al l
Yes → Repl ace the Transmi ssi on Sol enoi d/Pressure Swi tch Assembl y per
the Servi ce I nformati on.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 6
6 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the TCM harness connector.
Di sconnect the Transmi ssi on Sol enoi d/Pressure Swi tch Assembl y harness connector.
Note: Check connectors - Clean/repair as necessary.
Measure the resi stance of the L/R Pressure Swi tch Sense ci rcui t from the TCM
harness connector to the Transmi ssi on Sol enoi d/Pressure Swi tch Assembl y harness
connector.
I s the resi stance above 5.0 ohms?
Al l
Yes → Repai r the L/R Pressure Swi tch Sense ci rcui t for an open.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 7
101
TRANSMISSION - 42RLE
P0841-LR PRESSURE SWITCH SENSE CIRCUIT — Continued
TEST ACTION APPLICABILITY
7 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the TCM harness connector.
Di sconnect the Transmi ssi on Sol enoi d/Pressure Swi tch Assembl y harness connector.
Note: Check connectors - Clean/repair as necessary.
Measure the resi stance between ground and the L/R Pressure Swi tch Sense ci rcui t.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Repai r the L/R Pressure Swi tch ci rcui t for a short to ground.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 8
8 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the TCM harness connector.
Di sconnect the Transmi ssi on Sol enoi d/Pressure Swi tch Assembl y harness connector.
Remove the Transmi ssi on Control Rel ay from the PDC.
Note: Check connectors - Clean/repair as necessary.
Connect a jumper wi re between the Fused B+ci rcui t and Transmi ssi on Control Rel ay
Output ci rcui t i n the Transmi ssi on Control Rel ay connector.
I gni ti on on, engi ne not runni ng.
Measure the vol tage of the L/R Pressure Swi tch Sense ci rcui t.
I s the vol tage above 0.5 vol t?
Al l
Yes → Repai r the L/R Pressure Swi tch Sense ci rcui t for a short to
vol tage.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 9
9 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the Transmi ssi on Sol enoi d/Pressure Swi tch Assembl y harness connector.
Remove the Transmi ssi on Control Rel ay from the PDC.
Note: Check connectors - Clean/repair as necessary.
Connect a jumper wi re between the Fused B+ci rcui t and Transmi ssi on Control Rel ay
Output ci rcui t i n the Transmi ssi on Control Rel ay connector.
Usi ng a 12-vol t test l i ght connected to ground, check the Transmi ssi on Control Rel ay
Output ci rcui t i n the Sol enoi d/Pressure Swi tch Assembl y harness connector.
NOTE: The test light must illuminate brightly. Compare the brightness to
that of a direct connection to the battery.
Does the test l i ght i l l umi nate bri ghtl y?
Al l
Yes → Go To 10
No → Repai r the Transmi ssi on Control Rel ay Output ci rcui t for an open
or hi gh resi stance. I f the fuse i s open make sure to check for a
short to ground.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
10 Usi ng the schemati cs as a gui de, i nspect the wi ri ng and connectors. Repai r as
necessary. Pay parti cul ar attenti on to al l power and ground ci rcui ts.
I f there are no possi bl e causes remai ni ng, vi ew repai r
Al l
Repai r
Repl ace the Transmi ssi on Control Modul e per the Servi ce I nfor-
mati on. WI TH THE DRBI I I ௡ PERFORM QUI CK LEARN.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
102
TRANSMISSION - 42RLE
P0841-LR PRESSURE SWITCH SENSE CIRCUIT — Continued
TEST ACTION APPLICABILITY
11 The condi ti ons necessary to set thi s DTC are not present at thi s ti me.
Usi ng the schemati cs as a gui de, i nspect the wi ri ng and connectors speci fi c to thi s
ci rcui t.
Wi ggl e the wi ri ng whi l e checki ng for shorts and open ci rcui ts.
Wi th the DRBI I I ௡, check the EATX EVENT DATA to hel p i denti fy the condi ti ons i n
whi ch the DTC was set.
Were there any probl ems found?
Al l
Yes → Repai r as necessary.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Test Compl ete.
103
TRANSMISSION - 42RLE
P0841-LR PRESSURE SWITCH SENSE CIRCUIT — Continued
Symptom:
P0845-2/4 HYDRAULIC PRESSURE TEST FAILURE
When Monitored and Set Condition:
P0845-2/4 HYDRAULIC PRESSURE TEST FAILURE
When Moni tored: I n any forward gear wi th engi ne speed above 1000 RPM shortl y after
a shi ft and every mi nute thereafter.
Set Condi ti on: After a shi ft i nto a forward gear, wi th engi ne speed > 1000 RPM, the TCM
momentari l y turns on el ement pressure to the cl utch ckts that don’t have pressure to
i denti fy the correct pressure sw cl oses. I f the pressure sw does not cl ose 2 ti mes the code
sets.
POSSIBLE CAUSES
LOSS OF PRI ME P0944 PRESENT
RELATED DTC’S PRESENT
TRANSMI SSI ON CONTROL RELAY OUTPUT CI RCUI T OPEN
2/4 PRESSURE SWI TCH SENSE CI RCUI T OPEN
2/4 PRESSURE SWI TCH SENSE CI RCUI T SHORT TO GROUND
2/4 PRESSURE SWI TCH SENSE CI RCUI T SHORT TO VOLTAGE
I NTERNAL TRANSMI SSI ON
TRANSMI SSI ON CONTROL MODULE
I NTERMI TTENT WI RI NG AND CONNECTORS
104
TRANSMISSION - 42RLE
TEST ACTION APPLICABILITY
1 NOTE: Low fluid level can be the cause of many Transmission problems. If
the fluid level is low, locate and repair the leak, then check and adjust the
fluid level per the Service Information.
NOTE: Always perform diagnostics with a fully charged battery to avoid
false symptoms.
Wi th the DRBI I I ௡, read the engi ne DTC’s. Check and repai r al l engi ne DTC’s pri or
to performi ng Transmi ssi on Symptom Di agnosti cs.
Wi th the DRBI I I ௡, read Transmi ssi on DTC’s. Record al l DTC’s and 1 Tri p Fai l ures.
NOTE: Diagnose 1 Trip Failures as a fully matured DTC.
Usi ng the wi ri ng di agram/schemati c as a gui de, i nspect the wi ri ng and connectors.
Repai r as necessary.
Perform the Shi ft Lever Posi ti on Test. I f the test does not pass, refer to Symptom test
for P0706 Check Shi fter Si gnal .
For Gear Rati o DTC’s, check and record al l CVI ’s.
Most DTC’s set on start up but some must be set by dri vi ng the vehi cl e such that al l
di agnosti c moni tors have run.
NOTE: Verify flash level of Transmission Control Module. Some problems
are corrected by software upgrades to the Transmission Control Module.
NOTE: Check for applicable TSB’s related to the symptom.
Perform thi s procedure pri or to Symptom di agnosi s.
Al l
Conti nue
Go To 2
2 Wi th the DRBI I I ௡, check for other Transmi ssi on DTCs.
I s the DTC P0944 present al so?
Al l
Yes → Refer to the Transmi ssi on category and perform the appropri ate
symptom.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 3
3 Wi th the DRBI I I ௡, read Transmi ssi on DTC’s.
I s the DTC P0732, P0734 and/or P0846 present al so?
Al l
Yes → Repai r i nternal transmi ssi on as necessary. Refer to the Servi ce
I nformati on for the proper repai r procedure for components
rel ated to the OD cl utch.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 4
4 Wi th the DRBI I I ௡, Check the STARTS SI NCE SET counter for P0845.
NOTE: This counter only applies to the last DTC set.
I s the STARTS SI NCE SET counter 2 or l ess?
Al l
Yes → Go To 5
No → Go To 12
105
TRANSMISSION - 42RLE
P0845-2/4 HYDRAULIC PRESSURE TEST FAILURE — Continued
TEST ACTION APPLICABILITY
5 Turn the i gni ti on off to the l ock posi ti on.
CAUTION: Remove the Starter Relay from the PDC. This will prevent the
vehicle frombeing started in gear.
I nstal l the Transmi ssi on Si mul ator, Mi l l er tool #8333 and the El ectroni c Transmi s-
si on Adapter ki t 8333-1.
Note: Check connectors - Clean/repair as necessary.
I gni ti on on, engi ne not runni ng.
Wi th the Transmi ssi on Si mul ator, sel ect Љ2/4Љ on the Pressure Swi tch rotary swi tch.
Wi th the DRBI I I ௡, moni tor the 2/4 Pressure Swi tch state whi l e pressi ng the Pressure
Swi tch Test button on the Transmi ssi on Si mul ator.
Wi ggl e the wi ri ng l eadi ng to the TCM whi l e pressi ng the button.
Di d the 2-4 Pressure Swi tch state change to cl osed and remai n cl osed whi l e wi ggl i ng
the wi res?
Al l
Yes → Go To 6
No → Go To 7
6 I f there are no possi bl e causes remai ni ng, vi ew repai r. Al l
Repai r
Di sassembl e and i nspect the Val ve Body per the Servi ce I nforma-
ti on and repai r or repl ace as necessary. I f there are no probl ems
found i n the Val ve Body, repl ace the Transmi ssi on Sol enoi d/
Pressure Swi tch Assembl y per the Servi ce I nformati on.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
7 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the TCM harness connector.
Di sconnect the Transmi ssi on Sol enoi d/Pressure Swi tch Assembl y harness connector.
Note: Check connectors - Clean/repair as necessary.
Measure the resi stance of the 2/4 Pressure Swi tch Sense ci rcui t from the TCM
harness connector to the Transmi ssi on Sol enoi d/Pressure Swi tch Assembl y harness
connector.
I s the resi stance above 5.0 ohms?
Al l
Yes → Repai r the 2/4 Pressure Swi tch Sense ci rcui t or an open.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 8
8 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the TCM harness connector.
Di sconnect the Transmi ssi on Sol enoi d/Pressure Swi tch Assembl y harness connector.
Note: Check connectors - Clean/repair as necessary.
Measure the resi stance between ground and the 2/4 Pressure Swi tch Sense ci rcui t.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Repai r the 2/4 Pressure Swi tch Sense ci rcui t for a short to ground.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 9
106
TRANSMISSION - 42RLE
P0845-2/4 HYDRAULIC PRESSURE TEST FAILURE — Continued
TEST ACTION APPLICABILITY
9 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the TCM harness connector.
Di sconnect the Transmi ssi on Sol enoi d/Pressure Swi tch Assembl y harness connector.
Remove the Transmi ssi on Control Rel ay.
Note: Check connectors - Clean/repair as necessary.
Connect a jumper wi re between the Fused B+ ci rcui t and the Transmi ssi on Control
Rel ay Output ci rcui t i n the Transmi ssi on Control Rel ay connector.
I gni ti on on, engi ne not runni ng.
Measure the vol tage of the 2/4 Pressure Swi tch Sense ci rcui t.
I s the vol tage above 0.5 vol t?
Al l
Yes → Repai r the 2/4 Pressure Swi tch Sense ci rcui t for a short to vol tage.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 10
10 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the Transmi ssi on Sol enoi d/Pressure Swi tch Assembl y harness connector.
Remove the Transmi ssi on Control Rel ay.
Note: Check connectors - Clean/repair as necessary.
Connect a jumper wi re between the Fused B+ci rcui t and Transmi ssi on Control Rel ay
Output ci rcui t i n the Transmi ssi on Control Rel ay connector i n the PDC.
I gni ti on on, engi ne not runni ng.
Usi ng a 12-vol t test l i ght connected to ground, check the Transmi ssi on Control Rel ay
Output ci rcui t.
NOTE: The test light must illuminate brightly. Compare the brightness to
that of a direct connection to the battery.
Does the test l i ght i l l umi nate bri ghtl y?
Al l
Yes → Go To 11
No → Repai r the Transmi ssi on Control Rel ay Output ci rcui t for an open
or hi gh resi stance. I f the fuse i s open make sure to check for a
short to ground.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
11 Usi ng the schemati cs as a gui de, i nspect the wi ri ng and connectors. Repai r as
necessary. Pay parti cul ar attenti on to al l power and ground ci rcui ts.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace the Transmi ssi on Control Modul e per the Servi ce I nfor-
mati on. WI TH THE DRBI I I ௡ PERFORM QUI CK LEARN.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
12 The condi ti ons necessary to set thi s DTC are not present at thi s ti me.
Usi ng the schemati cs as a gui de, i nspect the wi ri ng and connectors speci fi c to thi s
ci rcui t.
Wi ggl e the wi ri ng whi l e checki ng for shorts and open ci rcui ts.
Wi th the DRBI I I ௡, check the EATX EVENT DATA to hel p i denti fy the condi ti ons i n
whi ch the DTC was set.
Were there any probl ems found?
Al l
Yes → Repai r as necessary.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Test Compl ete.
107
TRANSMISSION - 42RLE
P0845-2/4 HYDRAULIC PRESSURE TEST FAILURE — Continued
Symptom:
P0846-2/4 PRESSURE SWITCH SENSE CIRCUIT
When Monitored and Set Condition:
P0846-2/4 PRESSURE SWITCH SENSE CIRCUIT
When Moni tored: Whenever the engi ne i s runni ng.
Set Condi ti on: The appropri ate DTC i s set i f one of the Pressure Swi tches are open or
cl osed at the wrong ti me i n a gi ven gear .
POSSIBLE CAUSES
TRANSMI SSI ON RELAY DTC’S PRESENT
TRANSMI SSI ON CONTROL RELAY OUTPUT CI RCUI T OPEN
2/4 PRESSURE SWI TCH SENSE CI RCUI T OPEN
2/4 PRESSURE SWI TCH SENSE CI RCUI T SHORT TO GROUND
2/4 PRESSURE SWI TCH SENSE CI RCUI T SHORT TO VOLTAGE
2/4 PRESSURE SWI TCH
TRANSMI SSI ON CONTROL MODULE
I NTERMI TTENT WI RI NG AND CONNECTORS
TEST ACTION APPLICABILITY
1 NOTE: Low fluid level can be the cause of many Transmission problems. If
the fluid level is low, locate and repair the leak, then check and adjust the
fluid level per the Service Information.
NOTE: Always perform diagnostics with a fully charged battery to avoid
false symptoms.
Wi th the DRBI I I ௡, read the engi ne DTC’s. Check and repai r al l engi ne DTC’s pri or
to performi ng Transmi ssi on Symptom Di agnosti cs.
Wi th the DRBI I I ௡, read Transmi ssi on DTC’s. Record al l DTC’s and 1 Tri p Fai l ures.
NOTE: Diagnose 1 Trip Failures as a fully matured DTC.
Usi ng the wi ri ng di agram/schemati c as a gui de, i nspect the wi ri ng and connectors.
Repai r as necessary.
Perform the Shi ft Lever Posi ti on Test. I f the test does not pass, refer to Symptom test
for P0706 Check Shi fter Si gnal .
For Gear Rati o DTC’s, check and record al l CVI ’s.
Most DTC’s set on start up but some must be set by dri vi ng the vehi cl e such that al l
di agnosti c moni tors have run.
NOTE: Verify flash level of Transmission Control Module. Some problems
are corrected by software upgrades to the Transmission Control Module.
NOTE: Check for applicable TSB’s related to the symptom.
Perform thi s procedure pri or to Symptom di agnosi s.
Al l
Conti nue
Go To 2
108
TRANSMISSION - 42RLE
TEST ACTION APPLICABILITY
2 Wi th the DRBI I I ௡, read Transmi ssi on DTC’s
Are there any Transmi ssi on Control Rel ay DTC’s present al so?
Al l
Yes → Refer to the Transmi ssi on category and perform the appropri ate
symptom.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 3
3 Wi th the DRBI I I ௡, Check the STARTS SI NCE SET counter.
NOTE: This counter only applies to the last DTC set.
I s the STARTS SI NCE SET counter 2 or l ess for P0846?
Al l
Yes → Go To 4
No → Go To 11
4 Turn the i gni ti on off to the l ock posi ti on.
CAUTION: Remove the Starter Relay. This will prevent the vehicle from
being started in gear.
I nstal l the Transmi ssi on Si mul ator, Mi l l er tool #8333 and the El ectroni c Transmi s-
si on Adapter ki t 8333-1.
Note: Check connectors - Clean/repair as necessary.
I gni ti on on, engi ne not runni ng.
Wi th the Transmi ssi on Si mul ator, sel ect 2/4 on the Pressure Swi tch sel ector swi tch.
Wi th the DRBI I I ௡, moni tor the 2/4 Pressure Swi tch state whi l e pressi ng the Pressure
Swi tch Test button on the Transmi ssi on Si mul ator.
Di d the Pressure Swi tch state change from OPEN to CLOSED when the test button
was pressed?
Al l
Yes → Go To 5
No → Go To 6
5 I f there are no possi bl e causes remai ni ng, vi ew repai r. Al l
Repai r
Repl ace Transmi ssi on Sol enoi d/Pressure Swi tch Assembl y per the
Servi ce I nformati on.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
6 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the TCM harness connector.
Di sconnect the Transmi ssi on Sol enoi d/Pressure Swi tch Assembl y harness connector.
Note: Check connectors - Clean/repair as necessary.
Measure the resi stance of the 2/4 Pressure Swi tch Sense ci rcui t from the TCM
harness connector to the Transmi ssi on Sol enoi d/Pressure Swi tch Assembl y harness
connector.
I s the resi stance above 5.0 ohms?
Al l
Yes → Repai r the 2/4 Pressure Swi tch Sense ci rcui t for an open.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 7
109
TRANSMISSION - 42RLE
P0846-2/4 PRESSURE SWITCH SENSE CIRCUIT — Continued
TEST ACTION APPLICABILITY
7 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the TCM harness connector.
Di sconnect the Transmi ssi on Sol enoi d/Pressure Swi tch Assembl y harness connector.
Note: Check connectors - Clean/repair as necessary.
Measure the resi stance between ground and the 2/4 Pressure Swi tch Sense ci rcui t.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Repai r the 2/4 Pressure Swi tch Sense ci rcui t for a short to ground.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 8
8 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the TCM harness connector.
Di sconnect the Transmi ssi on Sol enoi d/Pressure Swi tch Assembl y harness connector.
Remove the Transmi ssi on Control Rel ay.
Note: Check connectors - Clean/repair as necessary.
Connect a jumper wi re between the Fused B+ ci rcui t and the Transmi ssi on Control
Rel ay Output ci rcui t i n the Transmi ssi on Control Rel ay connector.
I gni ti on on, engi ne not runni ng.
Measure the vol tage of the 2/4 Pressure Swi tch Sense ci rcui t.
I s the vol tage above 0.5 vol t?
Al l
Yes → Repai r the 2/4 Pressure Swi tch Sense ci rcui t for a short to vol tage.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 9
9 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the Transmi ssi on Sol enoi d/Pressure Swi tch Assembl y harness connector.
Remove the Transmi ssi on Control Rel ay.
Note: Check connectors - Clean/repair as necessary.
Connect a jumper wi re between the Fused B+ ci rcui t and the Transmi ssi on Control
Rel ay Output ci rcui t i n the Transmi ssi on Control Rel ay connector.
I gni ti on on, engi ne not runni ng.
Usi ng a 12-vol t test l i ght connected to ground, check the Transmi ssi on Control Rel ay
Output ci rcui t.
NOTE: The test light must illuminate brightly. Compare the brightness to
that of a direct connection to the battery.
Does the test l i ght i l l umi nate bri ghtl y?
Al l
Yes → Go To 10
No → Repai r the Transmi ssi on Control Rel ay Output ci rcui t for an open
or hi gh resi stance. I f the fuse i s open make sure to check for a
short to ground.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
10 Usi ng the schemati cs as a gui de, i nspect the wi ri ng and connectors. Repai r as
necessary. Pay parti cul ar attenti on to al l power and ground ci rcui ts.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace the Transmi ssi on Control Modul e per the Servi ce I nfor-
mati on. WI TH THE DRBI I I ௡ PERFORM QUI CK LEARN.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
110
TRANSMISSION - 42RLE
P0846-2/4 PRESSURE SWITCH SENSE CIRCUIT — Continued
TEST ACTION APPLICABILITY
11 The condi ti ons necessary to set thi s DTC are not present at thi s ti me.
Usi ng the schemati cs as a gui de, i nspect the wi ri ng and connectors speci fi c to thi s
ci rcui t.
Wi ggl e the wi ri ng whi l e checki ng for shorts and open ci rcui ts.
Wi th the DRBI I I ௡, check the EATX EVENT DATA to hel p i denti fy the condi ti ons i n
whi ch the DTC was set.
Were there any probl ems found?
Al l
Yes → Repai r as necessary.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Test Compl ete.
111
TRANSMISSION - 42RLE
P0846-2/4 PRESSURE SWITCH SENSE CIRCUIT — Continued
Symptom:
P0870-OD HYDRAULIC PRESSURE TEST FAILURE
When Monitored and Set Condition:
P0870-OD HYDRAULIC PRESSURE TEST FAILURE
When Moni tored: I n any forward gear wi th engi ne speed above 1000 RPM shortl y after
a shi ft and every mi nute thereafter.
Set Condi ti on: After a shi ft i nto a forward gear, wi th engi ne speed > 1000 RPM, the TCM
momentari l y turns on el ement pressure to the cl utch ckts that don’t have pressure to
i denti fy the correct pressure sw cl oses. I f the pressure sw does not cl ose 2 ti mes the code
sets
POSSIBLE CAUSES
LOSS OF PRI ME DTC P0944 PRESENT
RELATED DTC’S PRESENT
I NTERMI TTENT WI RI NG AND CONNECTORS
TRANSMI SSI ON CONTROL RELAY OUTPUT CI RCUI T OPEN
OD PRESSURE SWI TCH SENSE CI RCUI T OPEN
OD PRESSURE SWI TCH SENSE CI RCUI T SHORT TO GROUND
OD PRESSURE SWI TCH SENSE CI RCUI T SHORT TO VOLTAGE
I NTERNAL TRANSMI SSI ON
TRANSMI SSI ON CONTROL MODULE
112
TRANSMISSION - 42RLE
TEST ACTION APPLICABILITY
1 NOTE: Low fluid level can be the cause of many Transmission problems. If
the fluid level is low, locate and repair the leak, then check and adjust the
fluid level per the Service Information.
NOTE: Always perform diagnostics with a fully charged battery to avoid
false symptoms.
Wi th the DRBI I I ௡, read the engi ne DTC’s. Check and repai r al l engi ne DTC’s pri or
to performi ng Transmi ssi on Symptom Di agnosti cs.
Wi th the DRBI I I ௡, read Transmi ssi on DTC’s. Record al l DTC’s and 1 Tri p Fai l ures.
NOTE: Diagnose 1 Trip Failures as a fully matured DTC.
Usi ng the wi ri ng di agram/schemati c as a gui de, i nspect the wi ri ng and connectors.
Repai r as necessary.
Perform the Shi ft Lever Posi ti on Test. I f the test does not pass, refer to Symptom test
for P0706 Check Shi fter Si gnal .
For Gear Rati o DTC’s, check and record al l CVI ’s.
Most DTC’s set on start up but some must be set by dri vi ng the vehi cl e such that al l
di agnosti c moni tors have run.
NOTE: Verify flash level of Transmission Control Module. Some problems
are corrected by software upgrades to the Transmission Control Module.
NOTE: Check for applicable TSB’s related to the symptom.
Perform thi s procedure pri or to Symptom di agnosi s.
Al l
Conti nue
Go To 2
2 Wi th the DRBI I I ௡, check for other Transmi ssi on DTCs.
I s the DTC P0944 present al so?
Al l
Yes → Refer to the Transmi ssi on category and perform the appropri ate
symptom.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 3
3 Wi th the DRBI I I ௡, read Transmi ssi on DTC’s.
I s the DTC P0733 and/or P0871 present al so?
Al l
Yes → Repl ace the Transmi ssi on or Sol enoi d/Pressure Swi tch Assembl y
per the Servi ce I nformati on.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 4
4 Wi th the DRBI I I ௡, Check the STARTS SI NCE SET counter for P0870.
NOTE: This counter only applies to the last DTC set.
I s the STARTS SI NCE SET counter 2 or l ess?
Al l
Yes → Go To 5
No → Go To 12
113
TRANSMISSION - 42RLE
P0870-OD HYDRAULIC PRESSURE TEST FAILURE — Continued
TEST ACTION APPLICABILITY
5 Turn the i gni ti on off to the l ock posi ti on.
CAUTION: Remove the Starter Relay. This will prevent the vehicle from
being started in gear.
I nstal l the Transmi ssi on Si mul ator, Mi l l er tool #8333 and the El ectroni c Transmi s-
si on Adapter ki t 8333-1.
NOTE: Check connectors - Clean/repair as necessary.
Wi th the Transmi ssi on Si mul ator, sel ect ЉODЉ on the Pressure Swi tch rotary swi tch.
Wi th the DRBI I I ௡, moni tor the OD Pressure Swi tch state whi l e pressi ng the
Pressure Swi tch Test button on the Transmi ssi on Si mul ator.
Wi ggl e the wi res l eadi ng to the TCM whi l e pressi ng the test button.
Di d the O/D Pressure Swi tch state change to cl osed and remai n cl osed whi l e wi ggl i ng
the wi res?
Al l
Yes → Go To 6
No → Go To 7
6 I f there are no possi bl e causes remai ni ng, vi ew repai r. Al l
Repai r
Di sassembl e and i nspect the Val ve Body per the Servi ce I nforma-
ti on and repai r or repl ace as necessary. I f no probl ems are found i n
the Val ve Body, repl ace the Transmi ssi on Sol enoi d/Pressure
Swi tch Assembl y per the Servi ce I nformati on.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
7 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the TCM harness connector.
Di sconnect the Transmi ssi on Sol enoi d/Pressure Swi tch Assembl y harness connector.
Note: Check connectors - Clean/repair as necessary.
Measure the resi stance of the OD Pressure Swi tch Sense ci rcui t from the TCM
harness connector to the Transmi ssi on Sol enoi d/Pressure Swi tch Assembl y harness
connector.
I s the resi stance above 5.0 ohms?
Al l
Yes → Repai r the O/D Pressure Swi tch Sense ci rcui t for an open.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 8
8 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the TCM harness connector.
Di sconnect the Transmi ssi on Sol enoi d/Pressure Swi tch Assembl y harness connector.
Note: Check connectors - Clean/repair as necessary.
Measure the resi stance between ground and the OD Pressure Swi tch Sense ci rcui t.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Repai r the OD Pressure Swi tch Sense ci rcui t for a short to
ground.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 9
114
TRANSMISSION - 42RLE
P0870-OD HYDRAULIC PRESSURE TEST FAILURE — Continued
TEST ACTION APPLICABILITY
9 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the TCM harness connector.
Di sconnect the Transmi ssi on Sol enoi d/Pressure Swi tch Assembl y harness connector.
Remove the Transmi ssi on Control Rel ay.
Note: Check connectors - Clean/repair as necessary.
Connect a jumper wi re between the Fused B+ ci rcui t and the Transmi ssi on Control
Rel ay Output ci rcui t i n the Transmi ssi on Control Rel ay connector.
I gni ti on on, engi ne not runni ng.
Measure the vol tage of the OD Pressure Swi tch Sense ci rcui t.
I s the vol tage above 0.5 vol t?
Al l
Yes → Repai r OD Pressure Swi tch Sense ci rcui t for a short to vol tage.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 10
10 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the Transmi ssi on Sol enoi d/Pressure Swi tch Assembl y harness connector.
Remove the Transmi ssi on Control Rel ay.
Note: Check connectors - Clean/repair as necessary.
Connect a jumper wi re between the Fused B+ ci rcui t and the Transmi ssi on Control
Rel ay Output ci rcui t i n the Transmi ssi on Control Rel ay connector.
I gni ti on on, engi ne not runni ng.
Usi ng a 12-vol t test l i ght connected to ground, check the Transmi ssi on Control Rel ay
Output ci rcui t.
NOTE: The test light must illuminate brightly. Compare the brightness to
that of a direct connection to the battery.
Does the test l i ght i l l umi nate bri ghtl y?
Al l
Yes → Go To 11
No → Repai r the Transmi ssi on Control Rel ay Output ci rcui t for an open
or hi gh resi stance. I f the fuse i s open make sure to check for a
short to ground.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
11 Usi ng the schemati cs as a gui de, i nspect the wi ri ng and connectors. Repai r as
necessary. Pay parti cul ar attenti on to al l power and ground ci rcui ts.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace the Transmi ssi on Control Modul e per the Servi ce I nfor-
mati on. WI TH THE DRBI I I ௡ PERFORM QUI CK LEARN.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
12 The condi ti ons necessary to set thi s DTC are not present at thi s ti me.
Usi ng the schemati cs as a gui de, i nspect the wi ri ng and connectors speci fi c to thi s
ci rcui t.
Wi ggl e the wi ri ng whi l e checki ng for shorts and open ci rcui ts.
Wi th the DRBI I I ௡, check the EATX EVENT DATA to hel p i denti fy the condi ti ons i n
whi ch the DTC was set.
Were there any probl ems found?
Al l
Yes → Repai r as necessary.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Test Compl ete.
115
TRANSMISSION - 42RLE
P0870-OD HYDRAULIC PRESSURE TEST FAILURE — Continued
Symptom:
P0871-OD PRESSURE SWITCH SENSE CIRCUIT
When Monitored and Set Condition:
P0871-OD PRESSURE SWITCH SENSE CIRCUIT
When Moni tored: Whenever the engi ne i s runni ng.
Set Condi ti on: The appropri ate DTC i s set i f one of the Pressure Swi tches are open or
cl osed at the wrong ti me i n a gi ven gear.
POSSIBLE CAUSES
TRANSMI SSI ON CONTROL RELAY DTCS PRESENT
TRANSMI SSI ON CONTROL RELAY OUTPUT CI RCUI T OPEN
O/D PRESSURE SWI TCH SENSE CI RCUI T OPEN
O/D PRESSURE SWI TCH SENSE CI RCUI T SHORT TO GROUND
O/D PRESSURE SWI TCH SENSE CI RCUI T SHORT TO VOLTAGE
O/D PRESSURE SWI TCH
TRANSMI SSI ON CONTROL MODULE
I NTERMI TTENT WI RI NG AND CONNECTORS
TEST ACTION APPLICABILITY
1 NOTE: Low fluid level can be the cause of many Transmission problems. If
the fluid level is low, locate and repair the leak, then check and adjust the
fluid level per the Service Information.
NOTE: Always perform diagnostics with a fully charged battery to avoid
false symptoms.
Wi th the DRBI I I ௡, read the engi ne DTC’s. Check and repai r al l engi ne DTC’s pri or
to performi ng Transmi ssi on Symptom Di agnosti cs.
Wi th the DRBI I I ௡, read Transmi ssi on DTC’s. Record al l DTC’s and 1 Tri p Fai l ures.
NOTE: Diagnose 1 Trip Failures as a fully matured DTC.
Usi ng the wi ri ng di agram/schemati c as a gui de, i nspect the wi ri ng and connectors.
Repai r as necessary.
Perform the Shi ft Lever Posi ti on Test. I f the test does not pass, refer to Symptom test
for P0706 Check Shi fter Si gnal .
For Gear Rati o DTC’s, check and record al l CVI ’s.
Most DTC’s set on start up but some must be set by dri vi ng the vehi cl e such that al l
di agnosti c moni tors have run.
NOTE: Verify flash level of Transmission Control Module. Some problems
are corrected by software upgrades to the Transmission Control Module.
NOTE: Check for applicable TSB’s related to the symptom.
Perform thi s procedure pri or to Symptom di agnosi s.
Al l
Conti nue
Go To 2
116
TRANSMISSION - 42RLE
TEST ACTION APPLICABILITY
2 Wi th the DRBI I I ௡, read Transmi ssi on DTC’s
Are there any Transmi ssi on Control Rel ay DTC’s present al so?
Al l
Yes → Refer to the Transmi ssi on category and perform the appropri ate
symptom.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 3
3 Wi th the DRBI I I ௡, Check the STARTS SI NCE SET counter.
NOTE: This counter only applies to the last DTC set.
I s the STARTS SI NCE SET counter 2 or l ess for P0871?
Al l
Yes → Go To 4
No → Go To 11
4 Turn the i gni ti on off to the l ock posi ti on.
CAUTION: Remove the Starter Relay. This will prevent the vehicle from
being started in gear.
I nstal l the Transmi ssi on Si mul ator, Mi l l er tool #8333 and the El ectroni c Transmi s-
si on Adapter ki t 8333-1.
Note: Check connectors - Clean/repair as necessary.
I gni ti on on, engi ne not runni ng.
On the Transmi ssi on Si mul ator, sel ect OD on the Pressure Swi tch sel ector swi tch.
Wi th the DRBI I I ௡, moni tor the OD Pressure Swi tch state whi l e pressi ng the
Pressure Swi tch Test button on the Transmi ssi on Si mul ator.
Di d the Pressure Swi tch state change from OPEN to CLOSED when the test button
was pressed?
Al l
Yes → Go To 5
No → Go To 6
5 I f there are no possi bl e causes remai ni ng, vi ew repai r. Al l
Repai r
Repl ace Transmi ssi on Sol enoi d/Pressure Swi tch Assembl y per the
Servi ce I nformati on.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
6 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the TCM harness connector.
Di sconnect the Transmi ssi on Sol enoi d/Pressure Swi tch Assembl y harness connector.
Note: Check connectors - Clean/repair as necessary.
Measure the resi stance of the O/D Pressure Swi tch Sense ci rcui t from the TCM
harness connector to the Transmi ssi on Sol enoi d/Pressure Swi tch Assembl y harness
connector.
I s the resi stance above 5.0 ohms?
Al l
Yes → Repai r the O/D Pressure Swi tch Sense ci rcui t for an open.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 7
117
TRANSMISSION - 42RLE
P0871-OD PRESSURE SWITCH SENSE CIRCUIT — Continued
TEST ACTION APPLICABILITY
7 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the TCM harness connector.
Di sconnect the Transmi ssi on Sol enoi d/Pressure Swi tch Assembl y harness connector.
Note: Check connectors - Clean/repair as necessary.
Measure the resi stance between ground and the O/D Pressure Swi tch Sense ci rcui t.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Repai r the O/D Pressure Swi tch ci rcui t for a short to ground.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 8
8 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the TCM harness connector.
Di sconnect the Transmi ssi on Sol enoi d/Pressure Swi tch Assembl y harness connector.
Remove the Transmi ssi on Control Rel ay.
Note: Check connectors - Clean/repair as necessary.
Connect a jumper wi re between the Fused B+ ci rcui t and the Transmi ssi on Control
Rel ay Output ci rcui t i n the Transmi ssi on Control Rel ay connector.
I gni ti on on, engi ne not runni ng.
Measure the vol tage of the O/D Pressure Swi tch Sense ci rcui t.
I s the vol tage above 0.5 vol t?
Al l
Yes → Repai r the O/D Pressure Swi tch Sense ci rcui t for a short to
vol tage.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 9
9 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the Transmi ssi on Sol enoi d/Pressure Swi tch Assembl y harness connector.
Remove the Transmi ssi on Control Rel ay.
Note: Check connectors - Clean/repair as necessary.
Connect a jumper wi re between the Fused B+ ci rcui t and the Transmi ssi on Control
Rel ay Output ci rcui t i n the Transmi ssi on Control Rel ay connector.
I gni ti on on, engi ne not runni ng.
Usi ng a 12-vol t test l i ght connected to ground, check the Transmi ssi on Control Rel ay
Output ci rcui t.
NOTE: The test light must illuminate brightly. Compare the brightness to
that of a direct connection to the battery.
Does the test l i ght i l l umi nate bri ghtl y?
Al l
Yes → Go To 10
No → Repai r the Transmi ssi on Control Rel ay Output ci rcui t for an open
or hi gh resi stance. I f the fuse i s open make sure to check for a
short to ground.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
10 Usi ng the schemati cs as a gui de, i nspect the wi ri ng and connectors. Repai r as
necessary. Pay parti cul ar attenti on to al l power and ground ci rcui ts.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace the Transmi ssi on Control Modul e per the Servi ce I nfor-
mati on. WI TH THE DRBI I I ௡ PERFORM QUI CK LEARN.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
118
TRANSMISSION - 42RLE
P0871-OD PRESSURE SWITCH SENSE CIRCUIT — Continued
TEST ACTION APPLICABILITY
11 The condi ti ons necessary to set thi s DTC are not present at thi s ti me.
Usi ng the schemati cs as a gui de, i nspect the wi ri ng and connectors speci fi c to thi s
ci rcui t.
Wi ggl e the wi ri ng whi l e checki ng for shorts and open ci rcui ts.
Wi th the DRBI I I ௡, check the EATX EVENT DATA to hel p i denti fy the condi ti ons i n
whi ch the DTC was set.
Were there any probl ems found?
Al l
Yes → Repai r as necessary.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Test Compl ete.
119
TRANSMISSION - 42RLE
P0871-OD PRESSURE SWITCH SENSE CIRCUIT — Continued
Symptom:
P0884-POWER UP AT SPEED
When Monitored and Set Condition:
P0884-POWER UP AT SPEED
When Moni tored: When Transmi ssi on Control Modul e powers up.
Set Condi ti on: Thi s DTC wi l l set i f the TCM powers up and senses the vehi cl e i n a val i d
forward gear (no PRNDL DTCs) wi th a output speed above 800 RPM (approxi matel y
32Km/h or 20 MPH).
POSSIBLE CAUSES
POWER UP AT SPEED
TEST ACTION APPLICABILITY
1 Thi s DTC i s set when the TCM i s i ni ti al i zed whi l e the vehi cl e i s movi ng down the
road i n a val i d forward gear.
Check al l of the Fused B+, Fused I gni ti on Swi tch Output, and Ground ci rcui ts to the
TCM for an i ntermi ttent open or short to ground.
Were there any probl ems found?
Al l
Yes → Repai r wi ri ng and/or connectors as necessary.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 2
2 NOTE: Low fluid level can be the cause of many Transmission problems. If
the fluid level is low, locate and repair the leak, then check and adjust the
fluid level per the Service Information.
NOTE: Always perform diagnostics with a fully charged battery to avoid
false symptoms.
Wi th the DRBI I I ௡, read the engi ne DTC’s. Check and repai r al l engi ne DTC’s pri or
to performi ng Transmi ssi on Symptom Di agnosti cs.
Wi th the DRBI I I ௡, read Transmi ssi on DTC’s. Record al l DTC’s and 1 Tri p Fai l ures.
NOTE: Diagnose 1 Trip Failures as a fully matured DTC.
Usi ng the wi ri ng di agram/schemati c as a gui de, i nspect the wi ri ng and connectors.
Repai r as necessary.
Perform the Shi ft Lever Posi ti on Test. I f the test does not pass, refer to Symptom test
for P0706 Check Shi fter Si gnal .
For Gear Rati o DTC’s, check and record al l CVI ’s.
Most DTC’s set on start up but some must be set by dri vi ng the vehi cl e such that al l
di agnosti c moni tors have run.
NOTE: Verify flash level of Transmission Control Module. Some problems
are corrected by software upgrades to the Transmission Control Module.
NOTE: Check for applicable TSB’s related to the symptom.
Perform thi s procedure pri or to Symptom di agnosi s.
Al l
Conti nue
Test Compl ete.
120
TRANSMISSION - 42RLE
Symptom:
P0888-RELAY OUTPUT ALWAYS OFF
When Monitored and Set Condition:
P0888-RELAY OUTPUT ALWAYS OFF
When Moni tored: Conti nuousl y
Set Condi ti on: Thi s code i s set when l ess than 3 vol ts are present at the transmi ssi on
control rel ay output ci rcui ts at the Transmi ssi on Control Modul e when the TCM i s
energi zi ng the rel ay.
POSSIBLE CAUSES
FUSED B+ CI RCUI T OPEN
TRANSMI SSI ON CONTROL RELAY GROUND CI RCUI T OPEN
I NTERMI TTENT WI RI NG AND CONNECTORS
TEST ACTION APPLICABILITY
1 NOTE: Low fluid level can be the cause of many Transmission problems. If
the fluid level is low, locate and repair the leak, then check and adjust the
fluid level per the Service Information.
NOTE: Always perform diagnostics with a fully charged battery to avoid
false symptoms.
Wi th the DRBI I I ௡, read the engi ne DTC’s. Check and repai r al l engi ne DTC’s pri or
to performi ng Transmi ssi on Symptom Di agnosti cs.
Wi th the DRBI I I ௡, read Transmi ssi on DTC’s. Record al l DTC’s and 1 Tri p Fai l ures.
NOTE: Diagnose 1 Trip Failures as a fully matured DTC.
Usi ng the wi ri ng di agram/schemati c as a gui de, i nspect the wi ri ng and connectors.
Repai r as necessary.
Perform the Shi ft Lever Posi ti on Test. I f the test does not pass, refer to Symptom test
for P0706 Check Shi fter Si gnal .
For Gear Rati o DTC’s, check and record al l CVI ’s.
Most DTC’s set on start up but some must be set by dri vi ng the vehi cl e such that al l
di agnosti c moni tors have run.
NOTE: Verify flash level of Transmission Control Module. Some problems
are corrected by software upgrades to the Transmission Control Module.
NOTE: Check for applicable TSB’s related to the symptom.
Perform thi s procedure pri or to Symptom di agnosi s.
Al l
Conti nue
Go To 2
2 Wi th the DRBI I I ௡, Check the STARTS SI NCE SET counter for P0888.
Note: This counter only applies to the last DTC set.
I s the STARTS SI NCE SET counter set at 0?
Al l
Yes → Go To 3
No → Go To 5
121
TRANSMISSION - 42RLE
TEST ACTION APPLICABILITY
3 Turn the i gni ti on off to the l ock posi ti on.
Remove the Transmi ssi on Control Rel ay.
Note: Check connectors - Clean/repair as necessary.
I gni ti on on, engi ne not runni ng.
Usi ng a 12-vol t test l i ght connected to ground, check the Fused B+ ci rcui t i n the
Transmi ssi on Control Rel ay connector.
NOTE: The test light must illuminate brightly. Compare the brightness to
that of a direct connection to the battery.
Does the test l i ght i l l umi nate bri ghtl y?
Al l
Yes → Go To 4
No → Repai r the Fused B+ ci rcui t for an open or hi gh resi stance. I f the
fuse i s open make sure to check for a short to ground.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
4 Turn the i gni ti on off to the l ock posi ti on.
Remove the Transmi ssi on Control Rel ay.
Note: Check connectors - Clean/repair as necessary.
Usi ng a 12-vol t test l i ght connected to 12-vol ts, check the Transmi ssi on Control Rel ay
Ground ci rcui t.
NOTE: The test light must illuminate brightly. Compare the brightness to
that of a direct connection to the battery.
Does the test l i ght i l l umi nate bri ghtl y?
Al l
Yes → Test Compl ete.
No → Repai r the Transmi ssi on Control Rel ay Ground ci rcui t for an open
or hi gh resi stance.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
5 The condi ti ons necessary to set thi s DTC are not present at thi s ti me.
Usi ng the schemati cs as a gui de, i nspect the wi ri ng and connectors speci fi c to thi s
ci rcui t.
Wi ggl e the wi ri ng whi l e checki ng for shorts and open ci rcui ts.
Wi th the DRBI I I ௡, check the EATX EVENT DATA to hel p i denti fy the condi ti ons i n
whi ch the DTC was set.
Were there any probl ems found?
Al l
Yes → Repai r as necessary.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Test Compl ete.
122
TRANSMISSION - 42RLE
P0888-RELAY OUTPUT ALWAYS OFF — Continued
Symptom:
P0890-SWITCHED BATTERY
When Monitored and Set Condition:
P0890-SWITCHED BATTERY
When Moni tored: I gni ti on key i s turned from the OFF posi ti on to RUN posi ti on and/or
i gni ti on key i s turned from the CRANK posi ti on to RUN posi ti on.
Set Condi ti on: Thi s DTC i s set i f the Transmi ssi on Control Modul e senses vol tage on any
of the Pressure Swi tch I nputs pri or to the TCM energi zi ng the Transmi ssi on Control Rel ay.
POSSIBLE CAUSES
2/4 PRESSURE SWI TCH SENSE CI RCUI T SHORT TO VOLTAGE
L/R PRESSURE SWI TCH SENSE CI RCUI T SHORT TO VOLTAGE
I NTERMI TTENT WI RI NG AND CONNECTORS
TEST ACTION APPLICABILITY
1 NOTE: Low fluid level can be the cause of many Transmission problems. If
the fluid level is low, locate and repair the leak, then check and adjust the
fluid level per the Service Information.
NOTE: Always perform diagnostics with a fully charged battery to avoid
false symptoms.
Wi th the DRBI I I ௡, read the engi ne DTC’s. Check and repai r al l engi ne DTC’s pri or
to performi ng Transmi ssi on Symptom Di agnosti cs.
Wi th the DRBI I I ௡, read Transmi ssi on DTC’s. Record al l DTC’s and 1 Tri p Fai l ures.
NOTE: Diagnose 1 Trip Failures as a fully matured DTC.
Usi ng the wi ri ng di agram/schemati c as a gui de, i nspect the wi ri ng and connectors.
Repai r as necessary.
Perform the Shi ft Lever Posi ti on Test. I f the test does not pass, refer to Symptom test
for P0706 Check Shi fter Si gnal .
For Gear Rati o DTC’s, check and record al l CVI ’s.
Most DTC’s set on start up but some must be set by dri vi ng the vehi cl e such that al l
di agnosti c moni tors have run.
NOTE: Verify flash level of Transmission Control Module. Some problems
are corrected by software upgrades to the Transmission Control Module.
NOTE: Check for applicable TSB’s related to the symptom.
Perform thi s procedure pri or to Symptom di agnosi s.
Al l
Conti nue
Go To 2
2 Wi th the DRBI I I ௡, Check the STARTS SI NCE SET counter for P0890.
Note: This counter only applies to the last DTC set.
I s the STARTS SI NCE SET counter for P0890 set at 0?
Al l
Yes → Go To 3
No → Go To 5
123
TRANSMISSION - 42RLE
TEST ACTION APPLICABILITY
3 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the TCM harness connector.
Di sconnect the Transmi ssi on Sol enoi d/Pressure Swi tch Assembl y harness connector.
Remove the Transmi ssi on Control Rel ay.
Note: Check connectors - Clean/repair as necessary.
Connect a jumper wi re between the Fused B+ ci rcui t and the Transmi ssi on Control
Rel ay Output ci rcui t i n the Transmi ssi on Control Rel ay connector.
I gni ti on on, engi ne not runni ng.
Measure the vol tage of the 2/4 Pressure Swi tch Sense ci rcui t.
I s the vol tage above 0.5 vol t?
Al l
Yes → Repai r the 2/4 Pressure Swi tch Sense ci rcui t for a short to vol tage.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 4
4 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the TCM harness connector.
Di sconnect the Transmi ssi on Sol enoi d/Pressure Swi tch Assembl y harness connector.
Remove the Transmi ssi on Control Rel ay from the PDC.
Note: Check connectors - Clean/repair as necessary.
Connect a jumper wi re between the Fused B+ ci rcui t and the Transmi ssi on Control
Rel ay Output ci rcui t i n the Transmi ssi on Control Rel ay connector.
I gni ti on on, engi ne not runni ng.
Measure the vol tage of the L/R Pressure Swi tch Sense ci rcui t.
I s the vol tage above 0.5 vol t?
Al l
Yes → Repai r the L/R Pressure Swi tch Sense ci rcui t for a short to
vol tage.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Test Compl ete.
5 The condi ti ons necessary to set thi s DTC are not present at thi s ti me.
Usi ng the schemati cs as a gui de, i nspect the wi ri ng and connectors speci fi c to thi s
ci rcui t.
Wi ggl e the wi ri ng whi l e checki ng for shorts and open ci rcui ts.
Wi th the DRBI I I ௡, check the EATX EVENT DATA to hel p i denti fy the condi ti ons i n
whi ch the DTC was set.
Were there any probl ems found?
Al l
Yes → Repai r as necessary.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Test Compl ete.
124
TRANSMISSION - 42RLE
P0890-SWITCHED BATTERY — Continued
Symptom:
P0891-TRANSMISSION RELAY ALWAYS ON
When Monitored and Set Condition:
P0891-TRANSMISSION RELAY ALWAYS ON
When Moni tored: When the i gni ti on i s turned from the OFF posi ti on to the RUN posi ti on
and/or the i gni ti on i s turned from the CRANK posi ti on to RUN posi ti on.
Set Condi ti on: Thi s DTC i s set i f the Transmi ssi on Control Modul e senses greater than
3.0 vol ts at the Transmi ssi on Control Rel ay Output termi nal of the TCM pri or to the TCM
energi zi ng the Transmi ssi on Control Rel ay.
POSSIBLE CAUSES
I NTERMI TTENT WI RI NG AND CONNECTORS
TRANSMI SSI ON CONTROL RELAY STUCK CLOSED
TRANSMI SSI ON CONTROL RELAY OUTPUT CI RCUI T SHORT TO VOLTAGE
TRANSMI SSI ON RELAY CONTROL CI RCUI T SHORT TO VOLTAGE
TRANSMI SSI ON CONTROL MODULE
TEST ACTION APPLICABILITY
1 NOTE: Low fluid level can be the cause of many Transmission problems. If
the fluid level is low, locate and repair the leak, then check and adjust the
fluid level per the Service Information.
NOTE: Always perform diagnostics with a fully charged battery to avoid
false symptoms.
Wi th the DRBI I I ௡, read the engi ne DTC’s. Check and repai r al l engi ne DTC’s pri or
to performi ng Transmi ssi on Symptom Di agnosti cs.
Wi th the DRBI I I ௡, read Transmi ssi on DTC’s. Record al l DTC’s and 1 Tri p Fai l ures.
NOTE: Diagnose 1 Trip Failures as a fully matured DTC.
Usi ng the wi ri ng di agram/schemati c as a gui de, i nspect the wi ri ng and connectors.
Repai r as necessary.
Perform the Shi ft Lever Posi ti on Test. I f the test does not pass, refer to Symptom test
for P0706 Check Shi fter Si gnal .
For Gear Rati o DTC’s, check and record al l CVI ’s.
Most DTC’s set on start up but some must be set by dri vi ng the vehi cl e such that al l
di agnosti c moni tors have run.
NOTE: Verify flash level of Transmission Control Module. Some problems
are corrected by software upgrades to the Transmission Control Module.
NOTE: Check for applicable TSB’s related to the symptom.
Perform thi s procedure pri or to Symptom di agnosi s.
Al l
Conti nue
Go To 2
125
TRANSMISSION - 42RLE
TEST ACTION APPLICABILITY
2 Wi th the DRBI I I ௡, check the STARTS SI NCE SET counter for P0891.
Note: This counter only applies to the last DTC set.
I s the STARTS SI NCE SET counter set to 0?
Al l
Yes → Go To 3
No → Go To 7
3 Turn the i gni ti on off to the l ock posi ti on.
Remove the Transmi ssi on Control Rel ay from the PDC.
Note: Check connectors - Clean/repair as necessary.
Measure the resi stance between the Fused B+ ci rcui t and the Transmi ssi on Control
Rel ay Output Ci rcui t i n the Transmi ssi on Control Rel ay.
I s the resi stance above 5.0 ohms?
Al l
Yes → Go To 4
No → Repl ace the Transmi ssi on Control Rel ay.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
4 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the TCM harness connector.
Di sconnect the Sol enoi d/Pressure Swi tch Assembl y harness connector.
Remove the Transmi ssi on Control Rel ay from the PDC.
Note: Check connectors - Clean/repair as necessary.
I gni ti on on, engi ne not runni ng.
Measure the vol tage of the Transmi ssi on Control Rel ay Output ci rcui t i n the
Sol enoi d/Pressure Swi tch Assembl y harness connector.
I s the vol tage above 0.5 vol t?
Al l
Yes → Repai r the Transmi ssi on Control Rel ay Output ci rcui t for a short
to vol tage
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 5
5 Turn the i gni ti on off to the l ock posi ti on.
Remove the Transmi ssi on Control Rel ay from the PDC.
I gni ti on on, engi ne not runni ng.
Note: Check connectors - Clean/repair as necessary.
Measure the vol tage of the Transmi ssi on Rel ay Control ci rcui t i n the PDC connector.
I s the vol tage above 0.5 vol t?
Al l
Yes → Repai r Transmi ssi on Rel ay Control Ci rcui t for a short to vol tage.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 6
6 Usi ng the schemati cs as a gui de, i nspect the wi ri ng and connectors. Repai r as
necessary. Pay parti cul ar attenti on to al l power and ground ci rcui ts.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace the Transmi ssi on Control Modul e per the Servi ce I nfor-
mati on. WI TH THE DRBI I I ௡ PERFORM QUI CK LEARN.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
126
TRANSMISSION - 42RLE
P0891-TRANSMISSION RELAY ALWAYS ON — Continued
TEST ACTION APPLICABILITY
7 The condi ti ons necessary to set thi s DTC are not present at thi s ti me.
Usi ng the schemati cs as a gui de, i nspect the wi ri ng and connectors speci fi c to thi s
ci rcui t.
Wi ggl e the wi ri ng whi l e checki ng for shorts and open ci rcui ts.
Wi th the DRBI I I ௡, check the EATX EVENT DATA to hel p i denti fy the condi ti ons i n
whi ch the DTC was set.
Were there any probl ems found?
Al l
Yes → Repai r as necessary.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Test Compl ete.
127
TRANSMISSION - 42RLE
P0891-TRANSMISSION RELAY ALWAYS ON — Continued
Symptom:
P0897-WORN OUT/BURNT TRANSAXLE FLUID
When Monitored and Set Condition:
P0897-WORN OUT/BURNT TRANSAXLE FLUID
When Moni tored: Wi th each transi ti on from ful l Torque Convertor to parti al Torque
Convertor engagement for A/C bump preventi on.
Set Condi ti on: When vehi cl e shudder i s detected duri ng parti al engagement (PEMCC).
POSSIBLE CAUSES
WORN OUT/BURNT TRANSMI SSI ON FLUI D
TEST ACTION APPLICABILITY
1 NOTE: Low fluid level can be the cause of many Transmission problems. If
the fluid level is low, locate and repair the leak, then check and adjust the
fluid level per the Service Information.
NOTE: Always perform diagnostics with a fully charged battery to avoid
false symptoms.
Wi th the DRBI I I ௡, read the engi ne DTC’s. Check and repai r al l engi ne DTC’s pri or
to performi ng Transmi ssi on Symptom Di agnosti cs.
Wi th the DRBI I I ௡, read Transmi ssi on DTC’s. Record al l DTC’s and 1 Tri p Fai l ures.
NOTE: Diagnose 1 Trip Failures as a fully matured DTC.
Usi ng the wi ri ng di agram/schemati c as a gui de, i nspect the wi ri ng and connectors.
Repai r as necessary.
Perform the Shi ft Lever Posi ti on Test. I f the test does not pass, refer to Symptom test
for P0706 Check Shi fter Si gnal .
For Gear Rati o DTC’s, check and record al l CVI ’s.
Most DTC’s set on start up but some must be set by dri vi ng the vehi cl e such that al l
di agnosti c moni tors have run.
NOTE: Verify flash level of Transmission Control Module. Some problems
are corrected by software upgrades to the Transmission Control Module.
NOTE: Check for applicable TSB’s related to the symptom.
Perform thi s procedure pri or to Symptom di agnosi s.
Al l
Conti nue
Go To 2
128
TRANSMISSION - 42RLE
TEST ACTION APPLICABILITY
2 Turn the i gni ti on off.
Remove the Transmi ssi on Oi l Pan and Oi l Fi l ter per the Servi ce I nformati on.
I nstal l a new Transmi ssi on Oi l Fi l ter per Servi ce I nformati on.
Rei nstal l Transmi ssi on Oi l Pan, and refi l l wi th new Transmi ssi on Fl ui d per the
Servi ce I nformati on.
Note: The Transmission Cooler must be flushed before prodceeding.
Start the engi ne, check and adjust the Transmi ssi on Fl ui d Level per Servi ce
I nformati on.
Al l ow the engi ne to i dl e for 10 mi nutes, i n Park.
Fl ush the Transmi ssi on Oi l Cool er per the Servi ce I nformati on.
Turn the i gni ti on off.
Drai n and refi l l the Transmi ssi on Fl ui d.
Fl ush the Transmi ssi on Oi l Cool er agai n.
Start the engi ne, check and adjust the Transmi ssi on Fl ui d Level per Servi ce
I nformati on.
Wi th the DRBI I I ௡, perform a Battery Di sconnect.
Note: This must be done to re enable EMCC during an A/C Clutch engage-
ment.
The vehi cl e may exhi bi t i ntermi ttent shudder duri ng the fi rst few hundred mi l es.
Note: The oil will gradually penetrate the TCC friction material and the
shudder should disappear.
Erase the DTC and return the vehi cl e to the customer.
Di d the Code reset or does the vehi cl e sti l l shudder after a few thousand mi l es?
Al l
Yes → Repl ace the Torque Convertor per the Servi ce I nformati on. Note:
After repl aci ng the Torque Convertor, use the DRBI I I to perform
the TCC Break I n procedure. Thi s wi l l prevent a possi bl e shudder
condi ti on.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Test Compl ete.
129
TRANSMISSION - 42RLE
P0897-WORN OUT/BURNT TRANSAXLE FLUID — Continued
Symptom:
P0944-LOSS OF PRIME
When Monitored and Set Condition:
P0944-LOSS OF PRIME
When Moni tored: I f the transmi ssi on i s sl i ppi ng i n any forward gear and the pressure
swi tches are not i ndi cati ng pressure, a l oss of pri me test i s run.
Set Condi ti on: I f the Trans. begi ns to sl i p i n a forward gear & the press. swi tch(s) that
shoul d be cl osed are open a l oss of pri me test begi ns. Avai l abl e el ements are turned on by
the TCM to see i f pump pri me exi sts.The code sets i f no pressure swi tches respond.
POSSIBLE CAUSES
SHI FT LEVER POSI TI ON
PLUGGED TRANSMI SSI ON OI L FI LTER
TRANSMI SSI ON OI L PUMP
I NTERMI TTENT WI RI NG AND CONNECTORS
TEST ACTION APPLICABILITY
1 NOTE: Low fluid level can be the cause of many Transmission problems. If
the fluid level is low, locate and repair the leak, then check and adjust the
fluid level per the Service Information.
NOTE: Always perform diagnostics with a fully charged battery to avoid
false symptoms.
Wi th the DRBI I I ௡, read the engi ne DTC’s. Check and repai r al l engi ne DTC’s pri or
to performi ng Transmi ssi on Symptom Di agnosti cs.
Wi th the DRBI I I ௡, read Transmi ssi on DTC’s. Record al l DTC’s and 1 Tri p Fai l ures.
NOTE: Diagnose 1 Trip Failures as a fully matured DTC.
Usi ng the wi ri ng di agram/schemati c as a gui de, i nspect the wi ri ng and connectors.
Repai r as necessary.
Perform the Shi ft Lever Posi ti on Test. I f the test does not pass, refer to Symptom test
for P0706 Check Shi fter Si gnal .
For Gear Rati o DTC’s, check and record al l CVI ’s.
Most DTC’s set on start up but some must be set by dri vi ng the vehi cl e such that al l
di agnosti c moni tors have run.
NOTE: Verify flash level of Transmission Control Module. Some problems
are corrected by software upgrades to the Transmission Control Module.
NOTE: Check for applicable TSB’s related to the symptom.
Perform thi s procedure pri or to Symptom di agnosi s.
Al l
Conti nue
Go To 2
130
TRANSMISSION - 42RLE
TEST ACTION APPLICABILITY
2 Pl ace the gear sel ector i n park.
Start the engi ne.
NOTE: The TRANS TEMP DEG must be at least 43° C or 110° F before
performing the following steps.
The Transmi ssi on must be at operati ng temperature pri or to checki ng pressure. A
col d Transmi ssi on wi l l gi ve hi gher readi ngs.
Pl ace the Transmi ssi on i n Reverse.
Wi th the DRBI I I ௡, observe the Transmi ssi on Pressure Swi tch states.
Are any of the Pressure Swi tches cl osed?
Al l
Yes → Go To 3
No → Go To 5
3 The condi ti ons necessary to set thi s DTC are not present at thi s ti me.
Test dri ve the vehi cl e. Al l ow the Transmi ssi on to shi ft through al l gears and ranges.
Di d you experi ence a del ayed engagement and/or a no dri ve condi ti on?
Al l
Yes → Go To 5
No → Go To 4
4 The condi ti ons necessary to set thi s DTC are not present at thi s ti me.
Usi ng the schemati cs as a gui de, i nspect the wi ri ng and connectors speci fi c to thi s
ci rcui t.
Wi ggl e the wi ri ng whi l e checki ng for shorts and open ci rcui ts.
Wi th the DRBI I I ௡, check the EATX EVENT DATA to hel p i denti fy the condi ti ons i n
whi ch the DTC was set.
Were there any probl ems found?
Al l
Yes → Repai r as necessary.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Test Compl ete.
5 Wi th the DRBI I I ௡, perform a Shi ft Lever Posi ti on test. Fol l ow the i nstructi ons on the
DRBI I I ௡.
Di d the Shi ft Lever Posi ti on Test pass?
Al l
Yes → Go To 6
No → Refer to symptom l i st and perform test for DTC P0706.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
6 Remove and i nspect the Transmi ssi on Oi l Pan and Transmi ssi on Oi l Fi l ter per the
Servi ce I nformati on.
Does the Transmi ssi on Oi l Pan contai n excessi ve debri s and/or i s the Oi l Fi l ter
pl ugged?
Al l
Yes → Repai r the cause of the pl ugged Transmi ssi on Oi l Fi l ter. Refer to
the Servi ce I nformati on for the proper repai r procedure.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 7
131
TRANSMISSION - 42RLE
P0944-LOSS OF PRIME — Continued
TEST ACTION APPLICABILITY
7 I f there are no possi bl e causes remai ni ng, vi ew repai r. Al l
Repai r
Repl ace the Transmi ssi on Oi l Pump per the Servi ce I nformati on.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
132
TRANSMISSION - 42RLE
P0944-LOSS OF PRIME — Continued
Symptom:
P0992- 2-4/OD HYDRAULIC PRESSURE TEST FAILURE
When Monitored and Set Condition:
P0992- 2-4/OD HYDRAULIC PRESSURE TEST FAILURE
When Moni tored: I n any forward gear wi th engi ne speed above 1000 RPM shortl y after
a shi ft and every mi nute thereafter.
Set Condi ti on: After a shi ft i nto a forward gear, wi th engi ne speed > 1000 RPM, the TCM
momentari l y turns on el ement pressure to the cl utch ckts that don’t have pressure to
i denti fy the correct pressure sw cl oses. I f the pressure sw does not cl ose 2 ti mes the code
sets.
POSSIBLE CAUSES
CONDI TI ON P0992 PRESENT
TEST ACTION APPLICABILITY
1 NOTE: Low fluid level can be the cause of many Transmission problems. If
the fluid level is low, locate and repair the leak, then check and adjust the
fluid level per the Service Information.
NOTE: Always perform diagnostics with a fully charged battery to avoid
false symptoms.
Wi th the DRBI I I ௡, read the engi ne DTC’s. Check and repai r al l engi ne DTC’s pri or
to performi ng Transmi ssi on Symptom Di agnosti cs.
Wi th the DRBI I I ௡, read Transmi ssi on DTC’s. Record al l DTC’s and 1 Tri p Fai l ures.
NOTE: Diagnose 1 Trip Failures as a fully matured DTC.
Usi ng the wi ri ng di agram/schemati c as a gui de, i nspect the wi ri ng and connectors.
Repai r as necessary.
Perform the Shi ft Lever Posi ti on Test. I f the test does not pass, refer to Symptom test
for P0706 Check Shi fter Si gnal .
For Gear Rati o DTC’s, check and record al l CVI ’s.
Most DTC’s set on start up but some must be set by dri vi ng the vehi cl e such that al l
di agnosti c moni tors have run.
NOTE: Verify flash level of Transmission Control Module. Some problems
are corrected by software upgrades to the Transmission Control Module.
NOTE: Check for applicable TSB’s related to the symptom.
Perform thi s procedure pri or to Symptom di agnosi s.
Al l
Conti nue
Go To 2
133
TRANSMISSION - 42RLE
TEST ACTION APPLICABILITY
2 NOTE: Thevehiclemust bedriven toset thisDTC, thetransmission must be
warmor hot with the Engine RPM above 1000 RPM.
Thi s DTC i s an i ndi cator of a 2/4 and/or O/D Hydraul i c Pressure Swi tch DTC’s
present. Perform the tests for P0870 and/or P0845 to determi ne whi ch swi tch i s
fai l i ng.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Refer to the Transmi ssi on category and perform the appropri ate
symptom for P0870 and/or P0845.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
134
TRANSMISSION - 42RLE
P0992- 2-4/OD HYDRAULIC PRESSURE TEST FAILURE — Continued
Symptom:
P1652-SERIAL COMMUNICATION LINK MALFUNCTION
When Monitored and Set Condition:
P1652-SERIAL COMMUNICATION LINK MALFUNCTION
When Moni tored: Conti nuousl y wi th engi ne runni ng.
Set Condi ti on: The DTC sets i n approxi matel y 20 seconds i f no BUS messages are
recei ved by the TCM.
POSSIBLE CAUSES
NO COMMUNI CATI ON WI TH MI C
NO COMMUNI CATI ON WI TH PCM
I NTERMI TTENT WI RI NG AND CONNECTORS
TRANSMI SSI ON CONTROL MODULE
TEST ACTION APPLICABILITY
1 Wi th the DRBI I I ௡, erase TCM DTC’s.
Note: Erase P0700 DTC in the PCM to turn the MIL light off after making
transmission repairs.
Start the engi ne i n park.
Di d the DTC reset after the engi ne was started?
Al l
Yes → Go To 2
No → Go To 5
2 I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, attempt communi cati on wi th the MI C
Can you communi cate wi th the MI C?
Al l
Yes → Go To 3
No → Refer to the Communi cati on category for the rel ated symptom(s).
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
3 I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, sel ect the fol l owi ng screens i n order: ЉBODYЉ ЉMI CЉ ЉMONI TOR
DI SPLAYЉ ЉPCI BUS ENGI NE I NFOЉ.
Does the DRBI I I ௡, read ЉNO RESPONSEЉ from any of the l i sted PCM moni tors?
Al l
Yes → Refer to Communi cati on Category for the rel ated symptom(s).
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 4
135
TRANSMISSION - 42RLE
TEST ACTION APPLICABILITY
4 Usi ng the schemati cs as a gui de, i nspect the wi ri ng and connectors. Repai r as
necessary. Pay parti cul ar attenti on to al l power and ground ci rcui ts.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace the Transmi ssi on Control Modul e per the Servi ce I nfor-
mati on. WI TH THE DRBI I I ௡ PERFORM QUI CK LEARN.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
5 The condi ti ons necessary to set thi s DTC are not present at thi s ti me.
Usi ng the schemati cs as a gui de, i nspect the wi ri ng and connectors speci fi c to thi s
ci rcui t.
Wi ggl e the wi ri ng whi l e checki ng for shorts and open ci rcui ts.
Wi th the DRBI I I ௡, check the EATX EVENT DATA to hel p i denti fy the condi ti ons i n
whi ch the DTC was set.
Were there any probl ems found?
Al l
Yes → Repai r as necessary.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Test Compl ete.
136
TRANSMISSION - 42RLE
P1652-SERIAL COMMUNICATION LINK MALFUNCTION — Continued
Symptom:
P1684-BATTERY WAS DISCONNECTED
When Monitored and Set Condition:
P1684-BATTERY WAS DISCONNECTED
When Moni tored: Whenever the key i s i n the Run/Start posi ti on.
Set Condi ti on: Thi s code i s set whenever Transmi ssi on Control Modul e (TCM) i s
di sconnected from battery power B+ or ground. I t wi l l al so be set duri ng the DRBI I I ௡
Qui ck Battery Di sconnect procedure.
POSSIBLE CAUSES
QUI CK LEARN WAS PERFORMED
RECENT BATTERY DI SCONNECTI ON
TCM WAS REPLACED OR DI SCONNECTED
I NTERMI TTENT WI RI NG AND CONNECTORS
FUSED B+ CI RCUI T TO TCM OPEN
GROUND CI RCUI T OPEN
TEST ACTION APPLICABILITY
1 NOTE: Low fluid level can be the cause of many Transmission problems. If
the fluid level is low, locate and repair the leak, then check and adjust the
fluid level per the Service Information.
NOTE: Always perform diagnostics with a fully charged battery to avoid
false symptoms.
Wi th the DRBI I I ௡, read the engi ne DTC’s. Check and repai r al l engi ne DTC’s pri or
to performi ng Transmi ssi on Symptom Di agnosti cs.
Wi th the DRBI I I ௡, read Transmi ssi on DTC’s. Record al l DTC’s and 1 Tri p Fai l ures.
NOTE: Diagnose 1 Trip Failures as a fully matured DTC.
Usi ng the wi ri ng di agram/schemati c as a gui de, i nspect the wi ri ng and connectors.
Repai r as necessary.
Perform the Shi ft Lever Posi ti on Test. I f the test does not pass, refer to Symptom test
for P0706 Check Shi fter Si gnal .
For Gear Rati o DTC’s, check and record al l CVI ’s.
Most DTC’s set on start up but some must be set by dri vi ng the vehi cl e such that al l
di agnosti c moni tors have run.
NOTE: Verify flash level of Transmission Control Module. Some problems
are corrected by software upgrades to the Transmission Control Module.
NOTE: Check for applicable TSB’s related to the symptom.
Perform thi s procedure pri or to Symptom di agnosi s.
Al l
Conti nue
Go To 2
137
TRANSMISSION - 42RLE
TEST ACTION APPLICABILITY
2 Turn i gni ti on off to the l ock posi ti on.
Di sconnect the TCM harness connector.
I gni ti on on, engi ne not runni ng.
Measure the vol tage of the Fused B+ ci rcui t i n the TCM harness connector.
I s the vol tage bel ow 10.0 vol ts?
Al l
Yes → Go To 3
No → Go To 5
3 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the TCM harness connector.
Note: Check connectors - Clean/repair as necessary.
I gni ti on on, engi ne not runni ng.
Usi ng a 12-vol t test l i ght connected to ground, check the Fused B+ ci rcui t i n the TCM
harness connector.
NOTE: The test light must illuminate brightly. Compare the brightness to
that of a direct connection to the battery.
Does the test l i ght i l l umi nate bri ghtl y?
Al l
Yes → Go To 4
No → Repai r the Fused B+ ci rcui t for an open or hi gh resi stance. I f the
fuse i s open make sure to check for a short to ground.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
4 Turn i gni ti on off to the l ock posi ti on.
Di sconnect the TCM harness connector.
Note: Check connectors - Clean/repair as necessary.
Usi ng a 12-vol t test l i ght connected to 12-vol ts, check al l the ground ci rcui ts i n the
TCM harness connector.
NOTE: The test light must illuminate brightly. Compare the brightness to
that of a direct connection to the battery.
Does the l i ght i l l umi nate bri ghtl y at al l the ground ci rcui ts?
Al l
Yes → Test Compl ete.
No → Repai r the Ground ci rcui t(s) as necessary.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
5 Has the battery been di sconnected, l ost i t’s charge, or been repl aced recentl y? Al l
Yes → Thi s i s the cause of the DTC. Erase the DTC and return the
vehi cl e to the customer.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 6
6 Has the Qui ck Learn procedure been performed? Al l
Yes → Thi s i s the cause of the DTC. Erase the DTC and return the
vehi cl e to the customer.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 7
138
TRANSMISSION - 42RLE
P1684-BATTERY WAS DISCONNECTED — Continued
TEST ACTION APPLICABILITY
7 Has the TCM been repl aced or di sconnected? Al l
Yes → Repl aci ng or di sconnecti ng the TCM wi l l set thi s DTC. Erase the
DTC and return the vehi cl e to the customer.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 8
8 The condi ti ons necessary to set thi s DTC are not present at thi s ti me.
Usi ng the schemati cs as a gui de, i nspect the wi ri ng and connectors speci fi c to thi s
ci rcui t.
Wi ggl e the wi ri ng whi l e checki ng for shorts and open ci rcui ts.
Were there any probl ems found?
Al l
Yes → Repai r as necessary.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Test Compl ete.
139
TRANSMISSION - 42RLE
P1684-BATTERY WAS DISCONNECTED — Continued
Symptom:
P1687-NO COMMUNICATION WITH THE MIC
When Monitored and Set Condition:
P1687-NO COMMUNICATION WITH THE MIC
When Moni tored: Conti nuousl y wi th engi ne runni ng.
Set Condi ti on: The code sets i n approxi matel y 25 seconds i f no BUS messages are
recei ved from the MI C.
POSSIBLE CAUSES
OTHER BUS PROBLEMS PRESENT
I NTERMI TTENT WI RI NG AND CONNECTORS
MI C - NO COMMUNI CATI ON
TRANSMI SSI ON CONTROL MODULE
TEST ACTION APPLICABILITY
1 Wi th the DRBI I I ௡, Check the STARTS SI NCE SET counter for P1687.
Note: This counter only applies to the last DTC set.
I s the STARTS SI NCE SET counter set at 0?
Al l
Yes → Go To 2
No → Go To 5
2 Wi th the DRBI I I ௡, check al l of the other modul es on the vehi cl e for evi dence of a
vehi cl e bus probl em.
Bus rel ated DTC’s i n other modul es poi nt to an overal l vehi cl e bus probl em. Other
symptoms such as a customer compl ai nt of i ntermi ttent operati on of bus control l ed
features al so i ndi cate a bus probl em.
Does the PRNDL di spl ay i ndi cate ЉNo BusЉ or i s there any evi dence of an overal l
vehi cl e bus probl em?
Al l
Yes → Refer to the Communi cati ons category and perform the appropri -
ate symptom.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 3
3 I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, cl ear al l DTC’s.
Start the engi ne i n park.
Wi th the DRBI I I ௡, read the MI C DTC’s.
Can the DRBI I I ௡ communi cate wi th the MI C?
Al l
Yes → Go To 4
No → Refer to the Communi cati on category and perform the appropri -
ate symptom rel ated to No Response to MI C.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
140
TRANSMISSION - 42RLE
TEST ACTION APPLICABILITY
4 I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, erase TCM DTC’s.
Start the engi ne i n park.
Wi th the DRBI I I ௡, read Transmi ssi on DTC’s.
I s the DTC, P1687- No Communi cati on wi th the MI C, present?
Al l
Yes → Repl ace the Transmi ssi on Control Modul e per the Servi ce I nfor-
mati on. WI TH THE DRBI I I ௡ PERFORM QUI CK LEARN.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Test Compl ete.
5 The condi ti ons necessary to set thi s DTC are not present at thi s ti me.
Usi ng the schemati cs as a gui de, i nspect the wi ri ng and connectors speci fi c to thi s
ci rcui t.
Wi ggl e the wi ri ng whi l e checki ng for shorts and open ci rcui ts.
Wi th the DRBI I I ௡, check the EATX EVENT DATA to hel p i denti fy the condi ti ons i n
whi ch the DTC was set.
Were there any probl ems found?
Al l
Yes → Repai r as necessary.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Test Compl ete.
141
TRANSMISSION - 42RLE
P1687-NO COMMUNICATION WITH THE MIC — Continued
Symptom:
P1694-BUS COMMUNICATION WITH ENGINE MODULE
When Monitored and Set Condition:
P1694-BUS COMMUNICATION WITH ENGINE MODULE
When Moni tored: Conti nuousl y wi th i gni ti on key on.
Set Condi ti on: I f no bus messages are recei ved from the Powertrai n Control Modul e for
10 seconds.
POSSIBLE CAUSES
NO COMMUNI CATI ON WI TH PCM
OTHER BUS PROBLEMS PRESENT
I NTERMI TTENT WI RI NG AND CONNECTORS
TRANSMI SSI ON CONTROL MODULE
TEST ACTION APPLICABILITY
1 Wi th the DRBI I I ௡, Check the STARTS SI NCE SET counter for P1694.
Note: This counter only applies to the last DTC set.
I s the STARTS SI NCE SET counter for P1694 set to 0?
Al l
Yes → Go To 2
No → Go To 5
2 Wi th the DRBI I I ௡, check al l of the other modul es on the vehi cl e for evi dence of a
vehi cl e bus probl em.
Bus rel ated DTC’s i n other modul es poi nt to an overal l vehi cl e bus probl em. Other
symptoms such as a customer compl ai nt of i ntermi ttent operati on of bus control l ed
features al so i ndi cate a bus probl em.
Does the PRNDL di spl ay i ndi cate ЉNo BusЉ or i s there any evi dence of an overal l
vehi cl e bus probl em?
Al l
Yes → Refer to the Communi cati on category and perform the appropri -
ate symptom.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 3
3 I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, attempt to communi cate wi th the Powertrai n Control Modul e
(PCM).
Can the DRBI I I ௡ communi cate wi th the PCM?
Al l
Yes → Go To 4
No → Refer to the Communi cati on category and perform the appropri -
ate symptom.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
142
TRANSMISSION - 42RLE
TEST ACTION APPLICABILITY
4 I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, erase TCM DTC’s.
Start the engi ne i n park.
Wi th the DRBI I I ௡, read Transmi ssi on DTC’s.
Di d the DTC, P1694, return?
Al l
Yes → Repl ace the Transmi ssi on Control Modul e per the Servi ce I nfor-
mati on. WI TH THE DRBI I I ௡ PERFORM QUI CK LEARN.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 5
5 The condi ti ons necessary to set thi s DTC are not present at thi s ti me.
Usi ng the schemati cs as a gui de, i nspect the wi ri ng and connectors speci fi c to thi s
ci rcui t.
Wi ggl e the wi ri ng whi l e checki ng for shorts and open ci rcui ts.
Wi th the DRBI I I ௡, check the EATX EVENT DATA to hel p i denti fy the condi ti ons i n
whi ch the DTC was set.
Were there any probl ems found?
Al l
Yes → Repai r as necessary.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Test Compl ete.
143
TRANSMISSION - 42RLE
P1694-BUS COMMUNICATION WITH ENGINE MODULE — Continued
Symptom:
P1775-SOLENOID SWITCH VALVE LATCHED IN TCC POSITION
When Monitored and Set Condition:
P1775-SOLENOID SWITCH VALVE LATCHED IN TCC POSITION
When Moni tored: Duri ng an attempted shi ft i nto 1st gear.
Set Condi ti on: Thi s DTC i s set i f three unsuccessful attempts are made to shi ft i nto 1st
gear i n one gi ven i gni ti on start.
POSSIBLE CAUSES
RELATED DTC P0841 PRESENT
L/R PRESSURE SWI TCH
TRANSMI SSI ON CONTROL RELAY OUTPUT CI RCUI T OPEN
L/R PRESSURE SWI TCH SENSE CI RCUI T OPEN
L/R PRESSURE SWI TCH SENSE CI RCUI T SHORT TO GROUND
L/R PRESSURE SWI TCH SENSE CI RCUI T SHORT TO VOLTAGE
TRANSMI SSI ON CONTROL MODULE
I NTERMI TTENT WI RI NG AND CONNECTORS
TEST ACTION APPLICABILITY
1 NOTE: Low fluid level can be the cause of many Transmission problems. If
the fluid level is low, locate and repair the leak, then check and adjust the
fluid level per the Service Information.
NOTE: Always perform diagnostics with a fully charged battery to avoid
false symptoms.
Wi th the DRBI I I ௡, read the engi ne DTC’s. Check and repai r al l engi ne DTC’s pri or
to performi ng Transmi ssi on Symptom Di agnosti cs.
Wi th the DRBI I I ௡, read Transmi ssi on DTC’s. Record al l DTC’s and 1 Tri p Fai l ures.
NOTE: Diagnose 1 Trip Failures as a fully matured DTC.
Usi ng the wi ri ng di agram/schemati c as a gui de, i nspect the wi ri ng and connectors.
Repai r as necessary.
Perform the Shi ft Lever Posi ti on Test. I f the test does not pass, refer to Symptom test
for P0706 Check Shi fter Si gnal .
For Gear Rati o DTC’s, check and record al l CVI ’s.
Most DTC’s set on start up but some must be set by dri vi ng the vehi cl e such that al l
di agnosti c moni tors have run.
NOTE: Verify flash level of Transmission Control Module. Some problems
are corrected by software upgrades to the Transmission Control Module.
NOTE: Check for applicable TSB’s related to the symptom.
Perform thi s procedure pri or to Symptom di agnosi s.
Al l
Conti nue
Go To 2
144
TRANSMISSION - 42RLE
TEST ACTION APPLICABILITY
2 Wi th the DRBI I I ௡, check for other Transmi ssi on DTC’s
I s the DTC P0841 present al so?
Al l
Yes → Refer to the Transmi ssi on category and perform the appropri ate
symptom.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 3
3 Wi th the DRBI I I ௡, Check the STARTS SI NCE SET counter for P1775.
NOTE: This counter only applies to the last DTC set.
I s the STARTS SI NCE SET counter 2 or l ess?
Al l
Yes → Go To 4
No → Go To 10
4 Turn the i gni ti on off to the l ock posi ti on.
CAUTION: Remove the Starter Relay from the PDC. This will prevent the
vehicle frombeing started in gear.
I nstal l the Transmi ssi on Si mul ator, Mi l l er tool #8333 and the FWD Adapter Cabl e
ki t, Mi l l er tool #8333-1.
I gni ti on on, engi ne not runni ng.
Wi th the DRBI I I ௡, moni tor the L/R Pressure Swi tch state whi l e pressi ng the
Pressure Swi tch Test button on the Transmi ssi on Si mul ator.
Wi th the Transmi ssi on Si mul ator, sel ect the L/R on the Pressure Swi tch sel ector.
Whi l e observi ng the LR pressure swi tch state wi th the DRBI I I ௡, depress the
Pressure Swi tch Test button.
Di d the L/R Pressure Swi tch state change from OPEN to CLOSED when the test
button was pressed?
Al l
Yes → I nspect the Sol enoi d Swi tch Val ve i n the Val ve Body per the
Servi ce I nformati on and repai r or repl ace as necessary. I f no
probl ems are found i n Val ve Body, repl ace the Transmi ssi on
Sol enoi d/Pressure Swi tch Assembl y per the Servi ce I nformati on.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 5
5 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the TCM harness connector.
Di sconnect the Transmi ssi on Sol enoi d/Pressure Swi tch Assembl y harness connector.
Note: Check connectors - Clean/repair as necessary.
Measure the resi stance of the L/R Pressure Swi tch Sense ci rcui t from the TCM
harness connector to the Transmi ssi on Sol enoi d/Pressure Swi tch Assembl y harness
connector.
I s the resi stance above 5.0 ohms?
Al l
Yes → Repai r the L/R Pressure Swi tch Sense ci rcui t for an open.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 6
145
TRANSMISSION - 42RLE
P1775-SOLENOID SWITCH VALVE LATCHED IN TCC POSITION —
Continued
TEST ACTION APPLICABILITY
6 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the TCM harness connector.
Di sconnect the Transmi ssi on Sol enoi d/Pressure Swi tch Assembl y harness connector.
Note: Check connectors - Clean/repair as necessary.
Measure the resi stance between ground and the L/R Pressure Swi tch Sense ci rcui t.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Repai r the L/R Pressure Swi tch Sense ci rcui t for a short to
ground.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 7
7 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the TCM harness connector.
Di sconnect the Transmi ssi on Sol enoi d/Pressure Swi tch Assembl y harness connector.
Remove the Transmi ssi on Control Rel ay.
Note: Check connectors - Clean/repair as necessary.
Connect a jumper wi re between the Fused B+ ci rcui t and the Transmi ssi on Control
Rel ay Output ci rcui t i n the Transmi ssi on Control Rel ay connector.
I gni ti on on, engi ne not runni ng.
Measure the vol tage of the L/R Pressure Swi tch Sense ci rcui t.
I s the vol tage above 0.5 vol t?
Al l
Yes → Repai r the L/R Pressure Swi tch Sense ci rcui t for a short to
vol tage.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 8
8 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the TCM harness connector.
Di sconnect the Transmi ssi on Sol enoi d/Pressure Swi tch Assembl y harness connector.
Remove the Transmi ssi on Control Rel ay.
Note: Check connectors - Clean/repair as necessary.
Connect a jumper wi re between Fused B+ci rcui t and the Transmi ssi on Control Rel ay
Output ci rcui t.
I gni ti on on, engi ne not runni ng.
Usi ng a 12-vol t test l i ght connected to ground, check the Transmi ssi on Control Rel ay
Output ci rcui t i n the Sol enoi d/Pressure Swi tch Assembl y harness connector.
NOTE: The test light must illuminate brightly. Compare the brightness to
that of a direct connection to the battery.
Does the test l i ght i l l umi nate bri ghtl y?
Al l
Yes → Go To 9
No → Repai r the Transmi ssi on Control Rel ay Output ci rcui t for an open
or hi gh resi stance.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
146
TRANSMISSION - 42RLE
P1775-SOLENOID SWITCH VALVE LATCHED IN TCC POSITION —
Continued
TEST ACTION APPLICABILITY
9 Usi ng the schemati cs as a gui de, i nspect the wi ri ng and connectors. Repai r as
necessary. Pay parti cul ar attenti on to al l power and ground ci rcui ts.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace the Transmi ssi on Control Modul e per the Servi ce I nfor-
mati on. WI TH THE DRBI I I ௡ PERFORM QUI CK LEARN.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
10 The condi ti ons necessary to set thi s DTC are not present at thi s ti me.
Usi ng the schemati cs as a gui de, i nspect the wi ri ng and connectors speci fi c to thi s
ci rcui t.
Wi ggl e the wi ri ng whi l e checki ng for shorts and open ci rcui ts.
Wi th the DRBI I I ௡, check the EATX EVENT DATA to hel p i denti fy the condi ti ons i n
whi ch the DTC was set.
Test dri ve the vehi cl e.
Di d you experi ence any 2nd gear l aunches or no TCC engagement?
Al l
Yes → I nspect the Val ve Body for si gns of a stuck val ve or other probl em
i n the SSV area. I f no probl ems are found, repl ace the Sol enoi d/
Pressure Swi tch Assembl y. I f excessi ve debri s i s present i n the
Pan or Val ve Body, repai r cause of the debri s as necessary.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Test Compl ete.
147
TRANSMISSION - 42RLE
P1775-SOLENOID SWITCH VALVE LATCHED IN TCC POSITION —
Continued
Symptom:
P1776-SOLENOID SWITCH VALVE LATCHED IN LR POSITION
When Monitored and Set Condition:
P1776-SOLENOID SWITCH VALVE LATCHED IN LR POSITION
When Moni tored: Conti nuousl y when doi ng parti al or ful l EMCC (PEMCC or FEMCC).
Set Condi ti on: Thi s DTC wi l l set i f the TCM senses the L/R Pressure Swi tch cl osi ng whi l e
performi ng PEMCC or FEMCC or after two unsuccessful attempts to perform PEMCC or
FEMCC.
POSSIBLE CAUSES
RELATED DTC P0841 PRESENT
L/R PRESSURE SWI TCH
TRANSMI SSI ON CONTROL RELAY OUTPUT CI RCUI T OPEN
L/R PRESSURE SWI TCH SENSE CI RCUI T OPEN
L/R PRESSURE SWI TCH SENSE CI RCUI T SHORT TO GROUND
L/R PRESSURE SWI TCH SENSE CI RCUI T SHORT TO VOLTAGE
TRANSMI SSI ON CONTROL MODULE
I NTERMI TTENT WI RI NG AND CONNECTORS
TEST ACTION APPLICABILITY
1 NOTE: Low fluid level can be the cause of many Transmission problems. If
the fluid level is low, locate and repair the leak, then check and adjust the
fluid level per the Service Information.
NOTE: Always perform diagnostics with a fully charged battery to avoid
false symptoms.
Wi th the DRBI I I ௡, read the engi ne DTC’s. Check and repai r al l engi ne DTC’s pri or
to performi ng Transmi ssi on Symptom Di agnosti cs.
Wi th the DRBI I I ௡, read Transmi ssi on DTC’s. Record al l DTC’s and 1 Tri p Fai l ures.
NOTE: Diagnose 1 Trip Failures as a fully matured DTC.
Usi ng the wi ri ng di agram/schemati c as a gui de, i nspect the wi ri ng and connectors.
Repai r as necessary.
Perform the Shi ft Lever Posi ti on Test. I f the test does not pass, refer to Symptom test
for P0706 Check Shi fter Si gnal .
For Gear Rati o DTC’s, check and record al l CVI ’s.
Most DTC’s set on start up but some must be set by dri vi ng the vehi cl e such that al l
di agnosti c moni tors have run.
NOTE: Verify flash level of Transmission Control Module. Some problems
are corrected by software upgrades to the Transmission Control Module.
NOTE: Check for applicable TSB’s related to the symptom.
Perform thi s procedure pri or to Symptom di agnosi s.
Al l
Conti nue
Go To 2
148
TRANSMISSION - 42RLE
TEST ACTION APPLICABILITY
2 Wi th the DRBI I I ௡, check for other Transmi ssi on DTCs
I s the DTC P0841 present al so?
Al l
Yes → Refer to the Transmi ssi on category and perform the appropri ate
symptom.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 3
3 Wi th the DRBI I I ௡, Check the STARTS SI NCE SET counter for P1776.
NOTE: This counter only applies to the last DTC set.
I s the STARTS SI NCE SET counter 2 or l ess?
Al l
Yes → Go To 4
No → Go To 10
4 Turn the i gni ti on off to the l ock posi ti on.
CAUTION: Remove the Starter Relay. This will prevent the vehicle from
being started in gear.
I nstal l the Transmi ssi on Si mul ator, Mi l l er tool #8333 and the FWD Adapter Cabl e
ki t, Mi l l er tool #8333-1.
I gni ti on on, engi ne not runni ng.
On the Transmi ssi on Si mul ator sel ect L/R on the Pressure Swi tch sel ector swi tch.
Wi th the DRBI I I ௡, moni tor the L/R Pressure Swi tch state whi l e pressi ng the
Pressure Swi tch Test button on the Transmi ssi on Si mul ator.
Di d the Pressure Swi tch state change from OPEN to CLOSED when the test button
was pressed?
Al l
Yes → I nspect the Sol enoi d Swi tch Val ve i n the Val ve Body per the
Servi ce I nformati on and repai r or repl ace as necessary. I f no
probl ems are found i n Val ve Body, repl ace the Transmi ssi on
Sol enoi d/Pressure Swi tch Assembl y per the Servi ce I nformati on.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 5
5 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the TCM harness connector.
Di sconnect the Transmi ssi on Sol enoi d/Pressure Swi tch Assembl y harness connector.
Note: Check connectors - Clean/repair as necessary.
Measure the resi stance of the L/R Pressure Swi tch Sense ci rcui t from the TCM
harness connector to the Transmi ssi on Sol enoi d/Pressure Swi tch Assembl y harness
connector.
I s the resi stance above 5.0 ohms?
Al l
Yes → Repai r the L/R Pressure Swi tch Sense ci rcui t for an open.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 6
149
TRANSMISSION - 42RLE
P1776-SOLENOID SWITCH VALVE LATCHED IN LR POSITION —
Continued
TEST ACTION APPLICABILITY
6 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the TCM harness connector.
Di sconnect the Transmi ssi on Sol enoi d/Pressure Swi tch Assembl y harness connector.
Note: Check connectors - Clean/repair as necessary.
Measure the resi stance between ground and the L/R Pressure Swi tch Sense ci rcui t.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Repai r the L/R Pressure Swi tch Sense ci rcui t for a short to
ground.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 7
7 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the TCM harness connector.
Di sconnect the Transmi ssi on Sol enoi d/Pressure Swi tch Assembl y harness connector.
Remove the Transmi ssi on Control Rel ay from the PDC.
Note: Check connectors - Clean/repair as necessary.
Connect a jumper wi re between the Fused B+ ci rcui t and the Transmi ssi on Control
Rel ay Output ci rcui t i n the Transmi ssi on Control Rel ay connector.
I gni ti on on, engi ne not runni ng.
Measure the vol tage of the L/R Pressure Swi tch Sense ci rcui t.
I s the vol tage above 0.5 vol ts?
Al l
Yes → Repai r the L/R Pressure Swi tch Sense ci rcui t for a short to
vol tage.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 8
8 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the Transmi ssi on Sol enoi d/Pressure Swi tch Assembl y harness connector.
Remove the Transmi ssi on Control Rel ay.
Note: Check connectors - Clean/repair as necessary.
Connect a jumper wi re between the Fused B+ ci rcui t and the Transmi ssi on Control
Rel ay Output ci rcui t i n the Transmi ssi on Control Rel ay connector.
I gni ti on on, engi ne not runni ng.
Usi ng a 12-vol t test l i ght connected to ground, check the Transmi ssi on Control Rel ay
Output ci rcui t.
NOTE: The test light must illuminate brightly. Compare the brightness to
that of a direct connection to the battery.
Does the test l i ght i l l umi nate bri ghtl y?
Al l
Yes → Go To 9
No → Repai r the Transmi ssi on Control Rel ay Output ci rcui t for an open
or hi gh resi stance.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
9 Usi ng the schemati cs as a gui de, i nspect the wi ri ng and connectors. Repai r as
necessary. Pay parti cul ar attenti on to al l power and ground ci rcui ts.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace the Transmi ssi on Control Modul e per the Servi ce I nfor-
mati on. WI TH THE DRBI I I ௡ PERFORM QUI CK LEARN.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
150
TRANSMISSION - 42RLE
P1776-SOLENOID SWITCH VALVE LATCHED IN LR POSITION —
Continued
TEST ACTION APPLICABILITY
10 The condi ti ons necessary to set thi s DTC are not present at thi s ti me.
Usi ng the schemati cs as a gui de, i nspect the wi ri ng and connectors speci fi c to thi s
ci rcui t.
Wi ggl e the wi ri ng whi l e checki ng for shorts and open ci rcui ts.
Wi th the DRBI I I ௡, check the EATX EVENT DATA to hel p i denti fy the condi ti ons i n
whi ch the DTC was set.
Test dri ve the vehi cl e.
Di d you experi ence any 2nd gear l aunches or no TCC engagement?
Al l
Yes → I nspect the Val ve Body for si gns of a stuck val ve or other probl em
i n the SSV area. I f no probl ems are found, repl ace the Sol enoi d/
Pressure Swi tch Assembl y. I f excessi ve debri s i s present i n the
Pan or Val ve Body, repai r the cause of debri s as necessary.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Test Compl ete.
151
TRANSMISSION - 42RLE
P1776-SOLENOID SWITCH VALVE LATCHED IN LR POSITION —
Continued
Symptom:
P1790-FAULT IMMEDIATELY AFTER SHIFT
When Monitored and Set Condition:
P1790-FAULT IMMEDIATELY AFTER SHIFT
When Moni tored: After a speed rati o error i s stored.
Set Condi ti on: Thi s code i s set i f the associ ated speed rati o code i s stored wi thi n 1.3
seconds after a shi ft.
POSSIBLE CAUSES
CONDI TI ON P1790 PRESENT
TEST ACTION APPLICABILITY
1 NOTE: Low fluid level can be the cause of many Transmission problems. If
the fluid level is low, locate and repair the leak, then check and adjust the
fluid level per the Service Information.
NOTE: Always perform diagnostics with a fully charged battery to avoid
false symptoms.
Wi th the DRBI I I ௡, read the engi ne DTC’s. Check and repai r al l engi ne DTC’s pri or
to performi ng Transmi ssi on Symptom Di agnosti cs.
Wi th the DRBI I I ௡, read Transmi ssi on DTC’s. Record al l DTC’s and 1 Tri p Fai l ures.
NOTE: Diagnose 1 Trip Failures as a fully matured DTC.
Usi ng the wi ri ng di agram/schemati c as a gui de, i nspect the wi ri ng and connectors.
Repai r as necessary.
Perform the Shi ft Lever Posi ti on Test. I f the test does not pass, refer to Symptom test
for P0706 Check Shi fter Si gnal .
For Gear Rati o DTC’s, check and record al l CVI ’s.
Most DTC’s set on start up but some must be set by dri vi ng the vehi cl e such that al l
di agnosti c moni tors have run.
NOTE: Verify flash level of Transmission Control Module. Some problems
are corrected by software upgrades to the Transmission Control Module.
NOTE: Check for applicable TSB’s related to the symptom.
Perform thi s procedure pri or to Symptom di agnosi s.
Al l
Conti nue
Go To 2
2 Thi s DTC i s set al ong wi th a gear rati o DTC. Perform the appropri ate test for the
Gear Rati o DTC stored.
NOTE: Check 1 trip failures if there are no Gear Ratio DTC’s current.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Refer to the Transmi ssi on category and perform the appropri ate
symptom.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
152
TRANSMISSION - 42RLE
Symptom:
P1793-TRD LINK COMMUNICATION ERROR
When Monitored and Set Condition:
P1793-TRD LINK COMMUNICATION ERROR
When Moni tored: The transmi ssi on control l er pul ses the 12 vol t TRD si gnal from the
PCM to ground, duri ng torque managed shi fts wi th the throttl e angl e above 54 degrees.
The TRD system i s al so tested whenever the vehi cl e i s stopped and the engi ne speed i s at
i dl e.
Set Condi ti on: Thi s code i s set when the Transmi ssi on Control Modul e (TCM) sends two
subsequent torque reducti on messages to the Powertrai n Control Modul e (PCM) vi a the
TRD l i nk ci rcui t and does not recei ve a confi rmati on from the PCM over the communi ca-
ti on bus.
POSSIBLE CAUSES
RELATED DTC’S PRESENT
TORQUE MANAGEMENT REQUEST SENSE CI RCUI T OPEN
TORQUE MANAGEMENT REQUEST SENSE SHORT TO GROUND
TORQUE MANAGEMENT REQUEST SENSE CI RCUI T SHORT TO VOLTAGE
POWERTRAI N CONTROL MODULE
TRANSMI SSI ON CONTROL MODULE
I NTERMI TTENT WI RI NG AND CONNECTORS
TEST ACTION APPLICABILITY
1 NOTE: Low fluid level can be the cause of many Transmission problems. If
the fluid level is low, locate and repair the leak, then check and adjust the
fluid level per the Service Information.
NOTE: Always perform diagnostics with a fully charged battery to avoid
false symptoms.
Wi th the DRBI I I ௡, read the engi ne DTC’s. Check and repai r al l engi ne DTC’s pri or
to performi ng Transmi ssi on Symptom Di agnosti cs.
Wi th the DRBI I I ௡, read Transmi ssi on DTC’s. Record al l DTC’s and 1 Tri p Fai l ures.
NOTE: Diagnose 1 Trip Failures as a fully matured DTC.
Usi ng the wi ri ng di agram/schemati c as a gui de, i nspect the wi ri ng and connectors.
Repai r as necessary.
Perform the Shi ft Lever Posi ti on Test. I f the test does not pass, refer to Symptom test
for P0706 Check Shi fter Si gnal .
For Gear Rati o DTC’s, check and record al l CVI ’s.
Most DTC’s set on start up but some must be set by dri vi ng the vehi cl e such that al l
di agnosti c moni tors have run.
NOTE: Verify flash level of Transmission Control Module. Some problems
are corrected by software upgrades to the Transmission Control Module.
NOTE: Check for applicable TSB’s related to the symptom.
Perform thi s procedure pri or to Symptom di agnosi s.
Al l
Conti nue
Go To 2
153
TRANSMISSION - 42RLE
TEST ACTION APPLICABILITY
2 Wi th the DRBI I I ௡, read Transmi ssi on DTC’s.
Are any of the fol l owi ng DTCs P1694, P0731, P0732, P0733, P0734, P0736 present
al so?
Al l
Yes → I f any of these codes are present, di sregard the P1793 DTC and
refer to the Transmi ssi on category and perform the appropri ate
symptom.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 3
3 Wi th the DRBI I I ௡, Check the STARTS SI NCE SET counter.
Note: This counter only applies to the last DTC set.
I s the STARTS SI NCE SET equal to 0?
Al l
Yes → Go To 4
No → Go To 9
4 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the PCM harness connector.
Di sconnect the TCM harness connector.
Note: Check connectors - Clean/repair as necessary.
Measure the resi stance of the Torque Management Request Sense ci rcui t from the
TCM harness connector to the PCM harness connector.
I s the resi stance above 5.0 ohms?
Al l
Yes → Repai r the Torque Management Request Sense ci rcui t for an
open.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 5
5 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the PCM harness connector.
Di sconnect the TCM harness connector.
Note: Check connectors - Clean/repair as necessary.
Measure the resi stance between ground and the Torque Management Request Sense
ci rcui t.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Repai r Torque Management Request Sense ci rcui t for a short to
ground.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 6
6 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the TCM harness connector.
I gni ti on on, engi ne not runni ng.
Measure the vol tage of the Torque Management Request Sense ci rcui t.
I s the vol tage above 10.5 vol ts?
Al l
Yes → Repai r Torque Management Request Sense ci rcui t for a short to
vol tage.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 7
154
TRANSMISSION - 42RLE
P1793-TRD LINK COMMUNICATION ERROR — Continued
TEST ACTION APPLICABILITY
7 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the TCM harness connector.
I gni ti on on, engi ne not runni ng.
Measure the vol tage of the Torque Management Request Sense ci rcui t i n the TCM
harness connector.
I s the vol tage above 7.0 vol ts?
Al l
Yes → Repl ace the Transmi ssi on Control Modul e per the Servi ce I nfor-
mati on. WI TH THE DRBI I I ௡ PERFORM QUI CK LEARN.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 8
8 I f there are no possi bl e causes remai ni ng, vi ew repai r. Al l
Repai r
Repl ace and program the Powertrai n Control Modul e per the
Servi ce I nformati on.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
9 The condi ti ons necessary to set thi s DTC are not present at thi s ti me.
Usi ng the schemati cs as a gui de, i nspect the wi ri ng and connectors speci fi c to thi s
ci rcui t.
Wi ggl e the wi ri ng whi l e checki ng for shorts and open ci rcui ts.
Wi th the DRBI I I ௡, check the EATX EVENT DATA to hel p i denti fy the condi ti ons i n
whi ch the DTC was set.
Were there any probl ems found?
Al l
Yes → Repai r as necessary.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Test Compl ete.
155
TRANSMISSION - 42RLE
P1793-TRD LINK COMMUNICATION ERROR — Continued
Symptom:
P1794-SPEED SENSOR GROUND ERROR
When Monitored and Set Condition:
P1794-SPEED SENSOR GROUND ERROR
When Moni tored: The transmi ssi on gear rati o i s moni tored conti nuousl y whi l e the
transmi ssi on i s i n gear.
Set Condi ti on: After a TCM reset i n neutral and I nput/Output speed rati o equal s a rati o
of i nput to output of 2.5 to 1.
POSSIBLE CAUSES
SPEED SENSOR GROUND CI RCUI T OPEN
TRANSMI SSI ON CONTROL MODULE
I NTERMI TTENT WI RI NG AND CONNECTORS
TEST ACTION APPLICABILITY
1 NOTE: Low fluid level can be the cause of many Transmission problems. If
the fluid level is low, locate and repair the leak, then check and adjust the
fluid level per the Service Information.
NOTE: Always perform diagnostics with a fully charged battery to avoid
false symptoms.
Wi th the DRBI I I ௡, read the engi ne DTC’s. Check and repai r al l engi ne DTC’s pri or
to performi ng Transmi ssi on Symptom Di agnosti cs.
Wi th the DRBI I I ௡, read Transmi ssi on DTC’s. Record al l DTC’s and 1 Tri p Fai l ures.
NOTE: Diagnose 1 Trip Failures as a fully matured DTC.
Usi ng the wi ri ng di agram/schemati c as a gui de, i nspect the wi ri ng and connectors.
Repai r as necessary.
Perform the Shi ft Lever Posi ti on Test. I f the test does not pass, refer to Symptom test
for P0706 Check Shi fter Si gnal .
For Gear Rati o DTC’s, check and record al l CVI ’s.
Most DTC’s set on start up but some must be set by dri vi ng the vehi cl e such that al l
di agnosti c moni tors have run.
NOTE: Verify flash level of Transmission Control Module. Some problems
are corrected by software upgrades to the Transmission Control Module.
NOTE: Check for applicable TSB’s related to the symptom.
Perform thi s procedure pri or to Symptom di agnosi s.
Al l
Conti nue
Go To 2
2 Start the engi ne i n park.
Wi th the DRBI I I ௡, observe the I nput and Output Speed Sensor readi ngs.
I s the Output Speed Sensor readi ng twi ce the I nput Speed Sensor readi ng?
Al l
Yes → Go To 3
No → Go To 6
156
TRANSMISSION - 42RLE
TEST ACTION APPLICABILITY
3 Turn the i gni ti on off to the l ock posi ti on.
CAUTION: Remove the Starter Relay. This will prevent the vehicle from
being started in gear.
I nstal l the Transmi ssi on Si mul ator, Mi l l er tool #8333 and the El ectroni c Transmi s-
si on Adapter ki t 8333-1.
I gni ti on on, engi ne not runni ng.
Usi ng the Transmi ssi on Si mul ator, set the sel ector swi tch to the 3000/1250 posi ti on.
Turn the I nput/Output swi tch to ON.
Wi th the DRBI I I ௡, read the I nput and Output Speed Sensor RPM.
Does the I nput Speed read 3000 RPM and the Output Speed read 1250 RPM wi thi n
50 RPM?
Al l
Yes → Go To 5
No → Go To 4
4 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect I nput and Output Speed Sensor harness connectors.
Di sconnect the TRS harness connector.
Note: Check connectors - Clean/repair as necessary.
Measure the resi stance of the Speed Sensor Ground ci rcui t from the TCM harness
connector to the I nput and Output Speed Sensor harness connectors.
I s the resi stance above 5.0 ohms on ei ther Speed Sensor Ground ci rcui t?
Al l
Yes → Repai r the Speed Sensor Ground ci rcui t for an open or hi gh
resi stance.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 5
5 Usi ng the schemati cs as a gui de, i nspect the wi ri ng and connectors. Repai r as
necessary. Pay parti cul ar attenti on to al l power and ground ci rcui ts.
I f there are no possi bl e causes remai ni ng, vi ew repai r.
Al l
Repai r
Repl ace the Transmi ssi on Control Modul e per the Servi ce I nfor-
mati on. WI TH THE DRBI I I ௡ PERFORM QUI CK LEARN.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
6 The condi ti ons necessary to set thi s DTC are not present at thi s ti me.
Usi ng the schemati cs as a gui de, i nspect the wi ri ng and connectors speci fi c to thi s
ci rcui t.
Wi ggl e the wi ri ng whi l e checki ng for shorts and open ci rcui ts.
Wi th the DRBI I I ௡, check the EATX EVENT DATA to hel p i denti fy the condi ti ons i n
whi ch the DTC was set.
Were there any probl ems found?
Al l
Yes → Repai r as necessary.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Test Compl ete.
157
TRANSMISSION - 42RLE
P1794-SPEED SENSOR GROUND ERROR — Continued
Symptom:
P1797-MANUAL SHIFT OVERHEAT
When Monitored and Set Condition:
P1797-MANUAL SHIFT OVERHEAT
When Moni tored: Whenever engi ne i s runni ng and transmi ssi on i s i n the AutoSti ck
mode.
Set Condi ti on: I f the engi ne temperature exceeds 124° C or 255° F or the transmi ssi on
temperature exceeds 135° C or 275° F whi l e i n AutoSti ck mode. Note: Aggressi ve dri vi ng
or dri vi ng i n l ow for extended peri ods of ti me i n AutoSti ck௡ mode wi l l set thi s DTC.
POSSIBLE CAUSES
MANUAL SHI FT OVERHEAT
TEST ACTION APPLICABILITY
1 NOTE: Low fluid level can be the cause of many Transmission problems. If
the fluid level is low, locate and repair the leak, then check and adjust the
fluid level per the Service Information.
NOTE: Always perform diagnostics with a fully charged battery to avoid
false symptoms.
Wi th the DRBI I I ௡, read the engi ne DTC’s. Check and repai r al l engi ne DTC’s pri or
to performi ng Transmi ssi on Symptom Di agnosti cs.
Wi th the DRBI I I ௡, read Transmi ssi on DTC’s. Record al l DTC’s and 1 Tri p Fai l ures.
NOTE: Diagnose 1 Trip Failures as a fully matured DTC.
Usi ng the wi ri ng di agram/schemati c as a gui de, i nspect the wi ri ng and connectors.
Repai r as necessary.
Perform the Shi ft Lever Posi ti on Test. I f the test does not pass, refer to Symptom test
for P0706 Check Shi fter Si gnal .
For Gear Rati o DTC’s, check and record al l CVI ’s.
Most DTC’s set on start up but some must be set by dri vi ng the vehi cl e such that al l
di agnosti c moni tors have run.
NOTE: Verify flash level of Transmission Control Module. Some problems
are corrected by software upgrades to the Transmission Control Module.
NOTE: Check for applicable TSB’s related to the symptom.
Perform thi s procedure pri or to Symptom di agnosi s.
Al l
Conti nue
Go To 2
158
TRANSMISSION - 42RLE
TEST ACTION APPLICABILITY
2 Thi s i s an i nformati onal DTC onl y.
Check the Engi ne and Transmi ssi on Cool i ng Systems for proper operati on.
Check the Radi ator Cool i ng Fan operati on.
Check the Transmi ssi on Cool i ng Fan operati on i f equi pped.
Check the Transmi ssi on Fl ui d Level . Make sure i t i s not overfi l l ed.
NOTE: Aggressivedrivingor drivingin lowfor extended periods of timein
Autostick௡ mode will set this DTC.
Wi th the DRBI I I ௡, check the EATX EVENT DATA to hel p i denti fy the condi ti ons i n
whi ch the DTC was set.
Were there any probl ems found?
Al l
Yes → Repai r as necessary.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Test Compl ete.
159
TRANSMISSION - 42RLE
P1797-MANUAL SHIFT OVERHEAT — Continued
Symptom:
*BACKUP LAMPSCOME ONWHILE SHIFTER ISNOT INREVERSE
POSITION
POSSIBLE CAUSES
BACKUP LAMPS ALWAYS ON
BACKUP LAMP SUPPLY CI RCUI T SHORT TO VOLTAGE
I NTERMI TTENT WI RI NG AND CONNECTORS
TEST ACTION APPLICABILITY
1 I gni ti on on, engi ne not runni ng.
Fi rml y appl y brakes.
Pl ace the shi ft l ever i n the posi ti on whi ch causes the Backup Lamps to come on other
than Reverse.
Do the Backup Lamps come on wi th the shi ft l ever not i n the Reverse posi ti on?
Al l
Yes → Go To 2
No → Go To 4
2 I gni ti on on, engi ne not runni ng.
Pl ace the Shi ft Lever i n the posi ti on that causes the Backup Lamps to come on other
than Reverse.
Di sconnect the TRS harness connector.
NOTE: Thiswill causeaDTC P0706andpossibly other DTC’stobestoredin
theTCM. They must beerasedbeforereturningthevehicletothecustomer.
Di d the Backup Lamps go out when the TRS harness connector was di sconnected?
Al l
Yes → Repl ace the Transmi ssi on Range Sensor per the Servi ce I nforma-
ti on.
Perform TRANSMI SSI ON NO TROUBLE CODE VERI FI CA-
TI ON TEST.
No → Go To 3
3 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the Transmi ssi on TRS harness connector.
NOTE: Check connectors - Clean/repair as necessary.
I gni ti on on, engi ne not runni ng.
Measure the vol tage of the Back-up Lamp Suppl y ci rcui t i n the TCM harness
connector.
I s the vol tage above 0.5 vol t?
Al l
Yes → Repai r the Backup Lamp Suppl y ci rcui t for a short to vol tage.
Perform TRANSMI SSI ON NO TROUBLE CODE VERI FI CA-
TI ON TEST.
No → Test Compl ete.
160
TRANSMISSION - 42RLE
TEST ACTION APPLICABILITY
4 The condi ti on i s not present at thi s ti me.
Usi ng the schemati cs as a gui de, i nspect the wi ri ng and connectors speci fi c to thi s
ci rcui t.
Wi ggl e the wi ri ng whi l e checki ng for shorts and open ci rcui ts.
Were there any probl ems found?
Al l
Yes → Repai r as necessary.
Perform TRANSMI SSI ON NO TROUBLE CODE VERI FI CA-
TI ON TEST.
No → Test Compl ete.
161
TRANSMISSION - 42RLE
*BACKUP LAMPS COME ON WHILE SHIFTER IS NOT IN REVERSE
POSITION — Continued
Symptom:
*BACKUP LAMPS INOPERATIVE
POSSIBLE CAUSES
OPEN LEFT BACKUP LAMP BULB
OPEN RI GHT BACKUP LAMP BULB
BACKUP LAMP GROUND CI RCUI T OPEN
BACKUP LAMP SUPPLY CI RCUI T OPEN
FUSED I GNI TI ON SWI TCH OUTPUT CI RCUI T OPEN
BACKUP LAMP SUPPLY CI RCUI T SHORT TO GROUND
TRANSMI SSI ON RANGE SENSOR
I NTERMI TTENT WI RI NG AND CONNECTORS
TEST ACTION APPLICABILITY
1 I gni ti on on, engi ne not runni ng.
Pl ace foot fi rml y on brake pedal .
Pl ace the shi ft l ever i n the reverse posi ti on.
Do ei ther of the Backup Lamps work?
Al l
Yes → Go To 2
No → Go To 3
2 The condi ti on i s not present at thi s ti me.
Usi ng the schemati cs as a gui de, i nspect the wi ri ng and connectors speci fi c to thi s
ci rcui t.
Wi ggl e the wi ri ng whi l e checki ng for shorts and open ci rcui ts.
Were there any probl ems found?
Al l
Yes → Repai r as necessary.
Perform TRANSMI SSI ON NO TROUBLE CODE VERI FI CA-
TI ON TEST.
No → Test Compl ete.
3 Remove the l eft Backup Lamp bul b.
Measure the resi stance of the Backup Lamp bul b.
I s the resi stance above 5.0 ohms?
Al l
Yes → Repl ace the Backup Lamp bul b.
Perform TRANSMI SSI ON NO TROUBLE CODE VERI FI CA-
TI ON TEST.
No → Go To 4
4 Remove the ri ght Backup Lamp bul b.
Measure the resi stance of the Backup Lamp bul b.
I s the resi stance above 5.0 ohms?
Al l
Yes → Repl ace the Backup Lamp bul b.
Perform TRANSMI SSI ON NO TROUBLE CODE VERI FI CA-
TI ON TEST.
No → Go To 5
162
TRANSMISSION - 42RLE
TEST ACTION APPLICABILITY
5 Turn the i gni ti on off to the l ock posi ti on.
CAUTION: Remove the Starter Relay. This will prevent the vehicle from
being started in gear.
I nstal l the Transmi ssi on Si mul ator, Mi l l er tool #8333 and the FWD Adapter Cabl e
ki t, Mi l l er tool #8333-1.
I gni ti on on, engi ne not runni ng.
Press the ЉReverse Li ght TestЉ button on the Transmi ssi on Si mul ator whi l e observi ng
the backup l amps.
Do ei ther of the back-up l amps come on?
Al l
Yes → Go To 6
No → Go To 7
6 I f there are no possi bl e causes remai ni ng, vi ew repai r. Al l
Repai r
Repl ace Transmi ssi on Range Sensor per the Servi ce I nformati on.
Perform TRANSMI SSI ON NO TROUBLE CODE VERI FI CA-
TI ON TEST.
7 Remove the Backup Lamp bul b.
Usi ng a 12-vol t test l i ght connected to 12-vol ts, check the Backup Lamp Ground
ci rcui t i n the Backup Lamp socket.
NOTE: The test light must illuminate brightly. Compare the brightness to
that of a direct connection to the battery.
Does the test l i ght i l l umi nate bri ghtl y?
Al l
Yes → Go To 8
No → Repai r the Backup Lamp Ground ci rcui t for an open or hi gh
resi stance.
Perform TRANSMI SSI ON NO TROUBLE CODE VERI FI CA-
TI ON TEST.
8 Turn the i gni ti on off to the l ock posi ti on.
Remove the Backup Lamp bul b.
Di sconnect the Transmi ssi on TRS harness connector.
Note: Check connectors - Clean/repair as necessary.
Measure the resi stance of the Backup Lamp Suppl y ci rcui t from the Backup Lamp
Socket to the TRS harness connector.
I s the resi stance above 5.0 ohms?
Al l
Yes → Repai r the Backup Lamp Suppl y ci rcui t for an open.
Perform TRANSMI SSI ON NO TROUBLE CODE VERI FI CA-
TI ON TEST.
No → Go To 9
163
TRANSMISSION - 42RLE
*BACKUP LAMPS INOPERATIVE — Continued
TEST ACTION APPLICABILITY
9 Turn the i gni ti on off to the l ock posi ti on.
Di sconnect the Transmi ssi on TRS harness connector.
I gni ti on on, engi ne not runni ng.
Usi ng a 12-vol t test l i ght connected to ground, check the Fused I gni ti on Swi tch
Output ci rcui t i n the TRS harness connector.
NOTE: The test light must illuminate brightly. Compare the brightness to
that of a direct connection to the battery.
Does the test l i ght i l l umi nate bri ghtl y?
Al l
Yes → Go To 10
No → Repai r the Fused I gni ti on Swi tch Output ci rcui t for an open. I f
the fuse i s open make sure to check for a short to ground.
Perform TRANSMI SSI ON NO TROUBLE CODE VERI FI CA-
TI ON TEST.
10 Turn i gni ti on off to the l ock posi ti on.
Remove the Backup Lamp bul b.
Di sconnect the Transmi ssi on TRS harness connector.
Note: Check connectors - Clean/repair as necessary.
Measure the resi stance between ground and the Backup Lamp Suppl y ci rcui t.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Repai r Backup Lamp Suppl y ci rcui t for a short to ground. Check
the fuse and repl ace i f necessary.
Perform TRANSMI SSI ON NO TROUBLE CODE VERI FI CA-
TI ON TEST.
No → Test Compl ete.
164
TRANSMISSION - 42RLE
*BACKUP LAMPS INOPERATIVE — Continued
Symptom:
*CHECKING PARK/NEUTRAL SWITCH OPERATION
POSSIBLE CAUSES
P/N POSI TI ON SWI TCH SENSE CI RCUI T OPEN
P/N POSI TI ON SWI TCH SENSE CI RCUI T SHORTED TO GROUND
TRANSMI SSI ON RANGE SENSOR
PCM - P/N POSI TI ON SWI TCH
TEST ACTION APPLICABILITY
1 Turn the i gni ti on on.
Wi th the DRBI I I ௡, read the Park/Neutral Posi ti on Swi tch i nput state.
Whi l e movi ng the gear sel ector through al l gear posi ti ons, Park to 1 and back to Park,
watch the DRBI I I ௡ di spl ay.
Di d the DRBI I I ௡ di spl ay show P/N and D/R i n the correct gear posi ti ons?
Al l
Yes → Test Compl ete.
No → Go To 2
2 Turn the i gni ti on off.
Di sconnect the PCM harness connectors.
Di sconnect the Transmi ssi on Range Sensor harness connector.
Note: Check connectors - Clean/repair as necessary.
Measure the resi stance of the P/N Posi ti on Swi tch Sense ci rcui t.
I s the resi stance bel ow 5.0 ohms?
Al l
Yes → Go To 3
No → Repai r the P/N Posi ti on Swi tch Sense ci rcui t for an open.
Perform TRANSMI SSI ON NO TROUBLE CODE VERI FI CA-
TI ON TEST.
3 Turn the i gni ti on off.
Di sconnect the PCM harness connectors.
Di sconnect the Transmi ssi on Range Sensor harness connector.
Note: Check connectors - Clean/repair as necessary.
Measure the resi stance between ground and the P/N Posi ti on Swi tch Sense ci rcui t.
I s the resi stance above 100k ohms?
Al l
Yes → Go To 4
No → Repai r the P/N Posi ti on Swi tch Sense ci rcui t for a short to ground.
Perform TRANSMI SSI ON NO TROUBLE CODE VERI FI CA-
TI ON TEST.
165
TRANSMISSION - 42RLE
TEST ACTION APPLICABILITY
4 Turn the i gni ti on off.
Di sconnect the PCM harness connectors.
Move the Gear sel ector through al l gear posi ti ons, from Park to 1st and back.
Whi l e movi ng the gear sel ector through each gear, measure the resi stance between
ground and the P/N Posi ti on Swi tch Sense ci rcui t.
Di d the resi stance change from above 10.0 ohms to bel ow 10.0 ohms?
Al l
Yes → Go To 5
No → Repl ace the Transmi ssi on Range Sensor.
Perform TRANSMI SSI ON NO TROUBLE CODE VERI FI CA-
TI ON TEST.
5 I f there are no possi bl e causes remai ni ng, vi ew repai r. Al l
Repai r
Repl ace and program the Powertrai n Control Modul e per the
Servi ce I nformati on.
Perform POWERTRAI N VERI FI CATI ON TEST VER - 2.
166
TRANSMISSION - 42RLE
*CHECKING PARK/NEUTRAL SWITCH OPERATION — Continued
Symptom:
*INCORRECT TRANSMISSION FLUID LEVEL
POSSIBLE CAUSES
I NCORRECT FLUI D LEVEL
TEST ACTION APPLICABILITY
1 The transmi ssi on must be above 70 degree F. pri or to checki ng fl ui d l evel . Adjusti ng
fl ui d l evel on a col d transmi ssi on wi l l resul t i n an overfi l l ed transmi ssi on.
Check the transmi ssi on fl ui d l evel per the servi ce i nformati on.
I s the fl ui d l evel OK?
Al l
Yes → Test Compl ete.
No → Adjust fl ui d l evel . Repai r cause of i ncorrect fl ui d l evel .
Perform TRANSMI SSI ON NO TROUBLE CODE VERI FI CA-
TI ON TEST.
167
TRANSMISSION - 42RLE
Symptom:
*NO SPEEDOMETER OPERATION
POSSIBLE CAUSES
NO SPEEDOMETER OPERATI ON
TEST ACTION APPLICABILITY
1 Wi th the DRBI I I ௡, check the pi ni on factor setti ng i n the TCM.
I s the pi ni on factor mi ssi ng or set i ncorrectl y?
Al l
Yes → One possi bl e cause i s the pi ni on factor i s not set or i s set
i ncorrectl y i n the TCM.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Test Compl ete.
168
TRANSMISSION - 42RLE
Symptom:
*TRANSMISSION NOISY WITH NO DTC’S PRESENT
POSSIBLE CAUSES
I NCORRECT FLUI D LEVEL
I NTERNAL TRANSMI SSI ON PROBLEM - NOI SY
I NTERNAL TRANSMI SSI ON PROBLEM - NOI SY WHI LE STANDI NG STI LL
TEST ACTION APPLICABILITY
1 Check the Transmi ssi on Fl ui d Level per the Servi ce I nformati on.
I s the fl ui d l evel OK?
Al l
Yes → Go To 2
No → Adjust fl ui d l evel and repai r cause of i ncorrect fl ui d l evel .
Perform TRANSMI SSI ON NO TROUBLE CODE VERI FI CA-
TI ON TEST.
2 Pl ace vehi cl e on hoi st.
WARNING: BE SURE TO KEEP HANDS AND FEET CLEAR OF ROTATING
WHEELS.
Run vehi cl e on hoi st under condi ti ons necessary to dupl i cate the noi se.
NOTE: It may be necessary to test drive the vehicle to duplicate the noise.
Usi ng Chassi s Ears or other sui tabl e l i steni ng devi ce, veri fy the source of the noi se.
I s the noi se comi ng from the transmi ssi on?
Al l
Yes → Go To 3
No → Test Compl ete.
3 Wi th the shi ft l ever i n neutral , rai se the engi ne speed and l i sten to the noi se.
NOTE: THE RADIO MUST BE TURNED OFF. Alternator noise can come
through thespeakers and bemisinterpreted as Transmission Pump Whine.
This can happen even with the volume turned down.
Does the noi se get l ouder or change pi tch whi l e the engi ne speed i s changi ng?
Al l
Yes → Go To 4
No → Go To 5
4 I f there are no possi bl e causes remai ni ng, vi ew repai r. Al l
Repai r
Repai r i nternal transmi ssi on probl em as necessary. I nspect al l of
the transmi ssi on components for si gns of wear. I f no probl ems
found, repl ace the Transmi ssi on oi l pump..
Perform TRANSMI SSI ON NO TROUBLE CODE VERI FI CA-
TI ON TEST.
5 I f there are no possi bl e causes remai ni ng, vi ew repai r. Al l
Repai r
Repai r i nternal transmi ssi on probl em as necessary. I nspect al l of
the transmi ssi on components for si gns of wear. Pay parti cul ar
attenti on to beari ngs, pi ni on gears, etc. Repai r or repl ace as
necessary.
Perform TRANSMI SSI ON NO TROUBLE CODE VERI FI CA-
TI ON TEST.
169
TRANSMISSION - 42RLE
Symptom:
*TRANSMISSION SHIFTS EARLY WITH NO DTC’S
POSSIBLE CAUSES
BUS PROBLEMS
CHECK FOR I NTERMI TTENT WI RI NG & CONNECTORS
COLD TRANSMI SSI ON
TEST ACTION APPLICABILITY
1 Usi ng the DRBI I I ௡, check al l other Modul es for si gns of a PCI bus probl em such as
bus rel ated DTC’s and/or communi cati on probl ems.
Check and di agnose al l 1 tri p fai l ures as a hard code.
Al though i t takes two occurences of a mi ssed TRD l i nk message to set the DTC
P1793, one mi ssed message wi l l cause the transmi ssi on to short shi ft unti l the next
start up. I f the vehi cl e has any i ndi cati ons of a bus probl em, the bus must be repai red
fi rst
Do any of the other modul es show si gns of a bus probl em?
Al l
Yes → Repai r the PCI bus probl em.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 2
2 NOTE: If the Transmission shifts too early when the Transmission is cold,
this is a normal condition. The software is designed to protect the Trans-
mission fromhigh torque and/or high RPM shifts during cold operation.
Di d the probl em occur when the Transmi ssi on temperature was col d?
Al l
Yes → Thi s i s a normal condi ti on.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Go To 3
3 The condi ti ons necessary to set the DTC are not present at thi s ti me. Usi ng the
schemati cs as a gui de, i nspect the wi ri ng and connectors. Wi ggl e the wi res whi l e
checki ng for shorts and open ci rcui ts.
Al though i t takes two occurences of a mi ssed TRD l i nk message to set the DTC
P1793, one mi ssed message wi l l cause the transmi ssi on to short shi ft unti l the next
start up. I f the vehi cl e has any i ndi cati ons of a bus probl em, the bus must be repai red
fi rst
Were any probl ems found?
Al l
Yes → Repai r wi ri ng and/or connector as necessary.
Perform 42RLE TRANSMI SSI ON VERI FI CATI ON TEST - VER
1.
No → Test Compl ete.
170
TRANSMISSION - 42RLE
Symptom:
*TRANSMISSION SIMULATOR 8333 WILL NOT POWER UP
TEST ACTION APPLICABILITY
1 NOTE: If the Transmission Simulator Miller tool #8333 will not power up,
this is a symptom of the Transmission Relay being open, such as Limp-in,
and/or this also could be a indication of the Transmission Simulator not
installed correctly on the vehicle.
NOTE: Check the Simulator ground cable connection.
NOTE: Check all Transmission Simulator harness connections.
Repai r these symptoms before havi ng the Transmi ssi on Si mul ator Mi l l er Tool #8333
repai red.
Al l
Conti nue
Test Compl ete.
171
TRANSMISSION - 42RLE
Verification Tests
42RLE TRANSMISSION VERIFICATION TEST - VER 1 APPLICABILITY
1. Connect the DRBI I I ௡ to the Data Li nk Connector (DLC).
2. Reconnect any di sconnected components.
3. Wi th the DRBI I I ௡, erase al l Transmi ssi on DTC’s, al so erase the PCM DTC’s.
4. NOTE: EraseDTC P0700in thePCMtoturn theMalfunction Indicator Lamp(MIL)
off after making Transmission repairs.
5. Wi th the DRBI I I ௡, di spl ay Transmi ssi on Temperature. Start and run the engi ne unti l the
Transmi ssi on Temperature i s HOT - above 43° C or 110° F.
6. Check the Transmi ssi on Fl ui d and adjust i f necessary. Refer to the Servi ce i nformati on for
the Fl ui d Fi l l procedure.
7. NOTE: If theTransmission Control Moduleor theTransmission has been repaired
or replaced it is necessary toperformtheDRBIII௡ Quick Learn Procedureand reset
the ؆Pinion Factor؆
8. Road test the vehi cl e. Wi th the DRBI I I ௡, moni tor the engi ne RPM. Make 15 to 20 1-2, 2-3,
3-4 upshi fts. Perform these shi fts from a standi ng start to 45 MPH wi th a constant throttl e
openi ng of 20 to 25 degrees.
9. Bel ow 25 MPH, make 5 to 8 wi de open throttl e ki ckdowns to 1st gear. Al l ow at l east 5 seconds
each i n 2nd and 3rd gear between each ki ckdown.
10. For a speci fi c DTC, dri ve the vehi cl e to the Symptom’s When Moni tored/When Set
condi ti ons to veri fy the DTC repai r.
11. I f equi pped wi th AutoSti ck௡, up-shi ft and down-shi ft several ti mes usi ng the AutoSti ck௡
feature duri ng the road test.
12. NOTE:UsetheEATXOBDII Task Manager torunGoodTriptimeineachgear, this
will confirmthe repair and to ensure that the DTC has not re-matured.
13. Check for Di agnosti c Troubl e Codes (DTC’s) duri ng the road test. I f a DTC sets duri ng the
road test , return to the Symptom l i st and perform the appropri ate Symptom.
Were there any Di agnosti c Troubl e Codes (DTCs) set duri ng the road test?
Al l
Yes → Refer to the Symptom Li st for appropri ate Symptom(s).
No → Repai r i s compl ete.
172
VERIFICATION TESTS
POWERTRAIN VERIFICATION TEST VER - 2 APPLICABILITY
1. I nspect the vehi cl e to ensure that al l engi ne components are properl y i nstal l ed and
connected. Reassembl e and reconnect components as necessary.
2. I f thi s veri fi cati on procedure i s bei ng performed after a NO TROUBLE CODE repai r, perform
steps 3 and 4.
3. Check to see i f the i ni ti al symptom sti l l exi sts. I f there are no troubl e codes or the symptom
no l onger exi sts, the repai r was successful and testi ng i s compl ete.
4. I f the i ni ti al or another symptom exi sts, the repai r i s not compl ete. Check al l techni cal
servi ce bul l eti ns or fl ash updates and return to Symptoms i f necessary.
5. I f thi s veri fi cati on procedure i s bei ng performed after a DTC repai r, perform steps 6 through
13.
6. Connect the DRBI I I ௡ to the data l i nk connector. Usi ng the DRBI I I ௡ erase any di agnosti c
troubl e codes and reset al l val ues.
7. I f the PCM was not repl aced, ski p steps 8 through 10, then proceed wi th the veri fi cati on.
8. I f the PCM was repl aced the correct VI N and mi l eage must be programmed or a DTC wi l l set
i n the ABS and Ai r Bag modul es. I n addi ti on, i f the vehi cl e i s equi pped wi th Sentry Key
I mmobi l i zer System (SKI S), Secret Key data must be updated to enabl e start.
9. For ABS and Ai r Bag systems: Enter correct VI N and Mi l eage i n PCM. Erase codes i n ABS
and Ai r Bag modul es.
10. For SKI S theft al arm: Connect DRBI I I ௡ to data l i nk conn. Go to Theft Al arm, SKI M, and
Mi sc. Pl ace SKI M i n secured access mode by usi ng the correct PI N code for thi s vehi cl e. Sel ect
Update the Secret Key data. Data wi l l be transferred from SKI M to PCM.
11. Road test the vehi cl e. I f the test i s for an A/C DTC, ensure i t i s operati ng duri ng the
fol l owi ng test.
12. Dri ve the vehi cl e for at l east 5 mi nutes at 64 Km/h (40 mph). Ensure the transmi ssi on shi fts
properl y through al l gears. At some poi nt stop the vehi cl e and turn off the engi ne for at l east
10 seconds.
13. Wi th the DRBI I I ௡, read DTCs.
Are any DTCs or symptoms remai ni ng?
Al l
Yes → Check for any rel ated Techni cal Servi ce Bul l eti ns and/or refer to the
appropri ate Symptom l i st (Di agnosti c Procedure).
No → Repai r i s compl ete.
TRANSMISSION NO TROUBLE CODE VERIFICATION TEST APPLICABILITY
1. I nspect the vehi cl e to ensure that al l engi ne and transmi ssi on components are properl y
i nstal l ed and connected. Assembl e and connect components as necessary.
2. Check i f the i ni ti al symptom sti l l exi sts. I f the symptom sti l l exi sts, return to the symptom
l i st and perform the appropri ate symptom. Make sure to check for any Techni cal Servi ce
Bul l eti ns that my appl y.
3. Wi th the DRBI I I ௡, erase any erroneous DTCs that may have been set due to a test procedure.
Does the symptom sti l l exi st?
Al l
Yes → Repai r i s not compl ete, refer to appropri ate symptom.
No → Repai r i s compl ete.
173
VERIFICATION TESTS
Verification Tests — Continued
NOTES
174
8.0 COMPONENT LOCATIONS
8. 1 POWERTRAIN CONTROL MODULE
8. 2 INPUT/OUTPUT SPEED SENSORS/TRS COMPONENT LOCATIONS
8. 3 TRANSMISSION CONTROL MODULE
C
O
M
P
O
N
E
N
T
L
O
C
A
T
I
O
N
S
175
COMPONENT LOCATIONS
8. 4 TRANSMISSION SOLENOID/PRESSURE SWITCH ASSEMBLY
C
O
M
P
O
N
E
N
T
L
O
C
A
T
I
O
N
S
176
COMPONENT LOCATIONS
9.0 CONNECTOR PINOUTS
CRANKSHAFT POSITION SENSOR (2. 4L/4. 0L A/T) - BLACK 3 WAY
CAV CIRCUIT FUNCTION
1 K24 18GY/BK (2.4L) CRANKSHAFT POSITION SENSOR SIGNAL
1 K7 20OR (4.0L) 5V SUPPLY
2 K4 20BK/LB SENSOR GROUND 1
2 K4 18BK/LB (2.4L) SENSOR GROUND 1
3 K7 18OR (2.4L) 5V SUPPLY
3 K24 18GY/BK (4.0L) CRANKSHAFT POSITION SENSOR SIGNAL
DATA LINK CONNECTOR - BLACK 16 WAY
CAV CIRCUIT FUNCTION
1 - -
2 D25 20VT/YL PCI BUS
3 - -
4 Z2 20BK/LG GROUND
5 Z12 20BK/TN GROUND
6 D32 20LG/WT SCI RECEIVE
7 D21 20PK SCI TRANSMIT
8 - -
9 D23 20WT/BR FLASH PROGRAM ENABLE
10 - -
11 - -
12 - -
13 - -
14 D20 20LG/PK SCI RECEIVE
15 - -
16 M1 20PK/WT FUSED B(+)
INPUT SPEED SENSOR - 2 WAY
CAV CIRCUIT FUNCTION
1 T52 18RD/BK INPUT SPEED SENSOR SIGNAL
2 T13 18DB/BK SPEED SENSOR GROUND
OUTPUT SPEED SENSOR - 2 WAY
CAV CIRCUIT FUNCTION
1 T14 18LG/WT OUTPUT SPEED SENSOR SIGNAL
2 T13 18DB/BK SPEED SENSOR GROUND
C
O
N
N
E
C
T
O
R
P
I
N
O
U
T
S
177
CONNECTOR PINOUTS
OVERDRIVE OFF SWITCH - 4 WAY
CAV CIRCUIT FUNCTION
1 Z1 20BK GROUND
2 T6 18OR/WT OVERDRIVE OFF SWITCH SENSE
3 T56 18DG/LB OVERDRIVE OFF SWITCH INDICATOR
4 E2 20OR PANEL LAMPS FEED
C
O
N
N
E
C
T
O
R
P
I
N
O
U
T
S
178
CONNECTOR PINOUTS
C
O
N
N
E
C
T
O
R
P
I
N
O
U
T
S
179
CONNECTOR PINOUTS
TRANSMISSION CONTROL RELAY (IN PDC)
CAV CIRCUIT FUNCTION
A1 A30 16RD/WT FUSED B(+)
A1 A30 16RD/WT (OFF-ROAD
PACKAGE)
FUSED B(+)
A2 K30 18PK TRANSMISSION CONTROL RELAY CONTROL
A3 T16 16RD TRANSMISSION CONTROL RELAY OUTPUT
A4 Z1 18BK GROUND
A5 - -
POWERTRAIN CONTROL MODULE C1 - BLACK 32 WAY
CAV CIRCUIT FUNCTION
1 K18 18RD/YL (4.0L) IGNITION COIL NO. 3 DRIVER
2 F15 18DB/WT FUSED IGNITION SWITCH OUTPUT (RUN-START)
3 - -
4 K4 18BK/LB SENSOR GROUND 1
5 - -
6 T41 18BK/WT PARK/NEUTRAL POSITION SWITCH SENSE
7 K19 18BK/GY IGNITION COIL NO. 1 DRIVER
8 K24 18GY/BK CRANKSHAFT POSITION SENSOR SIGNAL
9 - -
10 K60 18YL/BK IDLE AIR CONTROL NO. 2 DRIVER
11 K40 18BR/WT IDLE AIR CONTROL NO. 3 DRIVER
12 K10 18DB/OR (2.4L) POWER STEERING PRESSURE SWITCH SENSE
13 T141 18YL/RD FUSED IGNITION SWITCH OUTPUT (START)
14 - -
15 K21 18BK/RD INTAKE AIR TEMPERATURE SENSOR SIGNAL
16 K2 18TN/BK ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
17 K7 18OR 5V SUPPLY
18 K44 18TN/YL CMP SIGNAL
19 K39 18GY/RD IDLE AIR CONTROL NO. 1 DRIVER
20 K59 18VT/BK IDLE AIR CONTROL NO. 4 DRIVER
21 - -
22 A14 14RD/WT FUSED B(+)
23 K22 18OR/DB THROTTLE POSITION SENSOR SIGNAL
24 K41 18BK/DG OXYGEN SENSOR 1/1 SIGNAL
25 K141 18TN/WT OXYGEN SENSOR 1/2 SIGNAL
26 K241 18LG/RD (4.0L EX-
CEPT EXPORT/4.0L J APAN
LOW EMISSION VEHICLE)
OXYGEN SENSOR 2/1 SIGNAL
27 K1 18DG/RD MAP SIGNAL
28 - -
29 K341 18TN/WT (4.0L EX-
CEPT EXPORT/4.0L J APAN
LOW EMISSION VEHICLE)
OXYGEN SENSOR 2/2 SIGNAL
30 - -
31 Z12 14BK/TN GROUND
32 Z12 14BK/TN GROUND
C
O
N
N
E
C
T
O
R
P
I
N
O
U
T
S
180
CONNECTOR PINOUTS
POWERTRAIN CONTROL MODULE C2 - WHITE 32 WAY
CAV CIRCUIT FUNCTION
1 - -
2 - -
3 - -
4 K11 18WT/DB FUEL INJ ECTOR NO. 1 DRIVER
5 K13 18YL/WT FUEL INJ ECTOR NO. 3 DRIVER
6 K38 18GY (4.0L) FUEL INJ ECTOR NO. 5 DRIVER
7 - -
8 - -
9 K17 18DB/TN IGNITION COIL NO. 2 DRIVER
10 K20 18DG GENERATOR FIELD
11 - -
12 K58 18BR/DB (4.0L) FUEL INJ ECTOR NO. 6 DRIVER
13 - -
14 - -
15 K12 18TN FUEL INJ ECTOR NO. 2 DRIVER
16 K14 18LB/BR FUEL INJ ECTOR NO. 4 DRIVER
17 - -
18 - -
19 C18 18DB (2.4L) A/C PRESSURE SIGNAL
20 - -
21 - -
22 - -
23 G60 18GY/YL ENGINE OIL PRESSURE SIGNAL
24 - -
25 - -
26 - -
27 G7 18WT/OR VEHICLE SPEED SENSOR SIGNAL
28 - -
29 - -
30 - -
31 K6 18VT/WT 5V SUPPLY
32 - -
C
O
N
N
E
C
T
O
R
P
I
N
O
U
T
S
181
CONNECTOR PINOUTS
POWERTRAIN CONTROL MODULE C3 - GRAY 32 WAY
CAV CIRCUIT FUNCTION
1 C13 18DB/OR (A/C) A/C COMPRESSOR CLUTCH RELAY CONTROL
2 C24 18DB/PK (2.4L) LOW SPEED RADIATOR FAN RELAY CONTROL
3 K51 18DB/YL AUTOMATIC SHUT DOWN RELAY CONTROL
4 V36 18TN/RD (SPEED
CONTROL)
SPEED CONTROL VACUUM SOLENOID CONTROL
5 V35 18LG/RD (SPEED
CONTROL)
SPEED CONTROL VENT SOLENOID CONTROL
6 - -
7 - -
8 K99 18BR/OR OXYGEN SENSOR 1/1 HEATER CONTROL
9 K512 18RD/YL (4.0L) OXYGEN SENSOR DOWNSTREAM HEATER RELAY CONTROL
10 K106 18WT/DG LEAK DETECTION PUMP SOLENOID CONTROL
11 V32 18YL/RD (SPEED
CONTROL)
SPEED CONTROL ON/OFF SWITCH SENSE
12 A142 14DG/PK AUTOMATIC SHUT DOWN RELAY OUTPUT
13 T10 18YL/DG (A/T) TORQUE MANAGEMENT REQUEST SENSE
14 K107 18OR LEAK DETECTION PUMP SWITCH SENSE
15 K118 18PK/YL BATTERY TEMPERATURE SENSOR SIGNAL
16 K299 18BR/WT OXYGEN SENSOR HEATER CONTROL
17 - -
18 - -
19 K31 18BR FUEL PUMP RELAY CONTROL
20 K52 18PK/BK EVAP/PURGE SOLENOID CONTROL
21 C27 18DB (2.4L) HIGH SPEED RADIATOR FAN RELAY CONTROL
22 C21 18DB/OR (A/C) A/C SWITCH SENSE
23 C90 18LG (A/C) A/C SELECT INPUT
24 K29 18WT/PK BRAKE LAMP SWITCH SENSE
25 K125 18WT/DB GENERATOR SOURCE
26 K226 18DB/LG (4.0L) FUEL LEVEL SENSOR SIGNAL
27 D21 18PK SCI TRANSMIT
28 - -
29 D32 18LG/WT SCI RECEIVE
30 D25 18VT/YL PCI BUS
31 - -
32 V37 18RD/LB (SPEED
CONTROL)
SPEED CONTROL SWITCH SIGNAL
THROTTLE POSITION SENSOR (2. 4L) - WHITE/BLUE 3 WAY
CAV CIRCUIT FUNCTION
1 K7 18OR 5 VOLT SUPPLY
2 K4 18BK/LB SENSOR GROUND 1
3 K22 18OR/DB THROTTLE POSITION SENSOR NO.1 SIGNAL
C
O
N
N
E
C
T
O
R
P
I
N
O
U
T
S
182
CONNECTOR PINOUTS
THROTTLE POSITION SENSOR (4. 0L) - 3 WAY
CAV CIRCUIT FUNCTION
1 K7 20OR 5-VOLT SUPPLY
2 K4 20BK/LB SENSOR GROUND 1
3 K22 18OR/DB THROTTLE POSITION SENSOR NO.1 SIGNAL
TRANSFER CASE SWITCH (EXCEPT OFF-ROAD PACKAGE) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
A G107 20BK/RD 4WD INDICATOR
B Z1 18BK GROUND
TRANSFER CASE SWITCH (OFF-ROAD PACKAGE) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 K77 18BR/WT TRANSFER CASE POSITION SENSOR INPUT
2 K4 18BK/LB SENSOR GROUND 1
C
O
N
N
E
C
T
O
R
P
I
N
O
U
T
S
183
CONNECTOR PINOUTS
TRANSMISSION CONTROL MODULE - 60 WAY
CAV CIRCUIT FUNCTION
1 T1 18LG/BK TRS T1 SENSE
2 - -
3 T3 18VT TRS T3 SENSE
4 - -
5 - -
6 K24 18GY/BK CRANKSHAFT POSITION SENSOR SIGNAL
7 D21 18PK SCI TRANSMIT
8 T141 18YL/RD FUSED IGNITION SWITCH OUTPUT (START)
9 T9 18OR/BK OVERDRIVE PRESSURE SWITCH SENSE
10 T10 18YL/DG TORQUE MANAGEMENT REQUEST SENSE
11 F15 18DB/WT FUSED IGNITION SWITCH OUTPUT (RUN-START)
12 K22 18OR/DB THROTTLE POSITION SENSOR SIGNAL
13 T13 18DB/BK SPEED SENSOR GROUND
14 T14 18LG/WT OUTPUT SPEED SENSOR SIGNAL
15 K30 18PK TRANSMISSION CONTROL RELAY CONTROL
16 T16 16RD TRANSMISSION CONTROL RELAY OUTPUT
17 T16 16RD TRANSMISSION CONTROL RELAY OUTPUT
18 T56 18DG/LB OVERDRIVE OFF SWITCH INDICATOR
19 T19 16WT 2-4 SOLENOID CONTROL
20 T20 16LB LOW/REVERSE SOLENOID CONTROL
21 - -
22 - -
23 - -
24 - -
25 - -
26 - -
27 - -
28 - -
29 - -
30 - -
31 - -
32 - -
33 - -
34 - -
35 - -
36 - -
37 - -
38 - -
39 - -
40 - -
41 T411 18WT/PK TRS T41 SENSE
42 T42 16VT/WT TRS T42 SENSE
43 D25 18VT/YL PCI BUS
44 - -
45 - -
46 D20 18LG SCI RECEIVE
47 T47 18YL/BK 2-4 PRESSURE SWITCH SENSE
48 - -
49 T6 18OR/WT OVERDRIVE OFF SWITCH SENSE
50 T50 18DG LOW/REVERSE PRESSURE SWITCH SENSE
51 K4 18BK/LB SENSOR GROUND 1
52 T52 18RD/BK INPUT SPEED SENSOR SIGNAL
53 Z112 16BK GROUND
54 T54 18VT TRANSMISSION TEMPERATURE SENSOR SIGNAL
55 - -
56 A30 16RD/WT FUSED B(+)
57 Z113 16BK/YL GROUND
58 - -
59 T59 16PK UNDERDRIVE SOLENOID CONTROL
60 T60 16BR OVERDRIVE SOLENOID CONTROL
C
O
N
N
E
C
T
O
R
P
I
N
O
U
T
S
184
CONNECTOR PINOUTS
TRANSMISSION RANGE SENSOR - 10 WAY
CAV CIRCUIT FUNCTION
1 F20 20VT/WT FUSED IGNITION SWITCH OUTPUT (RUN)
2 - -
3 T13 18DB/BK SPEED SENSOR GROUND
4 T54 18VT TRANSMISSION TEMPERATURE SENSOR SIGNAL
5 T41 20BK/WT PARK/NEUTRAL POSITION SWITCH SENSE (T41)
6 L1 20VT/BK BACK-UP LAMP FEED
7 T1 18LG/BK TRS T1 SENSE
8 T3 18VT TRS T3 SENSE
9 T42 16VT/WT TRS T42 SENSE
10 T411 18WT/PK TRS T41 SENSE
TRANSMISSION SOLENOID/PRESSURE SWITCH ASSEMBLY - 10 WAY
CAV CIRCUIT FUNCTION
1 T60 16BR OVERDRIVE SOLENOID CONTROL
2 T59 16PK UNDERDRIVE SOLENOID CONTROL
3 T16 16RD TRANSMISSION CONTROL RELAY OUTPUT
4 T19 16WT 2-4 SOLENOID CONTROL
5 T47 18YL/BK 2-4 PRESSURE SWITCH SENSE
6 T9 18OR/BK OVERDRIVE PRESSURE SWITCH SENSE
7 T20 16LB LOW/REVERSE SOLENOID CONTROL
8 - -
9 - -
10 T50 18DG LOW/REVERSE PRESSURE SWITCH SENSE
C
O
N
N
E
C
T
O
R
P
I
N
O
U
T
S
185
CONNECTOR PINOUTS
NOTES
186
10.0 SCHEMATIC DIAGRAMS
S
C
H
E
M
A
T
I
C
D
I
A
G
R
A
M
S
187
SCHEMATIC DIAGRAMS
NOTES
188
11.0 CHARTS AND GRAPHS
11. 1 PRESSURE SWITCH STATES
11. 2 SOLENOID APPLICATION CHART
11. 3 SHIFT LEVER ERROR CODES
C
H
A
R
T
S
A
N
D
G
R
A
P
H
S
189
CHARTS AND GRAPHS
11. 4 TRANSMISSION TEMPERATURE SENSOR
C
H
A
R
T
S
A
N
D
G
R
A
P
H
S
190
CHARTS AND GRAPHS

Sponsor Documents

Or use your account on DocShare.tips

Hide

Forgot your password?

Or register your new account on DocShare.tips

Hide

Lost your password? Please enter your email address. You will receive a link to create a new password.

Back to log-in

Close